Non-ferrous metals and alloys

NON-FERROUS METALS
AND ALLOYS

Al, Cu, Zn, Mg, Ti, Ni, Co, W, V …

and their alloys – all except of Fe and
ferrous alloys (steels and cast irons)

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Non-ferrous metals and alloys
Classification of non-ferrous
materials (1)
a) Density based:
– light metals and alloys ρ < 5000 kg/m3 (Mg, Al, Ti)
– medium metals and alloys ρ = 5000...10000 kg/m3 (Sn, Zn, Sb, Cr, Ni, Mn,
Fe, Cu)
– heavy metals and alloys ρ >10000 kg/m3 (Pb, Ag, Au, Ta, W, Mo)

b) Melting temperature based:

– low melting point Tm < TmPb = 327 °C (Sn, Pb, Bi)
– medium melting point = 327…1539 °C (Al, Mg, Mn, Cu, Ni, Co, Ag, Au)
– refractory Tm > TmFe = 1539 °C

Element Ti Cr V Nb Mo Ta W
Tm, °C 1660 1875 1900 2415 2610 2996 3410

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Non-ferrous metals and alloys

Classification of non-ferrous materials(2)

c) Manufacturing based (schematic classification by phase diagram):
- deformable alloys
- cast alloys L (Liquid)

L (Liquid) d) Heat treatment based:

HT: annealing, hardening,
ageing
- non heat treatable (no solubility)
- heat treatable (HT)

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The heat treatment effect
Non-ferrous metals and alloys

Aluminium and aluminium alloys

Pure Al Al-alloys Powder aluminium

Deformable Cast alloys

alloys

Heat- Non heat- Heat- Non heat-

treatable treatable treatable treatable
Partial No Partial No
solubility solubility solubility solubility

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Non-ferrous metals and alloys

Pure Al
- Metallurgical (99,5…99,8% Al)
- Refined (up to 99,9% Al)
Al 99,9% Rm = 70…135 N/mm2
Work hardening of Al
Conditions designations
O – annealed
H – work hardened
(degree of hardening H1-H9)
W – quenched
T – quenched and
aged (T1-T9)
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Non-ferrous metals and alloys

Heat treatment of Al-alloys (1)

Quenching → water → α-structure Rm, Rp0,2 ↓; A, Z ↑

Ageing:  naturally aged (20 °C) → structure  + Guinier`-Preston zones
artificially aged Rm, Rp0,2↑, A, Z ↓
Result –
precipitation
hardening low (100…150 °C) high (200…250 °C)
(Rp0,2/Rm = 0,6…0,7) (Rp0,2/Rm = 0,9…0,95) 6
Non-ferrous metals and alloys

Designation system of Al and Al-alloys

(EVS-EN573 and 1780)
Designation
(chemical composition based)
• deformable alloys – EN-AW...(EN-AW-AlCu4Mg1)
• cast alloys – EN-AC...(EN-AC-AlSi11)

Designation of heat treatment (EN515)

• O – annealed (for ex. 01, 02, 03)
• H – work hardened (for ex. H1, H2...H9)
• W – quenched
• T – heat treated (for ex. T1, T2...T10, T31, T3510)

Mainly used: T4 – quenching + natural ageing

T6 – quenching + artificial ageing

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Non-ferrous metals and alloys
Designation system of Al and Al-alloys(2)
Materials numbers
Deformable alloys
Series 1000 – pure Al
2000 – Al-Cu-alloys (for ex EN-AW-2014)
3000 – Al-Mn-alloys
4000 – Al-Si-alloys
5000 – Al-Mg-alloys
6000 – Al-Mg-Si-alloys
7000 – Al-Zn-alloys
8000 – Al-Fe-alloys
Cast alloys
Series 10000 – pure Al
20000 – Al-Cu-alloys
40000-48000 – Al-Si-alloys (for ex EN-AC-44000)
50000 – Al-Mg-alloys
70000 – Al-Zn-alloys

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Non-ferrous metals and alloys

Aluminium alloys (1)

Deformable alloys
- Deformable and heat treatable
Solubility
1) Al-Cu-Mg-alloys (duraluminium) Cu → 5,7%
2) Al-Cu-Mg-Si-alloys (forgable) Mg → 14,9%
3) Al-Mg-Si-alloys (corrosion resistance)
4) Al-Zn-Mg-Cu-alloys (high strength)
5) Al-Cu-Mg-Ni-Fe-alloys (heat resistance)

Rm → 500 N/mm2; Rp0,2 → 390 N/mm2; A → 25%

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Non-ferrous metals and alloys

Aluminium alloys (2)

- Deformable and non heat treatable
1) Al-Mn-alloys 1…2% Mn
2) Al-Mg-alloys (magnalium) 2…5% Mg

Rm → 300 N/mm2; Rp0,2 → 150 N/mm2; A → 25%

- plane bearing alloys (for mono- and bimetallic bearing shells)

