Extract Pages From Metallurgy and Materials Engineering - S. Ramachandran Et Al. (Air Walk Publications, 2016)

Strengthening Mechanism Alloy Steels, Cast Iron & Non-ferrous Alloys 4.
67
4.20 COPPER AND COPPER ALLOYS

It is one of the most widely used non-ferrous
metals in industries. Unalloyed copper is soft and
ductile that is difficult to machine and also it has
an almost unlimited capacity to be cold-worked.
Furthermore, it is highly resistant to corrosion in
diverse environments including ambient
atmosphere, seawater and some industrial
chemicals.
The mechanical and corrosion resistance
properties can be improved by alloying.
Most copper alloys cannot be hardened or
strengthened by heat - treating procedures.
It may be cast, forged, rolled and drawn into
wires.
Copper in the form of tubes is widely used in
mechanical engineering. It is also used for making
ammunitions.
4.20.1 Properties of Copper
It is having excellent resistance to corosion
It is having good non-magnetic properties
High thermal and electrical conductivity
Very good machinability
It can be soldered, welded (or) brazed.
Important properties of pure copper are given below
Melting point, 1033 C
Crystal structure, Face Centred Cubic (FCC)
Tensile strength, 220 MPa
4.68 Metallurgy & Materials Engineering - www.airwalkpublications.com
Youngs modulus, E 125.5 GPa
Electrical Resistivity, 1.67 10 8 m

Corrosion Resistance, Excellent
4.20.2 Applications of Copper
It is used to make electrical parts like wire,
switches etc.
Heat Exchanger tubes
It is used to make various copper alloys like brass
and bronze
It is used to make screw machine products.
4.20.3 Classification of Copper alloys
Copper alloys are broadly classified into following
groups
1. Copper-zinc alloys (Brasses) in which zinc is the
principal alloying metal.
2. Copper - tin alloys (Bronzes and Gun metals) in
which tin is the principal alloying metal.
3. Copper - Aluminium (Al.bronzes)
4. Copper - Nickel (cupronickels)
The important properties of copper and some copper
alloys are listed in the table 4.4.
Strengthening Mechanism Alloy Steels, Cast Iron & Non-ferrous Alloys 4.69
Table 4.4 The composition, properties and uses of

several copper alloys are given as follows.
Mechanical
Properties
Alloy
Composition Tensile Type Uses
Name
Strength of
(MPa) Product
Beryllium Springs, bellows,
1140 -
copper 1.9% Be, 0.20% Co 4 - 10 firing pins,
1310
bushings, valves.
Cartridge Automotive
brass radiator cores,
ammunition
30% Zn 300 68
components, lamp
fixtures, flashlight
shells.
Phosphor Bellows, Clutch
bronze disks, diaphragms,
5% Sn, 0.2% P 325 64
fuse clips, springs,
welding rods
Copper Condensor, and
nickel heat exchanger
30% Ni 380 36
components,
saltwater piping.
Leaded Furniture
yellow hardware, radiator
29% Zn, 3% Pb,
brass 234 83 fittings, light
1% Sn
fixtures, battery
clamps.
Tin Bearings,
bronze bushings, piston
10% Sn, 2% Zn 310 25
(Gun rings, steam
metal) fittings, gears.
Aluminium Bearings, gears,
bronze worms, bushings,
4% Fe, 11% Al 586 18 valve seats and
guards, pickling
hooks.
Mechanical
Properties
Alloy
Name
Strength of
(MPa) Product
Pure 220 Sheet, High conductivity
copper 99.95% Cu strip, electrical
350
Wire applications
220 All Chemical plant,
99.85% Cu wrought deep drawn and
360
forms spun articles
Arsenical 220 Retains strength
copper All at elevated
99.25% Cu;
wrougt temperatures.
0.5% As 360
forms Heat exchangers,
steam pipes
Brasses
Gilding 280 Sheet, Imitation
metal 90% Cu; 10% Zn strip, jewellery and
510
wire decorative work
Cartridge 325 High-ductility
Sheet,
brass 70% Cu; 30% Zn brass for deep
700 strip
drawing
General 340 Sheet, General purpose
cold strip, cold working alloy
65% Cu; 35% Zn
working 700 extrusions
brass
Muntz Hot Condenser and
metal rolled heat exchanger
plate plates.
60% Cu; 40% Zn 375
and
extrusions
High Cast Ships screws,

