Metallurgy 6918e
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Lecture 1
Nonferrous metallurgy Subjects of interest • Overviews of nonferrous metals • Aluminium and aluminium alloys • Magnesium and magnesium alloys • Titanium and titanium alloys • Copper and copper alloys • Zinc and its alloys • Nickel and its alloys • Other significant alloys
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Nonferrous metallurgy Course instruction Lecturer:
Dr. Tapany Udomphol
Assessment Assignment/quiz Midterm exam Final exam
20 % 40 % 40 %
Total
Suranaree University of Technology
100 %
Tapany Udomphol
May-Aug 2007
Objectives • This course provides fundamental knowledge of metals other than ferrous metals, for example aluminium, magnesium, copper, zinc, titanium and nickel alloys, which are significant for commercial uses. • This starts with when the metals are extracted, melted and formed in relation to their final applications. More importantly, the nature of the alloys associated with their physical and mechanical properties will be highlighted. • The selection of nonferrous alloys for the desired applications will be discussed such that the exploitation of nonferrous metals will be at its best.
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Overview of nonferrous metals Why nonferrous?
Light weight Stiffness –strength to weight ratio High temperature properties
Nonferrous
Oxidation resistance Corrosion resistance
High cost Depending on extraction and production Suranaree University of Technology
Biocompatibility Thermal/electrical conductivity Tapany Udomphol
May-Aug 2007
Nonferrous metals There are different types of nonferrous metals which are commercially used;
• Aluminium and its alloys • Magnesium and its alloys • Titanium and its alloys • Copper and its alloys • Zinc and its alloys • Nickel and its alloys
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
World consumption
• Aluminium, titanium and magnesium alloys are increasingly used in recent years due to its attractive properties. • The reserves for these alloys are adequate for demands in centuries to come but will be controlled by future cost.
World production figure for various metals and plastics. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Major chemical elements available in earth
Aluminium is the most abundant metal in earth. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Density of metals
Metal
Density (g.cm-3)
Iron Steel Aluminium Magnesium Titanium Copper Zinc Nickel Lead Silver Gold
Suranaree University of Technology
7.87 7.80 2.70 1.74 4.54 8.96 7.13 8.89 11.36 10.49 19.32
Tapany Udomphol
May-Aug 2007
Total energy consumption for the production of nonferrous metals Total energy consumption
Ti > Mg > Al > Cu > Zn > Steel
The energy consumption is mainly paid in the reduction process.
Total energy consumption in megawatt hours for each stage of production (1993).
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Mechanical properties in comparison
Relationship of specific 0.2% proof stress with temperature.
• Titanium alloys have superior specific strength than steels or aluminium good for high strength where space is critical such aircrafts. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Aluminium and its alloys Applications
Advantages:
• Light weight • High corrosion resistance • High electrical and thermal conductivities • High ductility • Easily deformable
• Building/construction • Container • Packaging • Transportation • Electrical conductors • Machinery/equipment
Building/ construction
Containers
Light-weight bike
Car body Suranaree University of Technology
Tapany Udomphol
Equipment
May-Aug 2007
Magnesium and its alloys Advantages:
• Weight saving • High machinability Disadvantages:
• Difficulty in melting process due to high reactivity.
Applications
• Used as alloying element for aluminium, steel and nodular (SG) cast iron. • Die casting for aerospace • Transport industry. • Light weight bodies.
Handy cam & mobile phone bodies Magnesium side s Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Titanium and its alloys Advantages:
• High strength to weight ratio • Moderate-high temperature properties • Corrosion resistance • Biocompatibility • Shape memory Disadvantages:
Applications
• Structure of high speed aircrafts • 75% in aerospace • Chemical industry www3.lehigh.edu
Turbine blades
Hip-t component
• High cost • Difficulty in extraction • Limited in high performance applications National science centre, Scotland Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Copper and its alloys Advantages:
• High electrical conductivity • High thermal conductivity • High corrosion resistance • Good ductility and malleability • Reasonable tensile strength.
