Non-ferrous metals

From last lecture Division of metals into ferrous and non-ferrous categories: over 90% by Iron and steel = general purpose metals weight of alloys in general industrial use (1995) Non-ferrous metals used in niche applications where properties of iron and steel are inadequate Main drawbacks of iron and steel: Low corrosion resistance High density High temperature strength could be better (Poor electrical conductivity)

low density

noble metals (Au, Pt, Ag) Al Pb Cu Ti Ni Sn

corrosion resistance

Mg

Ta

Zn

Co high temperature strength

low density

noble metals (Au, Pt, Ag) Al Pb Cu Ti Ni Sn

corrosion resistance

Mg

Ta

Zn

Co high temperature strength

Light alloys: Mg, Ti, Al

Density (g/cm3)

25 20 15 10 5 0 Mg Al Ti Fe Cu Ni Ag Au
1.7 2.7 4.5 7.9 8.9 8.9 10.5 19.3

21.5

Pt

Problem: Does lower density mean lower mass of component?

Solution: Ashby diagram

Youngs modulus (log scale)

density (log scale)

Designing for minimum weight

e.g. Beam (thickness variable, other dimensions constant) Wish to achieve a given stiffness for minimum weight For given stiffness and mass,

1/ 3

=C

Youngs modulus (log scale)

E1/3/ = C

density (log scale)

Mass required to produce beam of given stiffness

Mass (nominal units)

1.2 1 0.8 0.6 0.4 0.2 0 Mg Al Ti Fe

Aluminium
Properties:
Low density (2.7 g/cm3) Very good corrosion resistance in common environments (due to protective oxide layer, can be improved by anodising) Ductile (fcc crystal structure) High electrical and thermal conductivity BUT, low melting point: 660 C (e.g. mp of iron is 1535 C) restricts use at high temperatures Also, Youngs modulus not particularly high (E = 70 GPa)

Applications:
Aerospace & air travel: structural components of planes, fuel tanks in spacecraft Building and construction: panels, roofs, window frames Packaging: beverage cans, foil Transport: bikes, car engine parts, bus bodies Electrical: e.g. overhead cables

Metallurgy:
Pure aluminium has very low yield strength: 7-11 MPa essential in almost all applications Main alloying elements: Cu, Mg, Si, Mn, Zn, Li Binary, ternary and higher order alloys complex phases possible formation of many

alloying

Distinction between wrought alloys (i.e. cast as ingots, then rolled, extruded, or forged) and cast alloys (cast directly into shape. Most important: AlSi)

International Alloy Designation System

(Classification of wrought alloys) Designation 1xxx 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 8xxx Main alloying elements >99 wt% Al Cu Mn Si Mg Mg & Si Zn Others, including Li Applications (e.g.) Foil, cables Aircraft Cooking pans Beverage cans Window frames Aircraft

(No universally accepted designation system for cast alloys)

Strengthening mechanisms in wrought alloys

Distinguish between heat-treatable (precipitation hardening possible) and non-heat-treatable Non-heat-treatable alloys strengthened through workhardening (1xxx, 3xxx and 5xxx series) and solid solution strengthening (5xxx series)

Precipitation hardening
Major alloys: 2xxx series (AlCu) and 7xxx series (AlZnMg) Most important: Al 4wt% Cu

K = aluminium-rich solid solution

Precipitation hardening
Maximise strength by optimising precipitate distribution hardening
1. Solution treat uniform distribution of Cu atoms freeze 2. Quench solid solution in place 3. Age allow precipitation to occur distribution of second phase

age-

T( C)
550

fine

150

Thermal stability of aluminium

Low melting point atoms very mobile at room temperature and especially at elevated temperatures (e.g. frictional heating of 150C, welding) Concorde skin Changes in microstructure, loss of strength e.g. Over-aging: Coarsening of precipitates dislocations

easily bypassed by

formation Return to equilibrium microstructure in AlMg alloys of precipitates that give increased susceptibility to corrosive attack Age softening of work-hardened alloys dislocation density reduction in

Further reading on light alloys

IJ Polmear: Light alloys Ashby and Jones: Engineering Materials 2