85% Zn; 2% Mn;
tensile and hot rudders and
2% Al; 2% Fe; 600
brass worked high-tensile
balance Cu
forms applications
Mechanical
Properties
Alloy
Name
Strength of
(MPa) Product
Bronzes 95.5% Cu; 3% Sn; 325 British copper
Strip
1.5% Zn 725 coinage
5.5% Sn; 0.1% P; 360 Sheet, Springs and
strip, steam turbine
balance Cu 700
wire blades
General purpose
10% Sn; 0.5% P;
280 Castings castings and
balance Cu
bearings
Gunmetal Pressure-tight
10% Sn; 2% Zn;
300 Castings castings, pump
balance Cu
and valve bodies
Aluminium 400 Imitation jewellery
Strip,
bronze 95% Cu; 5% Al and condenser
770 tubing
tubes.
Hot High strength
worked castings and
10% Al; 2.5% Fe;
700 and forgings
2-5% Ni; bal. Cu
cast
products
Cupro- 360 British silver
75% Cu; 25% Ni Strip
nickel 600 coinage
375 condanser tubing,
tubing excelent
70% Cu; 30% Ni Sheet
650 corrosion
resistance.
Monel 29% Cu; 68% Ni; Excellent corrosion
All
1.25% Fe; 1.25% 550 resistance, used in
forms
Mn chemical plant
Beryllium-co 1 34 2 12% Be; balance Sheet, strip
1300
pper 1 %
2 Co Cu
Cadmium 285 Overhead
copper Wire, electrical wire,
99% Cu; 1% Cd
500 rod spot-welding
electrodes
Mechanical
Properties
Alloy
Name
Strength of
(MPa) Product
Chromium Wrought Welding
copper 0.4% - 0.8% Cr; forms electrodes,
450
bal.Cu and commutator
castings segments
Tellurium 0.3 - 0.7% Te; 225 Wrought Free-machining
copper bal. Cu 300 forms properties
4.20.4. Copper - Zinc Alloys (BRASSES)

The most widely used copper zinc alloy is brass.
There are various types of brasses, depending
upon the proportion of copper and zinc.
Some of the common uses for brass alloys include
costume jewellery, cartridge casings, automotive
radiators, musical instruments etc.
This is fundamentally a binary alloy of copper
with zinc (each 50%).
By adding small quantities of other elements, the
properties of brass may be greatly changed.
(i) Design strengths for Brass
Reasonable strength
Corrosion resistant
Easy to shape
(ii) Design weakness for Brass
Quite expensive
(iii) Typical products
Ornamental fittings
Plumbing fittings
Screws
Bullets
Suitable types of brass lend themselves to the following
processes: Casting, hot forging, cold forging, cold rolling into
sheets, drawing into wire and being extruded through dies
to give special shaped bars.
(iv) Properties of brass
The melting point of brass ranges from
800 C to 1000C .
The metal is soft, ductile and has high tensile
strength with good fusibility and surface finish
characteristics.
It is non-magnetic and is a poor conductor of
electricity.
The various types of brasses showing composition
are given in Table 4.5.
Table 4.5 Composition and Features of Brasses
Composition %
Sl.
Name Other Uses
No. Copper Zinc
elements
1. Guiding 90 10 Forgings, rivets,
metal jewellery
applications.
2. Low brass 80 20 Drawing and
forming operations.
Composition %
Sl.
Name Other Uses
No. Copper Zinc
elements
3. Cartridge 70 30 Cartridge cases,
brass condensor tubes,
sheet fabrication,
a general purpose
brass.
4. Admiralty 70 29 Sn 1 Condensor tubes
brass exposed to salt
water (high
corrosion
resistance).
5. High brass 66 34 Stamping and
drawing
operations.
6. Muntz 60 40 Suitable for many
metal hot working
operations, rolled
also cast valves
and marine
fittings.
7. Naval brass 60 39 Sn 1 As above, but
possess increased
corrosion
resistance.
8. Tobin 60 38 Sn 1, Brazing alloy for
bronze Al 1 naval brasses, etc.
9. Manganese 62 32 Al 4, High tensile
bronze Fe 1.5, casting metal;
Mn 2.25 yield point = 510
MN/m2, UTS =
710 MN/m2
10. Brazing 50 50 Brazing rods
brass
4.20.5 Copper - Nickel Alloy (CUPRONICKEL)