Copper trolley wires
www.reawire.com
Applications • Electrical conductance • Plating on components • Give different copper alloys brasses and bronzes.
www.bergquistcompany.com
Electronic products Suranaree University of Technology
Tapany Udomphol
www.silvexinc.com
Copper plating May-Aug 2007
Zinc and its alloys Advantages: • Fast rate of die casting • Excellent atmospheric corrosion resistance. • Ability to form a well-adhering coating on steel.
Applications • Used for galvanic protection in steel and decorative finish. • Used in die casting.
Disadvantages:
www.zincdiecast.com
• Cannot be strain hardened.
Zinc diecast www.vmzinc.com
Zinc roof protection
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Nickel and its alloys Advantages: • Tough and ductile • Good high and low temperature strength • High oxidation resistance • Good corrosion resistance
Applications • Applications required necessary corrosion or heat- resisting properties • Special engineering applications • Turbine blades in combustion section
Disadvantages: • High cost • Not normally mixed with cheaper alloying metals
www.immnet.com
Aerospace flow bodies
www.msm.cam.ac.uk Suranaree University of Technology
Tapany Udomphol
Turbine blades May-Aug 2007
References • Polmear I.J., Light alloys: metallurgy of the light metals, 3rd edition, 1995, Arnold, London, ISBN 0-340-63207-0. • Smith, W.F., Structure and properties of engineering alloys, second edition, 1993, McGraw-Hill, ISB 0-07-59172-5. • , กก ก, 2536, ก
ก !"
", ISBN 974-582155-1. • Kainer, K.U. (editor), Magnesium alloys and technology, DMG, 2003, WILEY-VCH, ISBN 3-527-30256-5. • Hatch, J.E., Aluminium, Properties and physical metallurgy, ASM, 1998. • Totten, G.E., Handbook of aluminium: Physical metallurgy and processes, Vol.1, Marcel Dekker, Inc., 2003, ISBN 0-8247-0494-0. • Avedesian, M.M., Baker, H., ASM specialty handbook, Magnesium and magnesium alloys, 1999, ISBN 0-87170-657-1.
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Nonferrous metallurgy Subjects of interest • Overviews of nonferrous metals • Aluminium and aluminium alloys • Magnesium and magnesium alloys • Titanium and titanium alloys • Copper and copper alloys • Zinc and its alloys • Nickel and its alloys • Other significant alloys
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Nonferrous metallurgy Course instruction Lecturer:
Dr. Tapany Udomphol
Assessment Assignment/quiz Midterm exam Final exam
20 % 40 % 40 %
Total
Suranaree University of Technology
100 %
Tapany Udomphol
May-Aug 2007
Objectives • This course provides fundamental knowledge of metals other than ferrous metals, for example aluminium, magnesium, copper, zinc, titanium and nickel alloys, which are significant for commercial uses. • This starts with when the metals are extracted, melted and formed in relation to their final applications. More importantly, the nature of the alloys associated with their physical and mechanical properties will be highlighted. • The selection of nonferrous alloys for the desired applications will be discussed such that the exploitation of nonferrous metals will be at its best.
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Overview of nonferrous metals Why nonferrous?
Light weight Stiffness –strength to weight ratio High temperature properties
Nonferrous
Oxidation resistance Corrosion resistance
High cost Depending on extraction and production Suranaree University of Technology
Biocompatibility Thermal/electrical conductivity Tapany Udomphol
May-Aug 2007
Nonferrous metals There are different types of nonferrous metals which are commercially used;
• Aluminium and its alloys • Magnesium and its alloys • Titanium and its alloys • Copper and its alloys • Zinc and its alloys • Nickel and its alloys
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
World consumption
• Aluminium, titanium and magnesium alloys are increasingly used in recent years due to its attractive properties. • The reserves for these alloys are adequate for demands in centuries to come but will be controlled by future cost.
