Non Ferrous Metals (BUILDING MATERIALS AND CONSTRUCTION)

Non-Ferrous Metals
Non-ferrous metals include aluminum, copper, lead, zinc and tin, as well as precious metals like gold and silver. Their main advantage over ferrous materials is their malleability. They also have no iron content, giving them a higher resistance to rust and corrosion, and making them ideal for gutters, liquid pipes, roofing and outdoor signs. Lastly they are non-magnetic, which is important for many electronic and wiring applications.

Aluminum
Aluminum is lightweight, soft and low strength. Aluminum is easily cast, forged, machined and welded. It’s not suitable for high-temperature environments. Because aluminum is lightweight, it is a good choice for the manufacturing of aircraft and food cans. Aluminum is also used in castings, pistons, railways, cars, and kitchen utensils.

1. Nonferrous ores

2. Non-Ferrous Metals Non-ferrous metals include aluminum, copper, lead, zinc and tin, as well as precious metals like gold and silver. Their main advantage over ferrous materials is their malleability. They also have no iron content, giving them a higher resistance to rust and corrosion, and making them ideal for gutters, liquid pipes, roofing and outdoor signs. Lastly they are non-magnetic, which is important for many electronic and wiring applications. Aluminum Aluminum is lightweight, soft and low strength. Aluminum is easily cast, forged, machined and welded. It’s not suitable for high-temperature environments. Because aluminum is lightweight, it is a good choice for the manufacturing of aircraft and food cans. Aluminum is also used in castings, pistons, railways, cars, and kitchen utensils.

3. Copper Copper is red in color, highly ductile, malleable and has high conductivity for electricity and heat. Copper is principally used in the electrical industry in the form of wire and other conductors. It’s also used in sheet roofing, cartridge cases, statutes, and bearings. Copper is also used to make brass, an alloy of copper and zinc. Lead Lead is a soft, heavy, malleable metal with a low melting point and low tensile strength. It can withstand corrosion from moisture and many acids. Lead is widely used in electrical power cables, batteries, building construction and soldering.

4. Tin Tin is very soft and malleable, ductile with low tensile strength. It’s often used to coat steel to prevent corrosion. Tinplate steel is used to make tin cans to hold food. In the late 19th century, tin foil was commonly used to wrap food products, but has since largely been replaced by aluminium foil. Tin is can also be alloyed with copper to produce tin brass and bronze. Zinc​ Zinc is a medium to low strength metal with a very low melting point. It can be machined easily, but heating may be required to avoid cleavage of crystals. Zinc is most widely used in galvanizing, the process of applying a protective zinc coating to iron or steel to prevent rust.​

5. Properties of aluminum: 1.Light Weight: Aluminum is a very light metal with a specific weight of 2.7 g/cm3, about a third of that of steel. This cuts the costs of manufacturing with aluminum. Again, its use in vehicles reduces dead-weight and energy consumption while increasing load capacity. This also reduces noise and improves comfort levels.

6. 3. Electrical and Thermal Conductivity:​ Aluminum is an excellent heat and electricity conductor and in relation to its weight is almost twice as good a conductor as copper.​ 4.Reflectivity:​ Aluminum is a good reflector of visible light as well as heat, and that together with its low weight, makes it an ideal material for reflectors in, for example, light fittings or rescue blankets. 2.Corrosion Resistance:​ Aluminum naturally generates a protective thin oxide coating which keeps the metal from making further contact with the environment.​ 5.Ductility: Aluminum is ductile and has a low melting point and density. It can be processed in several ways in a molten condition. ratures drop.

7. 6.Strength at Low Temperatures:​ In contrast to steel, which rapidly becomes brittle at low temperatures, aluminum shows increased tensile strength as Tempe 7.Impermeable and odorless: Moreover, the metal itself is non-toxic and odorless, which makes it ideal for packaging sensitive products such as food or pharmaceuticals. The fact that recycled aluminum can be used reduces the carbon footprint for this stage of food and beverage manufacturers as well. 8.Non-magnetic: Aluminum is non-magnetic, making it useful for electrical shieldings as in computer disks, dish antennas, busbars or magnet housings. 9.Non-toxic: Aluminum is non-toxic and is used to make woks, pressure cookers and many other cooking utensils without fear. It is easily cleaned and does not contaminate the food at any stage.