Al-Sn; Al-Ni; Al-Cu-Sb Typical structure of bearing material

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Non-ferrous metals and alloys

Aluminium alloys (3)

T, C
Cast alloys (1) 1000

L
Requirements: 800 1..2% of NaF+NaCl
L+Si
- low Tm (Al-Si eutectic alloys - 657
577 °C at 11,7 % Si, by 600 +L 577

mofification 564 °C at 14 % Si) 564
400
+ S i
- high fluidity (short interval of
liqvidus and solidus lines) 200

1 ,6 5 1 1 ,7 1 4 ,0
0
0 10 20 30 40 50
A l Si % Si

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Non-ferrous metals and alloys

Aluminium alloys (4)

Cast alloys (2)
1) Al-Si-alloys ↓ Rm (250), A = 1,7 % Pumps and engine
bodies, cylinder heads
2) Al-Cu-alloys Rm ↑ than I group Cylinder heads,
↓ high temp. strength apparatures bodies

3) Al-Si-Cu-alloys Rm ↑ than I group → 350 °C

↓ high temp. strength
4) Al-Mg-alloys Rm, A; good corr. resist.; → 100 °C
(magnalium) ↓ castability
5) Al- other inclusions high temperature → 350 °C
strength parts of aircraft
engines

Rm → 340 N/mm2; A → 8% (depending on casting mode)

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Non-ferrous metals and alloys

Copper and copper alloys

Pure Cu Cu-alloys

Brasses Bronzes Cupronickels

Deformable Cast Deformable Cast

alloys alloys alloys alloys

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Non-ferrous metals and alloys

Pure Cu
Annealed Cu (99,85% Cu); Rm → 250 N/mm2
El. conductivity 1/ρ = 58 Ω·mm2/m = 100% IACS
Strengthening of Cu at work hardening
Conditions designations
A – elongation (ex A007)
B – bending strength (ex B410)
G – grain size (ex G020)
H – HB or HV (ex H150)
R – tensile strength (ex R500)
Y – yield strength (ex Y460)

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Non-ferrous metals and alloys

Designation system of Cu and Cu-alloys (1)

Designation
• pure Cu – Cu-ETP etc.
• Cu deformable alloys – CuZn36Pb3
• Cu cast alloys – G-CuSn10 (types of casting : GS – sand casting,
GM – die casting, GZ – centrifugal casting,
GS – cont. casting , GP – pressure die casting)

Conditions (properties) based designation after main designation

(EN1173)
Letters
A – elonagtion (ex Cu-OF-A007)
B – bending strength (ex CuSn8-B410)
D – drawn, without mech. properties
G – grain size (ex CuZn37-G020)
H – hardness (Brinell or Vickers) (ex CuZn37-H150)
M – as manufactured cond. , without mech. properties
R – tensile strength (ex CuZn39Pb3-R500)
Y – yield strength (ex CuZn30-Y460)
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Non-ferrous metals and alloys

Designation system of Cu and Cu-alloys (2)

Materials numbers
Includes 2-digit marking, followed by three digit designating
the material group
(000...999)
C – copper based alloy
CB – ingot
CC – casting
CM – master alloy
CR – rafined Cu
CS – brazing and welding material
CW – wrought
CX – non standardized material

For example Designation Material No.

Deformable copper Cu-0F CW009A
Deformable alloys CuZn37 CW508L
Cast copper Cu-C CC040A
Cast alloys CuSn10-C CC480K 16
Non-ferrous metals and alloys

Copper alloys (1)

Cu-Zn alloys – brasses (ex CuZn20)
Influence of Zn to properties Influence of Pb to machining

Free cutting brass – 100%

(comp.: 40% Zn, 2% Pb) 
CuZn40Pb2

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Non-ferrous metals and alloys

Copper alloys (2)

Cu-Ni alloys (→ 50% Ni)
- permanent CTE
(constantan) – 45% Ni
- corrosion resistant
(Ni+Fe+Mn) – 30% Ni

Cu - 25% Ni
(coin melhior, cupronickel).
Cu - 10-20% Ni + 20-35% Zn
(new silver, alpaca).
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Non-ferrous metals and alloys

Copper alloys (3)

Cu with other elements - bronzes

- Cu-Sn (tin bronzes) → solubility 15,8% Sn (5…20%)

- Cu-Sn-P (phosphor bronzes) → 0,1%P
- Cu-Pb (lead bronzes) → 20% Pb
- Cu-Al (aluminium bronzes) → 9,8% Al (~10% Al)
Rm → 700 N/mm2
- Cu-Si (silicon bronzes) → 5,3% Si (~3% Si)
- Cu-Be (beryllium bronzes) – spring bronze
Rm → 1400 N/mm2 (H + AA) Typical structure of bearing material

Application as plane bearing

materials (as cast)
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Non-ferrous metals and alloys

