Copper and its alloys

Copper and its alloys

1. Copper and its
alloys
NON-FERROUS METAL

2. Table of contents:
1.Copper
2.Introduction of copper
3.Ores of copper
4.Properties of copper
5.Applications of copper
6.Classification of copper and copper alloys
7.Classification of copper
8.Classification of copper alloys

3. 1.Copper
• Atomic symbol (Cu)
•Non ferrous metal
• Transition element
• Atomic Number = 29
• Atomic Mass = 63.456

4. 2.Introduction of copper
• Copper is present in the Earth's crust at a concentration of about 50 parts
per million (ppm)
• There are 29 isotopes of copper. Cu and Cu are stable, with Cu comprising
approximately 69% of naturally occurring copper. The other isotopes are
radioactive.
•Copper occurs as native copper or in minerals or obtained from ores.
•Some ores of copper are given bellow:

5. 3.

6. 4.Properties
•Crystal structure FCC
•Soft
•malleable
•ductile material
•high thermal and electrical conductivities
•High corrosion resistance
•Reasonable tensile strength
•Melting point = 1085 degrees Celsius
•Good formability
•Attractive and good color
•Cold working characteristics
•Magnetic properties
•Easy castability
•Low coefficient of friction
•Atmospheric corrosion resistance
•Low density

7. 5.APPLICATION OF COPPER
•Approximately 65% of copper produced is used for electrical
applications ,making electrical parts such as generators,
transformers, motors, busbars and cables.
•Electrical equipment - providing circuitry, wiring and
contacts for PCs,TVs and mobile phones.

8. •Copper is used in heat exchangers, coolers, condensers, tanks,
pipework, valves and fittings.
•Screw maching products
•For household utensils, etc.










(valves and fittings) ( tubes and wire use
in heat exchanger etc.)
For making various copper alloys, such as brass and bronze.

9. Classification of copper
and
copper alloys

10. Copper and copper alloys are designated according to the
Copper Development Association (CDA).

1) Wrought alloys


2) Cast alloys

C100-C799
C800-C999

11. Classification of copper and
copper alloys
The wrought copper
1)Unalloyed copper
2) Brass 3) Bronze
4) Cu-Ni
based Alloy brasses
•(leaded brasses):Copper –zinc
alloys with Lead.
•(tin brasses):Copper – Zinc alloys
with Tin and Aluminum additions
BRASSES
Copper – Zinc alloys
•Copper – Tin alloys
•Copper – Aluminum alloys
•Copper – Silicon alloys
•Copper – Beryllium alloys
•Cupronickel (Cu-Ni)
•Nickel silver (Cu-Ni-Zn)
• Electrolytic tough pitch
• Oxygen – free
• Phosphorus deoxidised

12. 7.Classification of copper
The wrought copper:


►Copper content > 99.3%
►Wrought coppers are classified
according to oxygen and impurity
contents.
►Can be roughly divided into;
1) Unalloyed copper
1.Electrolytic tough pitch
2.Oxygen – free
3.Phosphorus deoxidized

13. 1)Electrolytic tough-pitch copper
•This copper contains 99.9% Cu with 0.045 O content.
•Used for the production of wire, rod plate and strip.
2)Oxygen free copper
•Oxygen-free copper is produced from electrorefined cathode copper
which is melt and cast in a reducing atmosphere of CO and N to prevent O.
•0.005% Pb, 0.001% Ni, 00.001% Ag and less than 0.0005% and 0.001% Fe and Bi
respectively.
•It is melted and cast in non oxidizing atmosphere.
3) Deoxidized copper
•99.85% copper, less than 0.05% As,0.003% iron, and 0.003% Bi.
•Phosphorus is sufficiently added to produce phosphorus pentoxide P2O5.
This reduces the amount of O and give high conductivity copper such as
deoxidized high phosphorus copper (CDA 122).
•The excess amount of the P lowers electrical conductivity.
•Phosphorus deoxidized copper used in pressure vessels or plumbing tubes
for electrical purposes.

14. Properties

►Good electrical, thermal conductivities
►High corrosion resistance
►Easily fabricated
►Reasonable tensile strength
►Controllable annealing properties
►Good soldering and joining properties

15. Alloying additions in Copper

16. 2) Brass
►Brasses contain zinc as the principle alloying element
►

►Brasses are sub divided in to two classes or groups; (Brass products)

►


8.Classification of copper alloys
wrought alloy brasses
•Leaded brasses: Copper – Lead alloys
•Tin brasses: Copper – Zinc alloys with Tin
and Aluminum additions
BRASSES
Copper – Zinc alloys
Cast alloy brasses
• (red, semi-red and yellow brasses):
Copper-Tin-Zinc alloys
• Cast Copper-Bismuth and Copper-Bismuth
Selenium alloys.
• (Silicon brasses and bronzes):
Copper-Zinc-Silicon alloys

