Copper Alloys-Nonferrous Metals

Nonferrous metallurgy is as varied as the ores and finished products. Almost every thermal, chemical, and physical process known to engineers is in use. The general classification scheme that follows gives an understanding of the emissions and control systems aluminum (primary and secondary), beryllium, copper (primary and secondary), lead (primary and secondary), mercury, zinc, alloys of nonferrous metals (primary and secondary), and other nonferrous metals. 

Alloys of nonferrous metals, primarily the brasses (copper and zinc) and the bronzes (copper and tin), can cause an air pollution problem during melting and casting. The type and degree of emissions depend on the furnace and the alloy. Control systems consist of hoods over the furnaces and pouring stahons to collect the hot gases, ducts and fans, and baghouses or ESPs. 

Although this reaction may cause slight problems, the primary issue concerning ammonia is ammoniacal corrosion of CR system metals where oxygen is present and the pH is over 8.3. Under these circumstances, copper and its alloys and other nonferrous metals are attacked, and severe damage results due to the formation of a stable cupric ammonium complex ion. 

Aluminum and aluminum alloys Copper and copper alloys Rare-earth and rare-earth-like metals and alloys Low-melting metals and alloys Miscellaneous nonferrous metals and alloys Nickel and nickel alloys Precious metals and alloys Reactive and refractory metals and alloys... 

The metal casting industry conventionally divides casting products into ferrous and nonferrous metals, in particular, iron-based, steel-based, aluminum-based, and copper-based castings. The other castings of low fractions include magnesium, lead, zinc, and their alloys. In the U.S., the foundry industry currently produces 11 million tons of metal product per year, with a shipment value of 19 billion. Of them, iron and steel accounted for 84% of metals cast.5 The remaining 15% of foundry operations are concerned with aluminum, copper, zinc, and lead production. Table 4.2 summarizes critical physical and thermal properties of aluminum, iron/steel, and cast iron. 

Nickel (Ni)/Copper (Cu)/Zinc (Zn) Nickel exhibits a mixture of ferrous and nonferrous metal properties, and Ni-based alloys are characterized by corrosion resistance. Therefore, Ni has been widely used in stainless steel (about 65% of the Ni consumed in the Western World) and superalloys/nonferrous alloys (12%). Turbine blades, discs and other critical parts of jet engines and land-based combustion turbines are fabricated from superalloys and Ni-based superalloys. The remaining 23% of consumption is applied in alloy steels, rechargeable batteries, catalysts and other chemicals, coinage, foundry products, and plating (USGS, 2006). 

Copper and its nonferrous metal alloys, bronze and brass, are used to manufacture tubing, ferrules, valves, and a variety of fittings. Although their use is somewhat limited in automotive fuel systems, they are found commonly throughout fuel storage and distribution systems. Copper steam coils and brass hardware may be utilized due to their excellent resistance to corrosion and high level of thermal conductivity. Described below are some of the more common alloys of copper and their applications ... 

Metal Coatings. Tellurium chlorides, as well as tellurium dioxide in hydrochloric acid solution, impart permanent and attractive black antique finish to silverware, aluminum, and brass. Anodized aluminum is colored dark gold by tellurium electro deposition. A solution containing sodium tellurate and copper ions forms a black or blue-black coating on ferrous and nonferrous metals and alloys. Addition of sodium tellurite improves the corrosion resistance of electroplated nickel. Tellurium diethyldithiocarbamate is an additive in bright copper electroplating (see Electroplating). 

A leather belt was still in place on the body and was fastened with a metal buckle and keeper. Both of these were cast in a nonferrous alloy and were originally plated with a copper alloy. The leather was in good condition, being intact but lacking flexibility due to burial. The metal had corroded to form a corrosion crust that was consistent with burial duration and conditions. The shoes were intact, consisting of leather uppers, synthetic sole and containing the remains of dyed cotton socks and the small bones of the foot. 

Diamond-coated tools are primarily used in the machining of nonferrous metals, alloys, and composite materials that are inherently very difficult to cut or machine. The range of materials that are suitable for machining by diamond-coated tools include aluminum and its alloys (in particular high-silicon aluminum alloys) magnesium audits alloys copper, lead, and manganese alloys graphite carbon plastics ... 

Fibers and chips of nonferrous metals and alloys like copper, brass, aluminum, zinc, and bronze are used in friction materials to provide the desired friction and wear performance. Porous and solid metal powders like tin, brass, copper, bronze, and iron are also used in some products. As mentioned earlier, some metal powders are also used as binders in sintered formulations. 

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