Cupronickel is an alloy of copper, nickel and
strengthening impurities, such as iron and
manganese.
Cupronickel does not corrode in seawater, because
its electronegativity is adjusted to be neutral with
regard to seawater. Because of this, it is used for
marine hardware, and sometimes for the
propellers, crankshafts, and hulls of premium
tugboats, fishing boats and other working boats.
The most common use is that most of the
silver-coloured modern circulation coins are
Cupronickel.
These coins contain a typical mix of 75% copper,
25% nickel and a trace amount of manganese.
In the past, true silver coins were coated with
cupronickel.
Cupronickel is used in thermocouples, and a 55%
copper, 45% nickel alloy is used to make very
accurate resistors.
The cupronickel alloy technology has been known
by the chinese since the 3rd century BC under the
name White Copper.
The table 4.6 shows some important type of
cupronickels, their compositions, properties, and typical
uses.
Table 4.6 Cupro-nickels and nickel-silvers

Typical
Composition % Mechanical
Alloy Condi- properties
Uses
name tion Tensile
Other Elong%
Cu Ni strengt
elements
h MPa
Cupro- 80 20 Mn 0.25 Soft 340 45 Used for
nickels bullet
envelopes,
because of
Hard 540 5 high
ductility and
corrosion -
resistance.
75 25 Mn 0.25 Soft 350 45 Mainly for
coinage - the
current
Hard 600 5 British
silver
coinage.
Monel 29 68 Fe 1.25 Soft 560 45 Monel metal
metal Mn 1.25 - good
mechanical
properties,
excellent
Hard 720 20 corrosion -
resistance.
Chemical
engineering
plant, etc.
Typical
Composition % Mechanical
Uses
name tion Tensile
Other Elong%
Cu Ni strengt
elements
h MPa
K Al 2.75 Soft 680 40 K Monel - a
Monel Fe 1.0 Hard 760 25 heat
Mn 0.4 treatable
alloy.
29 66
Heat-tre Used for
1060 22
Ti06 ated motor boat
propellor
shaft.
Nickel Nickel-Silver-sp
Zn Bal.
Silver 60 18 oons, forks,
Mn 0.4
(or) etc
German Leaded
Zn Bal.;
Silver nickel-silver
60 10 Pb 1.5;
- Yale type
Mn 0.25
keys., etc.
4.20.6 Bronze
The alloys of copper and tin, are usually termed
as bronzes. The usual range of composition is 75
to 95% copper and 5 to 25% tin.
Bronzes are alloys of copper and several other
elements, including tin, aluminium, silicon and
nickel.
The metal is comparatively hard, resists surface
wear and can be shaped or rolled into wires, rods
and sheets very easily.
In corrosion resistance properties, bronzes are
superior to brasses.
Some common types of bronze are given below.
1. Phosphor bronze
2. Silicon bronze
3. Beryllium bronze
4. Manganese bronze
1. Phosphor bronze
When bronze contains phosphorus, it is called
phosphor bronze.
A common type of phosphor bronze has the
following composition.
Copper 87% to 90%
Tin 9% to 10%
Phosphorus 0.1% to 0.3 %
Phosphorus increases strength, ductility and
soundness of castings.
The phosphor bronze alloy possesses good wearing
qualities and high elasticity.
The metal is resistant to salt water corrosion.
It is used for
bearings,
worm wheels,
gears,
nuts for machine lead screws,
pump parts,
linings,
springs and for many other purposes.
Table 4.7 Tin Bronzes and phosphor bronzes

