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Nonferrous Alloys
131 In some cases, we may be more interested in cost per unit volume than in cost per
unit weight. Rework Table 131 to show the cost in terms of $/cm3. Does this
change/alter the relationship between the different materials?
Solution:
We can find the density (in g/cm3) of each metal from Appendix A.
We can convert the cost in $/lb to $/g (using 454 g/lb) and then multiply
the cost in $/g by the density, giving $/cm3. The left hand side of the table
shows the results of these conversions, with the metals ranked in order of
cost per volume. The right hand side of the table shows the cost per pound.
Steels
Al
Mg
Zn
Pb
Cu
Ti
Ni
W
Be
cost/volume
rank
$0.0017/cm3
$0.0036/cm3
$0.0057/cm3
$0.0063/cm3
$0.0113/cm3
$0.014/cm3
$0.04/cm3
$0.0804/cm3
$0.169/cm3
$1.4262/cm3
1
2
3
4
5
6
7
8
9
10
cost/lb
Fe
$0.10
Pb
$0.45
Zn
$0.40
Al
$0.60
Cu
$0.71
Mg
$1.50
Ni
$4.10
Ti
$4.00
W
$4.00
Be $350.00
rank
1
2
3
4
5
6
8
7
7
10
149
150
132 Assuming that the density remains unchanged, compare the specific strength of the
2090T6 aluminum alloy to that of a die cast 443F aluminum alloy. If you considered the actual density, do you think the difference between the specific strengths
would increase or become smaller? Explain.
Solution:
Both should increase since both Li and Si (the major alloying elements)
are less dense than Al.
133 Explain why aluminum alloys containing more than about 15% Mg are not used.
Solution:
35 14.9
97.6%
35.5 14.9
The T9 treatment will give the higher strength; in this temper cold working and age hardening are combined, while in T6, only age hardening is
done.
138 Estimate the tensile strength expected for the following aluminum alloys.
(a) 1100H14
(b) 5182H12
(c) 3004H16
Solution: (a) The tensile strength for 1100H14 is the average of the 0 and H18
treatments.
11000 10% CW2: TS 13 ksi
13 24
18.5 ksi
2
(b) The tensile strength for 5182H12 is the average of the 0 and H14 treatments, and H14 is the average of the 0 and H18 treatments. We do not
have data in Table 135 for 5182H18. However, 5182H19 has a tensile
strength of 61,000 psi and H18 should be 2000 psi less, or 59,000 psi.
CHAPTER 13
Nonferrous Alloys
151
42 59
50.5 ksi
2
TSH12
42 50.5
46.25 ksi
2
(c) The tensile strength for 3004H16 is the average of the H14 and H18
treatments, and H14 is the average of the 0 and H18 treatments.
3004H0: TS 26 ksi
3004H18: TS 41 ksi
TSH14
26 41
33.5 ksi
2
TSH16
41 33.5
37.25 ksi
2
139 Suppose, by rapid solidification from the liquid state, that a supersaturated Al7%
Li alloy can be produced and subsequently aged. Compare the amount of b that will
form in this alloy with that formed in a 2090 alloy.
Solution:
The 2090 alloy contains 2.4% Li; from the AlLi phase diagram, the composition of the b is about 20.4% Li and that of the a is approximately 2%
Li at a typical aging temperature or at room temperature:
Al7% Li:
%b
72
100% 27%
20.4 2
2090:
%b
2.4 2
100% 2.2%
20.4 2
1310 Determine the amount of Mg2Al3 (b) expected to form in a 5182O aluminum
alloy. (See Figure 135.)
Solution:
The 5182 alloy contains 4.5% Mg. Thus from the MgAl phase diagram,
which shows the a contains about 0% Mg and B contains about 35% Mg:
%b
1311
4.5 0
100% 12.9%
35 0
Based on the phase diagrams, which of the following alloys would be most suited
for thixocasting? Explain your answer. (See Figures 133 and phase diagrams from
Chapters 10 and 11.)
(a) Al12% Si
Solution:
(b) Al1% Cu
(c) Al10% Mg
Alloys best suited for thixocasting are those with a large freezing range.
Of the alloys listed, Al10% Mg has a freezing range of 110C, which is
the largest freezing range of the three and is therefore most desirable.
Al12% Si is a eutectic alloy (approximately 0C freezing range), and
Al1% Mg has a freezing range of only 10C.
152
1312 From the data in Table 136, estimate the ratio by which the yield strength of magnesium can be increased by alloying and heat treatment and compare with that of
aluminum alloys.
Solution:
The exact values will differ depending on the alloys we select for comparison. The table below provides an example. Strengthening of Mg is
only about 110 as effective as in Al.
Magnesium
YS
YS/YS Mg
Pure Mg:
Cold Worked
Casting & T6
(ZK61AT6)
Wrought & T5
(AZ80AT5)
Aluminum
YS
YS/YSAl
13 ksi
17 ksi
28 ksi
1.3
2.2
Pure Al
CW 11000
51820 Alloy
2.5 ksi
22 ksi
19 ksi
8.8
7.6
40 ksi
3.1
2090T6
75 ksi
30.0
1313 Suppose a 24-in.-long round bar is to support a load of 400 lb without any
permanent deformation. Calculate the minimum diameter of the bar if it is made of
(a) AZ80AT5 magnesium alloy and (b) 6061T6 aluminum alloy.