Cu-alloys: Estonian* vs Euro coins**

Alloy: Nordic gold (Cu89Al5Zn5Sn1)
Alloy: Cu93Al5Ni2 Diameter (mm): 19,75
Diameter (mm): 17,20 Weight (g): 4,10
Weight (g): 1,87
Alloy: Nordic gold (Cu89Al5Zn5Sn1)
Diameter (mm): 22,25
Weight (g): 5,74
Alloy: Cu93Al5Ni2
Diameter (mm): 18,95
Alloy: Nordic gold (Cu89Al5Zn5Sn1)
Weight (g): 2,27
Diameter (mm): 24,25
Weight (g): 7,8

Alloy: rim - nickelbronze (Cu75Zn20Ni5);

Alloy: Cu93Al5Ni2 center - three layered: cupronickel (Cu75Ni25), nickel, cupronickel
Diameter (mm): 19,50 Diameter (mm): 23,25
Weight (g): 7,50
Weight (g): 2,99

Alloy: Cu89Al5Zn5Sn1
Diameter (mm): 23,25 Alloy: rim - kupronickel;
center - three layered: nickelbronze, nickel, nickelbronze
Weight (g): 5,00 Diameter (mm): 25,75
Weight (g): 8,50

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**Source: European Central Bank
*Source: Bank of Estonia
Non-ferrous metals and alloys

Zinc and zinc alloys

Pure Zn
Tm – 419 °C
Density – 7140 kg/m3
Good corrosion resistance

Zn- alloys
Zn – Al Precision casting material
Zn – Al – Cu Bearing alloy material

Designation Material No.

ex ZnAl8Cu1 ZP0810
Z – Zn-alloy
P – casting
first two numbers – Al%, 3.─ Cu%, 4.–T- rest

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Non-ferrous metals and alloys
Zinc cast alloys (EN12844)
Designation Rm Rpo,2 A HB Application
2 2 %
N/mm N/mm

ZnAl4 280 200 10 83 Excellent castability,

(ZP3)
ZnAl4Cu1 330 250 5 92 machinability;
(ZP5)
ZnAl8Cu1 370 220 8 100 Universal applications:
(ZP8)
ZnAl11Cu1 400 300 5 100 deep-draw and blow
(ZP12) molds for plastics
ZnAl27Cu2 425 300 2,5 120
(ZP27)

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Non-ferrous metals and alloys

Magnesium and magnesium alloys

Pure Mg
Tm – 649 °C
Density – 1740 kg/m3 (lightest among the engineering
materials)
Mg-alloys
- Mg – Mn (up to 2,5 %)
- Mg – Al – Zn (up to 10 % Al, 5 % Zn)
Heat treatment of Mg-alloys
Similar to Al-alloys
Quenching + age hardening (NA, AA → MgZn2, Mg4Al3 jt) →
Rm ↑ 20 … 30 %

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Non-ferrous metals and alloys
Mg-alloys
Designation
• deformable (ex MgMn2)
• cast alloys (ex designation MCMgAl8 / material No. MC21110)
Deformable Mg-alloys

Designation Rm Rp0,2 A Applications

2 %
N/mm

MgMn2 200 145 15 Corrosion resistant, weldable

MgAl8Zn 310 215 6 cold formable; conteiners, car ,
aircraft and machine
manufacturing
Mg cast alloys (EN173)
MCMgAl8Zn1 240 90 8 Good castability. Dynamically
MCMgAl6 190-250 120-150 4-14 loadable. Car and aircraft
MCMgAl4Si 200-250 120-150 3-12 manufacturing.
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Non-ferrous metals and alloys

Titanium and titanium alloys

Pure Ti
Tm – 1660 °C
Density – 4540 kg/m3
Very active to O, C, N → 2x hardnes increase
Ti-alloys, classification
Ti – Al – alloys (4…6 % Al) – -alloys
Ti – Al – Cr, V, Cu, Mo - alloys –  + -alloys
Ti – Al – Mo, Cr, Zr - alloys – -alloys
Heat treatment of Tialloys
Heating up to -area (850…950 °C) and cooling  martensitic
transformation.
Ageing (450…600 °C) – max effect by -stabilisators
(Cr, Mn, Fe, Ni, Cu, Si)
Additional heat treatment – nitriding (750…900 HV)

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Non-ferrous metals and alloys
Titanium alloys
Designation HB Rm Rpo,2 A Applications
2 2 %
N/mm N/mm

Ti 1…3 120-170 290-590 180-320 30-18 Weldable,

machinable and
cold formable.
Ti1Pd, 120-150 290-540 180-250 30-22 Corrosion resistant
Ti2 Pd light constructions.
TiAl6V4 310 900-920 830-870 8 Machine elements in
medicine, food,
ZnAL11Cu1 350  1050 1050 9 chemical and
(ZP12) aircraft industry.
Advantages:
• highest specific strength
• good formability
Disadvantages:
• need for a protective atmosphere at HT (Ar)
• problematically casted (reacting with ladle material, ZrO2 must be used) 26