8. 10.Sound and Shock Absorption: Aluminum is an excellent sound absorber and is used for constructing ceilings. It is also used in auto bumpers due to its shock-absorbing properties. 11.Non-sparking: Aluminum produces no sparks when it comes into contact with itself or non-ferrous metals. 12.Recyclability: Aluminum is 100% recyclable and recycled aluminum is identical to the virgin product. This makes it a much more cost-effective source material for production runs.

9. USE OF ALUMINIUM IN HOUSES : Exterior : Window frames Doors  Sliding doors  Green houses Interior: Partition Door handles  Locker Furniture  Book shelf

10. USE OF ALUMINIUM IN BUILDINGS: Roofing Curtain walls Solar panels Shades  Bridges  Domes

11. Uses of aluminum:  • Aluminum is used in a large variety of products including : 1. Cans  2. Foils 3. Kitchen utensils 4. Window frames 5. Aeroplan parts 6. Coins  • Aluminum is a good electrical conductor and is often used in electrical transmission lines. • Aluminum coatings have many uses including 1. Telescope mirrors  2. Decorative paper 3. Packages  4. Toys

12. Zinc Ore: Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a silvery-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi

13. In some respects, zinc is chemically similar to magnesium: both elements exhibit only one normal oxidation state (+2), and the Zn2+ and Mg2+ ions are of similar size.[note 1] Zinc is the 24th most abundant element in Earth's crust  ores of zinc: The solid material from which the pure metals can be obtained, it is called as ores. Zinc ores are sphalerite (ZnS), zincite ( ZnO ), franklinite [ ZnO ( Fe,Mn )2O3], calamine [Zn2(OH)2SiO3], and smith stone (ZnCO3). Zinc ores normally contain 5–15% zinc. zincite franklinite  calamine smith stone

14. The metal zinc can be mainly  obtained from  oreS which are called as sphalerite and Calamine. Sphalerite: It is commonly called as zinc blend. Its chemical formula is .(ZnS) Pure zinc is obtained from sphalerite through a process called froth flotation method. Calamine: It is made up of two compounds namely zinc carbonate and zinc silicate. The chemical formula is  and .[Zn2(OH)2SiO3] PRODUCTION OF ZINC METAL Extraction and refining Roasting and sintering Both of the main extraction methods for the production of zinc, electrolysis and smelting, require the prior removal of sulfur in a highly exothermic oxidation reaction:

15. The small fraction of zinc sulfide minerals present in the ore makes beneficiation necessary in order to produce a concentrate suitable for treatment.The most common method for accomplishing this concentration is to isolate the sulfide mineral from the impure constituents, or gangue, by flotation separation. In this process, the ore initially is crushed to about 1.9 centimetres (0.75 inch), combined with water, and ground to less than 0.1 millimetre in a ball mill. The finely ground particles and water form a slurry that flows from the mill to flotation cells or tanks, where, in the presence of selected chemical reagents that create a suspension of air bubbles, the slurry is agitated by beaters. The mineral particles cling to the bubbles and float to the surface, forming an oily froth that is constantly skimmed, while the gangue is wetted by the action of the chemicals and sinks in the cell. Production of zinc concentration of ore:

16. Chemical Equation:

17. Electrolysis The basic steps in this process include (1) preparation of a zinc sulfate solution by leaching zinc oxide calcines (produced by the roasting of sulfide concentrates) in dilute sulfuric acid, (2) purification of the resulting zinc sulfate solution, and (3) electrolysis of the purified solution. The theoretical voltage required to deposit zinc from zinc sulfate solution onto a cathode is about twice the voltage necessary to decompose water, so that, in theory, electrolysis should result in the production of hydrogen at the cathode and not the deposition of zinc. When a zinc cathode is used, however, overvoltage prevents the generation of hydrogen, and, hence, zinc is deposited. The hydrogen overvoltage depends crucially on the purity of the zinc sulfate electrolyte; the presence of certain impurities at even very low concentrations can cause a drastic lowering of the overvoltage and thus interfere with zinc deposition

