LESSON

3
LECTURE
NONFERROUS METALS
SUB-OBJECTIVE
At the end of the Lesson, the Trainees i!! "e a"!e to identif# the non-ferro$s %eta!s
$sed in %aintenan&e sho' or( and des&ri"e the 'ro'erties of so%e non ferro$s
%eta!s and ho the# are s$ited to &ertain $ses)
*)+ INTRO,UCTION
A nonferrous metal is any metal other than iron, although there may be some iron
present in trace quantities as an impurity. Copper, brass, lead and zinc are the
nonferrous metals most often dealt with by mechanics.
-)+ CO..ER
Probably the most abundant nonferrous metal used in the plant is copper. Copper is
also the basis for many nonferrous metal alloys. Copper is widely used in relatively
pure form for electrical wiring and fixtures, because of its high electrical conductivity.
Only silver is a better conductor than copper. Copper is also used for piping because
of its corrosion resistance. t is particularly resistant to the effects of salt water
corrosion.
n the shop and in the plant, copper is often used for gas!et material. Copper is quite
malleable, as well as ductile. "hen copper is annealed #a heat treatment used to
soften metals$, it becomes highly compressible, ma!ing it an ideal gas!et material.
Copper gas!ets can be used repeatedly, as long as they are not damaged. Annealing
can be used to renew a copper gas!et many times.
3)+ /INC
%inc is another widely used nonferrous metal. &ecause of its corrosion resistant
properties, zinc is often used as a coating to protect other metals that are less
resistant to corrosion. An example of this is the galvanized coating seen in ductwor!
for heating, ventilation, and air conditioning.
n steam and process plants that use salt water or brac!ish water as the coolant in
large heat exchangers, zinc is often used to protect the metals of the heat
exchangers from corrosion. 'sing a zinc plate attached to the metal to be protected
sets up an electrolytic reaction. (his reaction causes the zinc to be attac!ed more
readily than the metals of the heat exchanger, thus drawing the corrosive action away
from those metals. %inc plates used in this manner are called sacrificial anodes, or
sacrificial zinc)s, because they decompose rapidly.
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 3. PAGE 1 METALLURGY
0)+ LEA,
*ead is an extremely dense, soft metal with a very low melting point. &ecause lead is
so dense, it is an extremely effective shield against radiation. t is therefore used as
shielding in radiology and in radiographic non+destructive testing. *ead is alloyed with
tin to ma!e soft solder. (he babbitt metal of sliding surface bearings is another
important lead+tin alloy. *ead is corrosion resistant, and, in the past, was the basis for
paint used to prevent rust and corrosion. ,owever, lead is a highly poisonous
element, and chronic exposure can lead to irreversible physiological damage.
1)+ ALUMINUM
Aluminum is the lightest metal that is widely used in a variety of applications.
Although aluminum is not particularly strong or tough by itself, alloys of aluminum can
be created to do -obs requiring high strength and good toughness. n its various
forms, aluminum approaches the versatility of iron and steel. n the plant, aluminum
may be found in use as lightweight structural members, conduit, gear cases for
transmissions and speed reducers, and heat exchangers.
2)+ BRASS AN, BRON/E
(rue brass is an alloy of copper and zinc, and bronze was originally an alloy of copper
with tin. ,owever, more complex alloys of brass and bronze are being used today,
and the distinction between brass and bronze in modern commercial use is very
vague. .odern brass alloys often have tin added for corrosion+resistance/ aluminum,
lead, iron and manganese are also used as alloying elements.
(rue brass and some of the more complex alloys are found in the shop in sheet form
and as tubing. As sheet material, brass is often used for shim stoc! because it is
tough and hard, yet is easier to cut than other metals, such as steel. (ubes of
condensers and other heat exchangers may be made of a complex alloy of brass.
&rass is used extensively for loc!s and latches, hinges, and other hardware. 0ome
alloys found in these tuses may be referred to as commercial bronze, but they are, in
fact, a low alloy brass of mostly copper with 12 to 342 zinc.
3)+ CO..ER AN, NIC4EL-CO..ER ALLO5S
Copper+nic!el and nic!el+copper alloys are named according to the percentage of
their two ma-or alloying elements. Copper+nic!el is typically from 542 to 642 copper
with the remainder nic!el. 7ic!el+copper alloys are unique, because they are harder
and stronger than either nic!el or copper. (heir composition is usually from 842 to
542 nic!el with the rest copper. One of the most widely !nown nic!el+copper alloys in
.onel. #.oney is atrademar!ed product of the nternal 7ic!el Company.$ t is a
natural alloy, which contains about 852 nic!el and 992 copper with traces of 4: her
elements. (his combination of metals exists in the ore when it is mined, and it is
retained throughout the refining process.
;+.onel is also a trademar!ed product of the nternational 7ic!el Company. t is
essentially the same as .onel, with the addition of about 92 aluminum. (he use of
aluminum as an alloying agent produces as even harder, stronger alloy.
7ic!el+copper and copper+nic!el alloys are all extremely corrosion resistant, and they may be
found in use as piping and tubing. "here corrosion resistance is of prime importance,
nic!el+copper alloys may even be substituted for steel, because of their high strength.
MODULE 16 MECHANICAL MAINTENANCE COURSE
METALLURGY LESSON 3. PAGE 2
6)+ OT7ER NONFERROUS METALS
7ic!el and tin have been mentioned as alloying elements that are useful for their properties.
&oth are highly resistant to corrosion and are often used as coatings on other metals that are
less resistant to corrosion. Chromium is another metal used both as an alloying ingredient
and as a corrosion+resistant coating. (hese nonferrous metals are not oridinarily found in
use by them selves/ mostly, they are used in plating and in alloying.
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 3. PAGE 3 METALLURGY