World production figure for various metals and plastics. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Major chemical elements available in earth
Aluminium is the most abundant metal in earth. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Density of metals
Metal
Density (g.cm-3)
Iron Steel Aluminium Magnesium Titanium Copper Zinc Nickel Lead Silver Gold
Suranaree University of Technology
7.87 7.80 2.70 1.74 4.54 8.96 7.13 8.89 11.36 10.49 19.32
Tapany Udomphol
May-Aug 2007
Total energy consumption for the production of nonferrous metals Total energy consumption
Ti > Mg > Al > Cu > Zn > Steel
The energy consumption is mainly paid in the reduction process.
Total energy consumption in megawatt hours for each stage of production (1993).
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Mechanical properties in comparison
Relationship of specific 0.2% proof stress with temperature.
• Titanium alloys have superior specific strength than steels or aluminium good for high strength where space is critical such aircrafts. Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Aluminium and its alloys Applications
Advantages:
• Light weight • High corrosion resistance • High electrical and thermal conductivities • High ductility • Easily deformable
• Building/construction • Container • Packaging • Transportation • Electrical conductors • Machinery/equipment
Building/ construction
Containers
Light-weight bike
Car body Suranaree University of Technology
Tapany Udomphol
Equipment
May-Aug 2007
Magnesium and its alloys Advantages:
• Weight saving • High machinability Disadvantages:
• Difficulty in melting process due to high reactivity.
Applications
• Used as alloying element for aluminium, steel and nodular (SG) cast iron. • Die casting for aerospace • Transport industry. • Light weight bodies.
Handy cam & mobile phone bodies Magnesium side s Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Titanium and its alloys Advantages:
• High strength to weight ratio • Moderate-high temperature properties • Corrosion resistance • Biocompatibility • Shape memory Disadvantages:
Applications
• Structure of high speed aircrafts • 75% in aerospace • Chemical industry www3.lehigh.edu
Turbine blades
Hip-t component
• High cost • Difficulty in extraction • Limited in high performance applications National science centre, Scotland Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Copper and its alloys Advantages:
• High electrical conductivity • High thermal conductivity • High corrosion resistance • Good ductility and malleability • Reasonable tensile strength.
Copper trolley wires
www.reawire.com
Applications • Electrical conductance • Plating on components • Give different copper alloys brasses and bronzes.
www.bergquistcompany.com
Electronic products Suranaree University of Technology
Tapany Udomphol
www.silvexinc.com
Copper plating May-Aug 2007
Zinc and its alloys Advantages: • Fast rate of die casting • Excellent atmospheric corrosion resistance. • Ability to form a well-adhering coating on steel.
Applications • Used for galvanic protection in steel and decorative finish. • Used in die casting.
Disadvantages:
www.zincdiecast.com
• Cannot be strain hardened.
Zinc diecast www.vmzinc.com
Zinc roof protection
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
Nickel and its alloys Advantages: • Tough and ductile • Good high and low temperature strength • High oxidation resistance • Good corrosion resistance
Applications • Applications required necessary corrosion or heat- resisting properties • Special engineering applications • Turbine blades in combustion section
Disadvantages: • High cost • Not normally mixed with cheaper alloying metals
www.immnet.com
Aerospace flow bodies
www.msm.cam.ac.uk Suranaree University of Technology
Tapany Udomphol
Turbine blades May-Aug 2007
References • Polmear I.J., Light alloys: metallurgy of the light metals, 3rd edition, 1995, Arnold, London, ISBN 0-340-63207-0. • Smith, W.F., Structure and properties of engineering alloys, second edition, 1993, McGraw-Hill, ISB 0-07-59172-5. • , กก ก, 2536, ก
ก !"
", ISBN 974-582155-1. • Kainer, K.U. (editor), Magnesium alloys and technology, DMG, 2003, WILEY-VCH, ISBN 3-527-30256-5. • Hatch, J.E., Aluminium, Properties and physical metallurgy, ASM, 1998. • Totten, G.E., Handbook of aluminium: Physical metallurgy and processes, Vol.1, Marcel Dekker, Inc., 2003, ISBN 0-8247-0494-0. • Avedesian, M.M., Baker, H., ASM specialty handbook, Magnesium and magnesium alloys, 1999, ISBN 0-87170-657-1.
Suranaree University of Technology
Tapany Udomphol
May-Aug 2007
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