17. ✔Leaded brasses: (copper-zinc alloys with lead)
•Leaded brasses has small amounts of Pb (0.5-3.0%)
•They are added to many types of brasses to improve their machinability.
✔Tin brasses: (copper-zinc with addition of Sn and Aluminum)
•Cu 71%, Zn 28% and Sn 1%.
•used for the tubes and other parts of condenser cooled by fresh water and for
• many other purpose.
Properties:
•Brasses are high resistance to corrosion.
•it is easily machinable.
•It act as good bearing material.
•Zinc in the brass increases the ductility along with strength.
•Brass processes greater strength than copper , however it has a lower thermal
and electrical conductivity.

18. 3) Bronze
►An alloy of copper and elements other than nickel or zinc.
►Bronze is basically an alloy of copper and tin.
►Wrought Cu-Sn bronzes contain about 1.25-10% Sn with upto
0.1% P hence usually called phosphor bronzes. P is added as
deoxidizing agent to improve castability.
►Microstructure of 92%Cu-8%Sn consists of recrystallized α grains
with annealing twins.

19. Cast bronze alloys
•Copper-Tin alloys (Tin Bronzes)
•Copper-Tin-Lead alloys(Leaded
and high leaded Tin Bronzes)
•Copper-Tin-Nickel alloys
(nickel-tin bronzes)
•Copper-Aluminium alloys
(Aluminum Bronzes)
Wrought bronze alloys
•Copper-Tin-Phosphorus alloys
(Phosphor Bronzes)
•Copper-Tin-Lead-Phosphorus
alloys (Leaded Phosphor Bronzes)
•Copper-Aluminium alloys
(Aluminum Bronzes)
Properties:
•It possesses superior mechanical properties and corrosion resistance than brass.
•it is comparatively hard and it resist surface wear.
•It can be rolled in to wire, rod, and sheets.

Bronzes are classified into two families:

20. 1)Tin Bronzes
Alloys of copper and tin.
•Other alloying elements may
also be present with the
exception of zinc.
• Also called Phosphor bronzes.
•Phosphorus content (0.01-0.5%)
Tin Content (1-11%).
Properties:
•High corrosion resistance ,
•Toughness
•Low coefficient of friction
•free from seasonal cracking.
2) Beryllium Bronzes
• Alloys of Cu & Beryllium.
Properties:
• It is increased by age hardening
• They have excellent formability
•high tensile strength
•creep
•Resistance
•High electrical conductivity.
Applications:
These are used in diaphragms ,
surgical instrument ,bolts & screws ,
firing pins , dies.

21. 3) Silicon Bronzes
• Alloys of Copper And Silicon
• Alloys contains less than 5% Si.
•1-4% si,0.5-1.0% iron, 0.25-1.25% Mn
Properties:
•These are the Strongest of the work
hard enable Copper Alloys.
•Their Mechanical Properties are
comparable to mild steel and
corrosion resistance is comparable
to copper.
Applications :
These are used for Tanks , pressure
vessels , Marine construction ,
hydraulic pressure lines.

4) Aluminum Bronzes
• Alloys of Al & Cu
•89% Cu, 7% Al, and 3.5% Sn.
•Commercial Al bronzes contain (4-
11%)Al.
Properties:
•High strength
•Good machinability
•High corrosion
•High resistance
Applications:
These are used for water condenser
tubes, nuts, bolts, corrosion
resistance vessels ,and in marine
application.

22. (Tin bronze) (Beryllium bronze)









(Silicon bronze) (Aluminum bronze)

23. 4) Copper nickel based alloys:
Classification:
1.Cupro-Nickels
►Alloys of Cu & Ni , contains up to 30 % Ni
►Cupronickels Alloys are single phase alloys.
Properties:
►No heat treatment is required
►Properties are improved only by cold working
►They have high fatigue resistance ,
high corrosion & erosion resistance toward sea water. COPPER –NICKLE
Flanges
Applications:
►These are widely used in condenser , heat exchanger tubes , coastal power plants.

24. 2.Nickel Silver
• Alloys of Cu-Ni-Zn
• Commercial Alloys are contain Cu (50-70%) , Ni (5-10%) , Zn (5-40%).
Properties:
•Ductile & easily workable at room temperature.
• Addition of Zinc imparts silver-blue-white color ,good corrosion resistance.
• These are Excellent base metals for plating with Cr ,Ni ,Ag.
Applications:
These are used For Rivets, screws, Costume jewelry , name plates & radio
Dials.







Nickel-silver
spoons

25. Mechanical properties of copper and its alloys