Calculate the weight of the bar and the approximate cost (based on pure Al and Mg)
in each case.
Solution:
A FYield Strength
(a) AZ80AT5: YS 40 ksi
A 40040,000 0.01 in.2
d 14Ap 0.113 in.
d 0.113 in.
10,002 m 10,000 m
0.0002 m/m 0.0002 in./in.
10,000 m
CHAPTER 13
Nonferrous Alloys
153
1317 Compare the percentage increase in the yield strength of commercially pure
annealed aluminum, magnesium, and copper by strain hardening. Explain the
differences observed.
Solution:
Al:
22,000
1100H18
100% 440%
11000
5,000
Mg:
C.W.
17,000
100% 130%
Annealed
13,000
Cu:
70% C.W.
53,000
100% 1100
Annealed
4,800
Both Al and Cu (with an FCC structure) have high strain hardening coefficients and can be cold worked a large amount (due to their good ductility). Mg has the HCP structure, a low strain hardening coefficient, and a
limited ability to be cold worked.
1318 We would like to produce a quenched and tempered aluminum bronze containing
13% Al. Recommend a heat treatment, including appropriate temperatures.
Calculate the amount of each phase after each step of the treatment.
Solution:
13 9.4
54.5%
16 9.4
The lead rich phase may melt during hot working or may form stringers
during cold working.
We must be sure that the temperature is low enough to avoid melting of
the lead phase.
154
1320 Would you expect the fracture toughness of quenched and tempered aluminum
bronze to be high or low? Would there be a difference in the resistance of the alloy
to crack nucleation compared to crack growth? Explain.
Solution:
1321 Based on the photomicrograph in Figure 138(a), would you expect the g
precipitate or the carbides to provide a greater strengthening effect in superalloys at low
temperatures? Explain.
Solution:
The g
phase is more numerous and also more uniformly and closely
spaced; consequently the g
should be more effective than the smaller
number of coarse carbides at blocking slip at low temperatures.
1322 The density of Ni3Al is 7.5 g/cm3. Suppose a Ni5 wt% Al alloy is heat treated so
that all of the aluminum reacts with nickel to produce Ni3Al. Determine the volume
percent of the Ni3Al precipitate in the nickel matrix.
Solution:
Lets assume that the density of the Ni5 wt% Al alloy is the same as that
of pure Ni (8.902 g/cm3).
In 100 g of the alloy, the total atoms present are:
195 g/Ni2NA
15 g Al2NA
58.71 g/mol
26.981 g/mol
1.6181 NA 0.1853 NA 1.803 NA
atoms
If all of the Al reacts to form Ni3Al, then the number of atoms in the compound is 0.1853 NA of Al and (3)(0.1853 NA) 0.5559 NA of Ni.
The weight of the Ni3Al is then:
10.1853 NA of Al2126.981 g/mol2
NA
10.5559 NA of Ni2158.71 g/mol2
NA
37.64 g of Ni3Al
wt
CHAPTER 13
Nonferrous Alloys
155
1324 When steel is joined using arc welding, only the liquid fusion zone must be protected by a gas or flux. However, when titanium is welded, both the front and back
sides of the welded metal must be protected. Why must these extra precautions be
taken when joining titanium?
Solution:
13 25 Both a Ti15% V alloy and a Ti35% V alloy are heated to a temperature at which
all b just forms. They are then quenched and reheated to 300C. Describe the
changes in microstructures during the heat treatment for each alloy, including the
amount of each phase. What is the matrix and what is the precipitate in each case?
Which is an age-hardening process? Which is a quench and temper process? [See
Figure 1314(a)]
2
Solution:
46 15
100% 76%
46 5
b 24%
46 35
100% 27%
46 5
b 73%
% u 36.3%
156
1328 Determine the specific strength of the strongest Al, Mg, Cu, Ti, and Ni alloys. Use the
densities of the pure metals, in lb/in.3, in your calculations. Try to explain their order.
Solution:
Ti
Al
Mg
Cu
Monel
W
Strength
(psi)
Density
Strength-toweight ratio
176,000
73,000
40,000
175,000
110,000
220,000
Titanium is both strong and relatively low density. Cu, Ni, W are strong
but dense. Al and Mg have modest strength but light weight.
1329 Based on the phase diagrams, estimate the solubilities of Ni, Zn, Al, Sn, and Be in
copper at room temperature. Are these solubilities expected in view of HumeRotherys conditions for solid solubility? Explain.
Solution:
Solubility
Structure
Valence
CuNi
100% Ni
FCC
CuZn
30% Zn
HCP
CuAl
8% Al
FCC
CuBe
0.2% Be
hex
CuSn
0% Sn
DC
100
2.7%
100 4.2%
100 12.1%
100
10.6%
100 9.9%