Nonferrous Metals and Alloys: Production, General Properties, and Applications

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1 Nonferrous Metals and Alloys: Production, General Properties, and Applications Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-1

2 Approximate Cost per Unit Volume for Wrought Metals and Plastics Relative to Carbon Steel TABLE 6.1 Approximate Cost per Unit Volume for Wrought Metals and Plastics Relative to Cost of Carbon Steel Gold 2 4 Silver 2 3 Molybdenum alloys 1.4 Nickel 1.2 Titanium alloys 1 Copper alloys Zinc alloys , Magnesium alloys Aluminum alloys High- low-alloy steels Gray cast iron Carbon steel Nylons, acetals, and silicon rubber * Other plastics and elastomers * Stainless steels *As molding compounds. Note: Costs vary significantly with quantity of purchase, supply and demand, size and shape, and various other factors. Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-2

3 General Characteristics of Nonferrous Metals and Alloys TABLE 6.2 Material Nonferrous alloys Aluminum Magnesium Copper Superalloys Titanium Refractory metals Precious metals Characteristics More expensive than steels and plastics; wide range of mechanical, physical, and electrical properties; good corrosion resistance; high-temperature applications. High -to-weight ratio; high thermal and electrical conductivity; good corrosion resistance; good manufacturing properties. Lightest metal; good -to-weight ratio. High electrical and thermal conductivity; good corrosion resistance; good manufacturing properties. Good and resistance to corrosion at elevated temperatures; can be iron-, cobalt-, and nickel-base. Highest -to-weight ratio of all metals; good and corrosion resistance at high temperatures. Molybdenum, niobium (columbium), tungsten, and tantalum; high at elevated temperatures. Gold, silver, and platinum; generally good corrosion resistance. Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-3

4 Example of Alloy Usage Figure 6.1 Crosssection of a jet engine (PW2037) showing various components and the alloys used in manufacturing them. Source: Courtesy of United Aircraft Pratt & Whitney. Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-4

5 Properties of Selected Aluminum Alloys at Room Temperature TABLE 6.3 Alloy (UNS) 1100 (A91100) (A92024) (A93003) (A95052) (A96061) (A97075) 7075 Temper O H14 O T4 O H14 O H34 O T6 O T6 tensile Yield in 50 mm (%) Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-5

6 Manufacturing Properties and Applications of Selected Wrought Aluminum Alloys TABLE 6.4 Characteristics* Alloy Corrosion resistance Machinability Weldability Typical applications 1100 A C D A Sheet metal work, spun hollow ware, tin stock 2024 C B C B C Truck wheels, screw machine products, aircraft structures 3003 A C D A Cooking utensils, chemical equipment, pressure vessels, sheet metal work, builders hardware, storage tanks 5052 A C D A Sheet metal work, hydraulic tubes, and appliances; bus, truck and marine uses 6061 B C D A Heavy-duty structures where corrosion resistance is needed, truck and marine structures, railroad cars, furniture, pipelines, bridge rail-ings, hydraulic tubing 7075 C B D D Aircraft and other structures, keys, hydraulic fittings * A, excellent; D, poor. Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-6

7 All-Aluminum Automobile Figure 6.2 (a) The Audi A8 automobile which has an allaluminum body structure. (b) The aluminum body structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc. Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-7

8 Properties and Typical Forms of Selected Wrought Magnesium Alloys TABLE 6.5 Composition (%) tensile Yield Alloy Al ZnMn Zr Condition in 50 mm (%) Typical forms AZ31 B F Extrusions H Sheet and plates AZ80A T Extrusions and forgings HK31A 3Th 0.7 H Sheet and plates ZK60A T Extrusions and forgings Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-8

9 Properties and Typical Applications of Selected Wrought Copper and Brasses TABLE 6.6 Type and UNS number Electrolytic tough pitch copper (C11000) Red brass, 85% (C23000) Cartridge brass, 70% (C26000) Free-cutting brass (C36000) Naval brass (C46400 to C46700) tensile Yield in 50 mm Nominal composition (%) (%) Typical applications Cu, 0.04 O Downspouts, gutters, roofing, gaskets, auto radiators, busbars, nails, printing rolls, rivets 85.0 Cu, 15.0 Zn Weather-stripping, conduits, sockets, fas-teners, fire extinguishers, condenser and heat exchanger tubing 70.0 Cu, 30.0 Zn Radiator cores and tanks, flashlight shells, lamp fixtures, fasteners, locks, hinges, ammunition components, plumbing accessories 61.5 Cu, 3.0 Pb, 35.5 Zn 60.0 Cu, Zn, 0.75 Sn Gears, pinions, automatic highspeed screw machine parts Aircraft turnbuckle barrels, balls, bolts, marine hardware, propeller shafts, rivets, valve stems, condenser plates Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-9