Typical
Composition % melchanical
Uses
Name tion Tensile Elong
Other
Cu Sn strength -ation
elements
MPa %
Coinage Soft 320 65 British
bronze copper
coinage now
95.5 3 Zn 1.5 contains less
Hard 725 5
tin (0.5%)
and more
zinc (2.5%).
Low-tin Soft 340 65 Springs and
bronze instrument
parts. Good
96 3.75 P 0.1 elastic
Hard 740 15
properpties
and corrosion
- resistance.
Drawn 94 5.5 P 0.2 Soft 350 65 Generally
Phosphor used in the
bronze work-hardened
condition;
steam-turbine
blading.
Hard 700 15 Other
components
subjected to
friction or
corrosive
conditions.
Cast Supplied as
Phosphor cast sticks
Sand
bronze 89 10 P 0.5 280 15 for turning
cast
small
bearings etc.
Typical
Uses
Other
elements
MPa %
High-tin Bearings
Bronze subjected to
Sand heavy loads
81 18 P 0.5 170 2
cast bridge and
turntable
bearings.
Admiralty Pumps,
gunmetal valves and
miscellaneous
castings
(mainly for
marine work,
Zn 2, because of its
Sand
88 10 Ni 2 290 16 high
cast
(max) corrosion
resistance);
also for
statuary,
because of
casting
properties.
Leaded A substitute
gunmetal for Admiralty
Zn 5,
(or red gunmetal;
Pb 5, Sand
brass) 85 5 220 13 also where
Ni 2 cast
pressure
(max)
tightness is
required.
Typical
Uses
Other
elements
MPa %
Leaded A bearing
bronze alloy, can be
Pb 20,
Sand bonded to
75 5 Ni 2 160 6
cast steel shafts
(max)
for added
strength.
2. Silicon bronze
It contains
96% copper,
3% silicon and
1% manganese or zinc.
It has good corrosion resistance when copper
combined with higher strength.
It can be cast, rolled, stamped, forged and pressed
at either hot or cold temperatures and it can be
welded by all usual methods.
It is widely used in
boilers,
tanks,
stores or where high strength and good
corrosion resistance is required.
3. Beryllium bronze
The most common precipitation hardenable copper
alloys are the beryllium coppers. They possess
remarkable combination of properties, high tensile
strength, excellent electrical and corrosion

properties and wear resistance when properly
lubricated. They may be cast, hot worked or cold
worked.
It is a copper alloy containing about
97.75% copper and
2.25% beryllium.
It has - High yield point,
High fatigue limit
Excellent cold and hot corrosion resistance.
It is particularly suitable material for springs,
heavy duty electrical switches, cams and bushes.
Since the wear resistance of beryllium copper is
five times that of phosphor bronze, therefore it
may be used as a bearing metal in place of
phosphor bronze.
4. Manganese bronze
It is an alloy of copper, zinc and little percent of
manganese.
The useful composition of this bronze is as follows.
Copper 60%
Zinc 35%
Manganese 5%
The metal is highly resistant to corrosion.
It is harder and stronger than phosphor bronze.
It is generally used for bushes, plungers, feed
pumps, rods etc.
Worm gears are frequently made from Manganese

bronze.
5. Aluminium bronze
It is an alloy of copper and aluminium.
The aluminium bronze with 6 to 8% aluminium
has valuable cold working properties. They are
most suitable for making components exposed to
severe corrosion conditions.
When iron is added to these bronzes, the ductility
is improved.
The aluminium bronzes are widely used for
making
gears,
propellers,
condensor bolts,
pump components,
tubes,
air pumps,
slide valves and
bushes etc.
Cams and rollers are made from aluminium
bronze.
A 6% aluminium alloy has a fine gold colour,
which is used for jewellery and decorative
purposes.
The tables 4.8 and 4.9 show some important types
of Aluminium bronze, tin bronze and phosphor bronze and
their composition, properties and typical uses.
Table 4.8 Aluminium Bronzes

Typical
Composition % mechanical
Condition properties
Uses
Tensile Elong
Other
Cu Al strength -ation
elements
MPa %
7.5 Fe, Mn, Hot 430 45 Chemical
Remaining
and Ni worked engineering,

upto 2.5 particularly at
total fairly high
temperatures.
80 10 Fe 5, Ni Forged 725 20 Forged
5 propeller-shafts,
spindles, etc. for
marine work.
Can be
heat-treated by
quenching and
tempering.
9.5 Fe 2.5., Cast 520 30 The most widely
Ni and used aluminium
Mn upto bronze for both
1.0 each die- and sand-
Remaining
(optional) casting. Used in

chemical plant
and marine
conditions -
pump-casting,
valve-parts,
gears, propellers,
etc.
Table 4.9 Tin bronzes and phosphor bronzes
Typical
Alloy properties
Condition Uses
Name Other Tensile Elog
Cu Sn elements strengt ation
h MPa %
Coinage 95.5 3 Zn 1.5 Soft 320 65 British
bronze Hard 725 5 copper
coinage now
contains
rather less
tin (0.5%)
and more
zinc (2.5%).
Low-tin 96 3.75 P 0.1 Soft 340 65 Springs and
bronze Hard 740 15 instrument
parts. Good
elastic
properties
and
corrosion-resis
tance.
Drawn Soft 350 65 Generally
phosphor used in the
bronze work-hardened
condition,
steam-turbine
blading.
94 5.5 P 0.2
Hard 700 15 Other
components
subjected to
friction or
corrosive
conditions.
Typical
Alloy properties
Condition Uses
h MPa %
89 10 P 0.5 Sand cast 280 15 Supplied as

