Non Ferrous Metals

These are the non ferrous metals and their uses:

Aluminium An alloy of aluminium, copper and manganese. Very lightweight and easily worked. Used in
aircraft manufacture, window frames and some kitchen ware.

Copper Copper is a natural occurring substance. The fact that it conducts heat and electricity means that it
is used for wiring, tubing and pipe work.

Brass A combination of copper and zinc, usually in the proportions of 65% to 35% respectively. Is used
for ornamental purposes and within electrical fittings.

Silver Mainly a natural substance, but mixing with copper creates sterling silver. Used for decorative
impact in jewellery and ornaments, and also to solder different metals together.

Lead Lead is a naturally occurring substance. It is heavy and very soft and is often used in roofing, in
batteries and to make pipes.
http://www.castlemetalseurope.com/blog/ferrous-nonferrous-metals-uses/

http://copperalliance.org.uk/copper-and-its-alloys/properties

Copper is a metal that is extracted from the earth, is essential to the development of all forms of life and
has been vital in the progress of civilisation, contributing to both social and technological development
for more than 10,000 years

Chemical Properties

The chemical symbol for copper is Cu, from the Latin 'cuprum', meaning from Cyprus, from where the Romans
obtained much of their copper. Copper has the Atomic Number 29 (the number of protons in an atom) and is in the
group called 'Transition Metals' in the Periodic Table.

All common metals and alloys react with a moist atmosphere and corrode. Only in hot/dry (deserts) and cold/dry
environments do metals resist corrosion. However, with copper the corrosion process is very slow. The corrosion
resistance of copper and copper alloys is based on their ability to form stable compounds that provide some
protection from corrosive attack. When exposed to the atmosphere, protective layers of oxides and poorly soluble
basic salts form on the surface of copper and copper alloys. Suitable alloying elements can positively influence the
formation of these coatings.

Copper is in the same periodic table group as silver and gold. Therefore, it is relatively inert against chemicals. In
most of its compounds it can have the valency (oxidation state) of +I or the valency state +II. The aqueous solutions
of copper ions in the oxidation state +II have a blue colour, whereas copper ions in the oxidation state +I are
colourless. Copper and copper compounds give a greenish colour to a flame.

Mechanical Properties

The hardness, strength and ductility of copper determine its condition. The material condition (alternative term -
temper) is designated in standards by a letter with H representing hardness and R tensile strength.

Copper can be supplied in a range of conditions from annealed (soft) to fully hard, which is obtained by cold working.

Annealed copper (H040) has a hardness range 40 to 65HV, tensile strength 200 to 250 N/mm (R200) with fully cold
worked copper (H110) having a hardness of 110HV minimum and tensile strength of 360 N/mm ( R360) minimum.

The ductility of fully cold worked copper is much less than in the annealed condition with a value of 2% elongation.

The strength and hardness of copper can also be increased by alloying, but this results in a decrease in electrical
conductivity. The strongest copper alloy of all is produced by alloying with beryllium, resulting in a tensile strength of
up to 1500 N/mm.

Alloys
Coppers performance can be expanded to suit many industrial
applications. This is achieved by alloying: making a solid material out of two
or more different metals. By combining copper with other metals, alloys can
be made to fit almost any application.
Copper alloy tree
Pure copper has the best electrical and thermal conductivity of any commercial metal. Today, over half of the
copper produced is used in electrical and electronic applications and this leads to a convenient classification of the
types of copper into electrical (high conductivity) and non-electrical (engineering).
Copper forms alloys more freely than most metals and with a wide range of alloying elements to produce the
following alloys:

Brass is the generic term for a range of copper-zinc alloys with differing combinations of properties, including
strength, machinability, ductility, wear-resistance, hardness, colour, antimicrobial, electrical and thermal conductivity,
and corrosion-resistance.

Bronze alloys are made from copper and tin, and were the first to be developed about four thousand years ago.
They were so important that they led to a period in time being named the Bronze Age.

Gunmetals are alloys of copper with tin, zinc and lead and have been used for at least 2000 years due to their
ease of casting and good strength and corrosion resistance.
Copper-nickel alloys have excellent resistance to marine corrosion and biofouling. The addition of nickel to
copper improves strength and corrosion resistance, but good ductility is retained.

Nickel silver alloys are made from copper, nickel and zinc, and can be regarded as special brasses. They have
an attractive silvery appearance rather than the typical brassy colour.

Beryllium copper is the hardest and strongest of any copper alloy, in the fully heat treated and cold worked
condition. It is similar in mechanical properties to many high strength alloy steels but, compared to steels, it has better
corrosion resistance.

Physical Properties

Electrical Conductivity
The generation, transmission and use of electricity has transformed the modern world. This has been made possible
by copper (of at least 99.9% purity), which has the best electrical conductivity of any common metal and is available
in wrought form as wire, cable, strip and busbars and as castings for such components as electrical switchgear and
welding equipment.

Copper drives todays technology

Imagine a world without electricity: no lighting, TVs, DVD players, iPads, electric kettles, mobiles, washing machines,
fridges, vacuum cleaners, computers, cars, buses, electrified railways, underground transport systems or trams.

Cars and trucks

A high-purity copper wire harness system carries current from the battery throughout a vehicle to equipment such as
lights, central locking, onboard computers and satellite navigation systems. Electric motors, which are wound with
high conductivity wire, are used in many of these devices. The average car contains about 1 km of wire.

Thermal Conductivity
Copper is a good conductor of heat (about 30 times better than stainless steel and 1.5 times better than aluminium).
This leads to applications where rapid heat transfer is required such as heat exchangers in air conditioning units,
vehicle radiators, heat sinks in computers, heat sealing machines and televisions, and as water-cooled furnace
components.