10 Properties and Typical Applications of Selected Wrought Bronzes TABLE 6.7 Type and UNS number Architectural bronze (C38500) Phosphor bronze, 5% A (C51000) Free-cutting phosphor bronze (C54400) Low silicon bronze, B (C65100) Nickel silver, (C74500) Nominal composition (%) 57.0 Cu, 3.0 Pb, 40.0 Zn 95.0 Cu, 5.0 Sn, trace P tensile 415 (As extruded) Yield in 50 mm (%) Typical applications Architectural extrusions, store fronts, thresholds, trim, butts, hinges Bellows, clutch disks, cotter pins, diaphragms, fasteners, wire brushes, chemical hardware, textile machinery 88.0 Cu, 4.0 Pb, 4.0 Zn, 4.0 Sn Bearings, bushings, gears, pinions, shafts, thrust washers, valve parts 98.5 Cu, 1.5 Si Hydraulic pressure lines, bolts, marine hardware, electrical conduits, heat exchanger tubing 65.0 Cu, 25.0 Zn, 10.0 Ni Rivets, screws, slide fasteners, hollow ware, nameplates Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-10

11 Properties and Typical Applications of Selected Nickel Alloys TABLE 6.8 Properties and Typical Applications of Selected Nickel Alloys (All are Trade Names) tensile Yield in 50 mm (%) Typical applications Nominal Type and UNS number composition (%) Nickel 200 (annealed) None Chemical and food processing industry, aerospace equipment, electronic parts Duranickel Al, 0.6 Ti Springs, plastics extrusion equipment, (age hardened) molds for glass, diaphragms Monel R-405 (hot rolled) 30 Cu Screw-machine products, water meter parts Monel K Cu, 3 Al Pump shafts, valve stems, springs (age hardened) Inconel 600 (annealed) 15 Cr, 8 Fe Gas turbine parts, heat-treating equipment, electronic parts, nuclear reactors Hastelloy C-4 (solutiontreated and quenched) 16 Cr, 15 Mo High temperature stability, resistance to stress-corrosion cracking Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-11

12 Properties and Typical Applications of Selected Nickel-Base Superalloys at 870 C TABLE 6.9 Properties and Typical Applications of Selected Nickel-Base Superalloys at 870 C (1600 F) (All are Trade Names) tensile Yield in 50 mm (%) Typical applications Alloy Condition Astroloy Wrought Forgings for high temperature Hastelloy X Wrought Jet engine sheet parts IN-100 Cast Jet engine blades and wheels IN-102 Wrought Superheater and jet engine parts Inconel 625 Wrought Aircraft engines and structures, chemical processing equipment lnconel 718 Wrought Jet engine and rocket parts MAR-M 200 Cast Jet engine blades MAR-M 432 Cast Integrally cast turbine wheels René 41 Wrought Jet engine parts Udimet 700 Wrought Jet engine parts Waspaloy Wrought Jet engine parts Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-12

13 Properties and Typical Applications of Selected Wrought Titanium Alloys TABLE 6.10 Properties and Typical Applications of Selected Wrought Titanium Alloys at Various Temperatures Nominal composition (%) UNS Condition tensile Yield (%) Reduction of area (%) Manufacturing Engineering and Technology 2001 Prentice-Hall Page 6-13 Temp. ( C) tensile Yield Typical Applications 99.5 Ti R50250 Annealed Airframes; chemical, desalination, and marine parts; plate type heat exchangers 5 Al, 2.5 Sn 6 Al, 4V 13 V, 11 Cr, 3 Al R54520 Annealed Aircraft engine compressor blades and ducting; steam turbine blades R56400 Annealed Rocket motor cases; blades and disks for aircraft turbines and compressors; structural forgings and fasteners; orthopedic implants Solution + age R58010 Solution + age in 50 mm (%) Reduction of area High fasteners; aerospace components; honeycomb panels