Cast
cast sticks for
phosphor
turning small
bronze
bearings, etc.
High-tin 81 18 P 0.5 Sand cast 170 2 Bearing
bronze subjected to
heavy loads
- bridge and
turntable
bearings.
Admira 88 10 Zn 2, Sand cast 290 16 Pumps,
lty Ni 2 valves and
gunmet (max) miscellaneous
al castings
(mainly for
marine
work,
because of
its high
corrosionresist
ance); also
for statuary,
because of
good casting
properties.
Typical
Alloy properties
Condition Uses
h MPa %
Leaded 85 5 Zn 5, Sand cast 220 13 A substitute

gunmet Pb 5, for
al (or Ni 2 Admiralty
red (max) gunmetal,
brass) also where
pressure
tightness is
required.
Leaded 75 5 Pb 20, Sand cast 160 6 A bearing
bronze Ni 2 alloy, can
(max) be bounded
to steel
shafts for
added
strength.
4.21 ALUMINIUM AND ALUMINIUM ALLOYS

4.21.1 Aluminium
Aluminium is a silvery white metal and it possesses
the following Characteristics (or) Properties
It is a light metal, with a density about one third
that of steels (or) brass.
It is a very good conductor of electricity.
It is very soft and ductile
It is having good corrosion resistance.
It is having low specific gravity
4.21.2 Important properties of Aluminium
1. Melting point 660C

2. Crystal structure FCC (Face Centred
cubic)
3. Tensile Strength 45 MPa
4. Electrical resistivity 2.66 10 8 m
5. Corrosion resistance Excellent
6. Density 2.70 10 3kg/m3
4.21.3 Applications of Aluminium

It is used for making Aeroplane parts, house hold
items, electric wires, furniture, surgical
instruments and foils.
It is also used for making paints in the form of
powder.
It is used in chemical plants and food processing
equipment due to its corrosion resistance.
Aluminium and its alloys are characterised by a
relatively low density (2.7 g/cm 3 as compared to
3
7.9 g/cm for steel), high electrical and thermal
conductivities, and a resistance to corrosion in some
common environments, including the ambient
atmosphere.
Many of these alloys are easily formed by virtue of
its ductility; this is evidenced by the thin aluminium
foil sheet into which the relatively pure metal may
be rolled.
Since aluminium has FCC crystal structure, its
ductility is retained at very low temperatures.
The chief limitation of aluminium is its low

melting temperature, which restricts the
maximum temperature at which it can be used.
The mechanical strength of aluminium may be
enhanced by cold work and by alloying; however
both processes tend to diminish resistance to
corrosion.
Principal alloying elements include copper,
magnesium, silicon, manganese and zinc.
In its pure state, the metal would be weak and
soft for most purposes, but when mixed with small
amounts of other metals, it becomes hard and
rigid.
The strength can also be increased by heat
treatment.
Aluminium is quite reactive, but protects itself
very effectively with a thin oxide layer. The
surface can be anodised, to resist corrosion and
to give decorative effects.
4.21.4 Aluminium alloys Classification
Aluminium alloys can be classified as cast or
wrought, both groups containing alloys that are
age-hardened.
The alloys in each of these two classes are further
classified according to whether they respond to
heat treatment of the strengthening type.
For the casting of general engineering use,
aluminium is alloyed with small amounts of
copper and zinc in the proportion of
12.5 to 14.5 % zinc and
2.5 to 3 % copper.
An important series of casting and forging alloys
of high strength have recently been developed for
the use in aeroplane construction. One example of
such alloy is;
Zinc 5%, Magnesium 3%,
Copper 2.2%,
nickel upto 1%,
aluminium the remainder.
Al-Cu Alloys: There are two important Aluminium
- Copper alloys
1. Duralumin
2. Y-alloy
1. Duralumin
An important and interesting wrought alloy is
duralmin.
This is composed of
3.5 to 4.5% copper,
0.4 to 0.7% manganese,
0.4 to 0.7% magnesium and
aluminium the remainder.
It is widely used in wrought conditions, for
forgings,
stampings,
bars,
sheets,
tubes and
rivets.
It is interesting because of its age-hardening
property.
After working, if the metal is allowed to age 3-4
days, it will be hardened. This phenomenon is
called AGE HARDENING.
2. Y-Alloy
Another alloy containing copper, nickel and
magnesium, and which may be cast (or) wrought
is known as Y-alloy. This alloy contains
3.5 to 4.5% copper,
1.8 to 2.3% nickel and
1.2 to 1.7% magnesium.
Y-alloy has the characteristic of retaining a good
strength at high temperature.
Y-alloy is therefore useful for pistons and other
components in aero-engines.
It is also largely used in the form of sheet and
strip, and after proper heat treatment may be
brought to minimum tensile strength of about 350
N /mm2.
Table 4.10 Mechanical Properties and Applications of