Good-quality spark plugs have a central copper electrode to enable heat to be removed and prevent overheating. The
 best quality saucepans are copper bottomed to ensure uniform, rapid heating.

Copper plays a crucial role in modern society. It is used by more individuals, and in more applications, than most
people realise.

Ease of Joining
Copper can be readily joined by brazing, soldering, bolting or adhesives. In industry, this is very useful for plumbing
pipework and joining busbars, which are vital elements of power distribution systems. Elsewhere, it is also an
important feature for artists crafting sculptures and statues, and for jewellery makers and other artisans working with
this beautiful metal.

Pipework
Water: Copper was used by the ancient Egyptians; samples taken from the Pyramids are still in good condition.
Today copper tube is used for approximately 90% of European and North American hot and cold water supplies in
diameters ranging from 6 to 159mm.

Gas: As well as distributing water for domestic plumbing, copper tubes are used to safely convey natural gas to
homes and businesses.

Coppers

Today, over half of the copper produced is used in electrical and electronic applications and this leads to a
convenient classification of the types of copper into:

Electrical (high conductivity)

Non-electrical (engineering).

High Conductivity Coppers (Electrical)

Wrought high conductivity copper has excellent ductility and, as a result, is available in forms such as wire, tube,
extrusions, bar and sheet.

The main grade of copper used for electrical applications such as building wire, motor windings, cables and busbars
is electrolytic tough pitch copper CW004A (was C101) which is at least 99.90% pure and has an electrical
conductivity of at least 101% IACS minimum. Tough pitch copper contains a small % of oxygen (0.02 to 0.04%) so if
the high conductivity copper is to be welded or brazed or used in a reducing atmosphere, then the more expensive
oxygen free high conductivity copper CW008A (was C103) may be used.

Wrought high conductivity coppers (CW004A and CW008A) can only be strengthened and hardened by cold working
such as occurs on cold drawing or bending (typically tensile strength 250N/mm2 with 12% elongation). They cannot
be strengthened by heat treatment so, if a stronger grade of high conductivity copper is required, then small amounts
(less than 1%) of alloying elements such as silver, cadmium, magnesium or tin are used. These additions give solid
solution hardening and contribute to work hardening when the alloys are cold drawn into wires or tubes or rolled into
sheet. However, there is a small loss of conductivity. These alloys, with 90 to 100% IACS values are typically used for
overhead conducting and catenary wires on railway and tram systems to transmit electric current to the electric
motors of trains and trams.

High conductivity copper may also be produced as die and sand castings (CC040A), typically for electrical switchgear
and electrode holders.

The electrical conductivity of castings may be slightly lower than in wrought copper, however a minimum value of
93% IACS is guaranteed but values up to 100% are reached.

Higher Strength Alloys

Small additions of silver, cadmium, magnesium or tin are used to give a small increase in the strength of copper
conductors but, for significant increases in strength, the heat treatable copper chromium (0.5-1.2% Cr) and copper
chrome zirconium (0.1% Zr) alloys have been developed in cast and wrought form. These alloys combine high
strength (tensile strength 450N/mm2 with 10% elongation, up to 400oC) with high electrical conductivity (75 to 78%
IACS) and high thermal conductivity. The properties of these alloys are developed by a heat treatment process which
involves heating to 950-1000oC (solution treatment), followed by water quenching then reheating to 425-500oC
(precipitation hardening). In addition to this heat treatment wrought alloys are strengthened by cold working.
Applications for these alloys include resistance welding electrodes, switchgear, heat sinks, current carrying arms and
steel casting moulds where copper would be ideal from the electrical and thermal conductivity standpoint but is simply
not strong enough.

Free Machining Copper

An addition of approximately 0.5% tellurium or sulphur raises the machinability rating from 20% to 90%, based on a
scale where free machining brass is rated at 100%. The particles of copper telluride or copper sulphide act as chip
breakers leading to excellent machinability without substantially affecting the electrical conductivity which is rated at
93% IACS. Free machining copper is used where a large amount of repetitive machining at high rates is required.
One example is in the production of gas, laser and plasma cutting nozzles which involves the drilling of small holes in
rods followed by cold forming to the finished shape. Other applications include screws, fasteners, contacts,
connectors, clamps and bolts used in the electrical and semi-conductor industries.

Engineering Copper (Non-Electrical)

The usual grade of copper used for engineering applications is CW024A (was C106). Many of the applications of
copper depend upon properties other than its high electrical conductivity.
 The properties which make copper the standard material for engineering, including architecture and plumbing, are:

Thermal conductivity - the thermal conductivity of copper, 394W/mK, is about twice that of aluminium and thirty times
that of stainless steel. This means that copper is used for components where rapid heat transfer is essential.
Examples include saucepan bottoms, heat exchangers, car and vehicle radiators and heat sinks in computers, disk
drives and TV sets.
Corrosion resistance - copper is non-reactive and does not rust or become brittle in sunlight.
Ease of joining - by brazing or soldering. The latest technology called CuproBraze is used to fabricate strong and
reliable brazed copper/brass heat exchangers for cooling in vehicles which include cars, trucks, locomotives, tractors
and JCBs.
High ductility - tubes are easily bent even when hard
Toughness - does not become brittle at sub zero temperatures
Heat resistance - withstands fire well, melting point is 1083oC
Antimicrobial - copper is a naturally hygienic metal which slows down the growth of harmful germs such as E.Coli,
MRSA and legionella. Copper's ease of shaping, corrosion resistance and antimicrobial properties make it ideal for
brewing vessels.
Range of colours and malleability - widely used by designers and architects for exterior and interior applications.
Recyclability - copper is 100% recyclable without loss of properties. The price of scrap copper is high.