Common Aluminium Alloys
Condition
A annealed
Tensile Yield
W cold Percentage Character-
Composition strength strength
worked elongation istics
MN/m2 MN/m2
H.T (mm) and uses
Heat
treated
1.2% Mn A 110 41 30 A non heat -
(remaining W 200 186 4 treatable
content work -
aluminium) hardening
wrought alloy
used for
general sheet
- metal
applications
& cooking
utensils.
4.0% Cu, A 180 69 20 Duralmin, an
0.5% Mg, H.T 425 275 20 age-hardening
0.5% Mn, wrought
0.5% Si alloy,
hardened by
quenching
and ageing,
used for
aircraft
construction
in the form
of Alclad.
4.4% Cr, A 186 96 12 A strong
0.8% Si age-hardening
alloy for
forgings and
extrusion.
Condition
A annealed
Tensile Yield
W cold Percentage Character-
Composition strength strength
worked elongation istics
MN/m2 MN/m2
H.T (mm) and uses
Heat
treated
7.0% Cu, As Cast 165 105 1.5 General
2.0% Si purpose,
1.7% Zn sand casting
alloy that is
not
age-hardened.
4.0% Cu, As Cast 186 124 1.0 A sand
1.5% Mg, casting alloy
2.0% Ni capable of
withstanding
high
temperature.
12% Si As Cast 270 145 2.7 A general
purpose
non-heat
treatable die
casting alloy
having
excellent
corrosion
resistance.
9.5% Si, As Cast 300 186 3.0 A die-casting
0.5% Mg alloy having
high strength
and good
corrosion
resistance.
4.22 NICKEL ALLOYS

Nickel alloys are used extensively because of their
corrosion resistance, high temperature strength and their
special magnetic and thermal expansion properties. Nickel
is white in colour and has good workability and good
mechanical properties. The most common alloying elements
of Nickel is copper, iron, chromium, silicon, molybdenum,
manganese and aluminium.
4.22.1 Nickel-copper alloys:
The nickel-copper alloys are sometimes referred to as
MONEL and contains nickel with copper and small amount
of iron and manganese. This nickel-copper alloys contain
63% nickel, minimum 28-34% of copper, maximum of 2%
manganese and 2.5% iron.
Nickel-copper alloys are widely used in oil refining
and marine applications where long-corrosion free life is
required.
4.22.2 Nickel-Silicon-Copper based alloys
It is a casting alloy which is strong, tough and
extremely hard. The most important characteristics of this
alloy is that, at elevated temperatures it shows excellent
corrosion resistance to concentrated sulfuric acid. Ni-Si-Cu
alloy contains 10% Silicon, 3% Copper and remaining is
Nickel.
4.22.3 Nickel-Chromium-Iron based alloys
Nichrome (60 Ni - 16 Cr - 24 Fe) is used as electrical
heating element for toasters, hot-water heaters etc. These
alloys find applications where heat resistance and corrosion
resistance is required.
4.22.4 Nickel-Molybdenum-Iron based alloys

These alloys are noted for their high resistance to
corrosion by hydrochloric, phosphoric and non-oxidizing
acids.
Examples: Haste alloy A (57 Ni - 20 Mo - 20 Fe) and Haste
alloy B (62 Ni - 28 Mo - 5 Fe) are the best known alloys.
4.23 MAGNESIUM ALLOYS
Magnesium has the density of 1.7/cm 3 which is the

lowest of all the structural metals. Therefore magnesium
alloys are used where light weight is an important
consideration. Magnesium has an HCP crystal structure. It
is relatively soft and has a low elastic modulus. Aluminium,
zinc, manganese and some of the rare earths are the major
alloying elements.
Cast alloys:
Mg - 9% Al, 0.13 % Mn is used in the automotive
wheels
Mg - 9% Al, 0.15% Mn, 0.7% Zn is used in the die-cast
parts of automobiles, luggage and electronic device.
Wrought alloys:
The structural shapes of magnesium alloys are
usually formed by extrusion (or) forging
Mg - 5.5% Zn, 0.5% Zr is the high strength extrusion
alloy for aircraft.
4.24 BEARING ALLOYS

If the metal alloys are used to make bearings, then
they are called bearing alloys.
4.24.1 Properties of Bearing materials
Bearing materials have high thermal conductivity.
They have good resistance to corrosion.
They have sufficient hardness and wear resistance
and low co-efficient of friction.
They are tough
They are shock resistant
4.24.2 Bearing Alloys Classification
Bearing alloys may be classified into the following
groups.
1. White metals
(i) Tin-base bearing alloys (Babbit metals)
containing tin ( Sn 86%), antimony (Sb 10%),
and copper (Cu 4%).
(ii) Lead-base bearing alloys containing lead (Pb
74%), tin (Sn 12%) and antimony (Sb 14%).
(iii) Cadmium-base bearing alloys containing
cadmium and nickel.
2. Copper-base bearing alloys containing copper (7.5%),
tin (5%), and lead (Pb 20%).
3. Aluminium base alloys
4. Plastic materials
5. Ceramics
Those alloys in which tin, lead, and cadmium are
predominating elements are designated as
white-metal bearing alloys.
They have properties of high plasticity combined

with low hardness and low melting point which
facilitates the formation of bearings by casting the
metal directly in place and require no machining.
Copper-base alloys are harder and stronger than
white metals and are used for bearings which are
required to resist heavier pressures.
Tin-base white metals are used where bearings
are subjected to high pressure and load,
For high loads and pressure, lead-base alloys are
used.
Cadmium base bearing metals have more
fovourable properties, especially at elevated
temperatures, than tin-base alloys.
The compressive strength of cadmium base
bearing alloys are greater than those of tin-base
alloys.
To give an efficient bearing combination, the following
conditions are necessary.
1. The shaft and bearing should be dissimilar in their
nature with bearing softer than the shaft.
2. The most efficient bearing metal should be is one
consisting of small pieces of a comparatively hard
metal embedded in the soft body of another metal.
3. The bearing metals should have sufficient
compressive strength to carry bearing pressure,
should have wear resistance to smooth surfaces as
they rub together, and should develop a minimum
friction when they actually come in contact.

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Strengthening Mechanism Alloy Steels, Cast Iron & Non-ferrous Alloys 4.

4.20 COPPER AND COPPER ALLOYS

Youngs modulus, E 125.5 GPa

Electrical Resistivity, 1.67 10 8 m

Table 4.4 The composition, properties and uses of

High Cast Ships screws,

4.20.4. Copper - Zinc Alloys (BRASSES)

4.20.5 Copper - Nickel Alloy (CUPRONICKEL)

Table 4.6 Cupro-nickels and nickel-silvers

Table 4.7 Tin Bronzes and phosphor bronzes

strength, excellent electrical and corrosion

Worm gears are frequently made from Manganese

Table 4.8 Aluminium Bronzes

and Ni worked engineering,

(optional) casting. Used in

Table 4.9 Tin bronzes and phosphor bronzes

89 10 P 0.5 Sand cast 280 15 Supplied as

Leaded 85 5 Zn 5, Sand cast 220 13 A substitute

4.21 ALUMINIUM AND ALUMINIUM ALLOYS

4.21.2 Important properties of Aluminium

1. Melting point 660C

4.21.3 Applications of Aluminium

The chief limitation of aluminium is its low

Table 4.10 Mechanical Properties and Applications of

4.22 NICKEL ALLOYS

4.22.4 Nickel-Molybdenum-Iron based alloys

4.23 MAGNESIUM ALLOYS

Magnesium has the density of 1.7/cm 3 which is the

4.24 BEARING ALLOYS

They have properties of high plasticity combined

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