18. For this reason, extreme purification of the electrolyte is a critical necessity in the process and is accomplished in two stages. The first stage is the removal of iron as a solid residue in the form of either jarosite (a basic ferric sulfate) or the oxides goethite or hematite. This is then followed by cementation with zinc dust to remove other metallic impurities (including copper, nickel, cadmium, cobalt, and germanium) from the solution. Electrolysis is performed in lead-lined concrete cells with anodes of lead containing 0.5–1.0 percent silver and cathodes of aluminum sheet. The zinc deposits are stripped from the cathodes every 24 to 48 hours and remelted in an induction furnace before casting into ingots or pigs. The purification of the electrolyte ensures that the normal product will reach a purity of 99.99 percent or more. In existing plants, outputs vary from 50,000 to 300,000 tons per annum.

19. The zinc-lead blast furnace: Sintered zinc and lead concentrates, mixed with metallurgical coke, are charged into the top of a shaft furnace, into which preheated air is blown through nozzles, or tuyeres, at the base (see figure). This procedure is similar to that followed in an iron blast furnace, with the important difference that the major products of reduction here are a zinc-bearing gas and liquid phases that separate in the furnace hearth and are tapped periodically. (The liquids consist of molten lead, containing recoverable copper and silver, and the gangue content of the charge, in the form of a molten oxide slag. The gas stream, containing 8 percent zinc, 10 percent carbon dioxide, and 20 percent carbon monoxide, is directed from the upper shaft to a lead-splash condenser, a chamber in which an intense shower of lead droplets is thrown up by rotors revolving in a pool of molten lead.

20. In existing smelters, shaft furnaces vary in area from 15 to 27 square metres (180 to 290 square feet), and capacities range from 50,000 to 100,000 tons of zinc and 30,000 to 50,000 tons of lead per annum. The zinc-lead blast furnace has the flexibility to accept a wide range of mixed ores and residues in its feed. Complex sulfide ores have to be sintered, but oxidized residues such as zinc ashes and drosses recovered from galvanizing processes, oxides produced from low-grade residues, lead smelter dusts, and steel-mill dust high in lead and zinc can bypass the sinter roasting process. A number of cold and hot briquetting techniques are available to consolidate these low-grade materials so that they may be charged directly to the furnace.

21. Distillation refining: The blast furnace produces an ordinary grade of zinc containing 1.2 percent lead. This can be used in general galvanizing, but an additional refluxing operation must be performed to produce high-grade zinc. The operation is performed in two fractionating columns, each consisting of a series of superposed rectangular trays made of bonded silicon carbide refractory material and arranged to allow a descending flow of liquid metal and an ascending flow of metal vapour . In the first column, a large part of the zinc is vaporized and freed from impurities with higher boiling points, such as lead and iron. The distilled vapour is condensed and fed into the second column, where the liquid’s remaining impurity, cadmium, with a boiling point lower than that of zinc, is distilled. High-purity zinc is then run off from the bottom of the column.

22. Common Alloys: Brass: 3-45% Zn by weight, it's used in musical instruments, valves, and hardware. Nickel silver: 20% Zn by weight, it's used for its shiny silver appearance in jewelry, silverware, model train tracks, and musical instruments. Zinc die casting alloys: >78% Zn by weight, it usually contains small amounts (less than a few percentage points) of Pb, Sn, Cu, Al, and Mg to improve die casting characteristics and mechanical properties. It's used to make small intricate shapes and suitable for moving parts in machines. The cheapest of these alloys are referred to as pot metal, and they serve as inexpensive replacements for steel.

23. Applications of the commodity zinc: Zinc is used in a number of applications. 1. Galvanizing against corrosion Zinc is commonly used to coat iron or steel to protect these metals against corrosion. As it is more reactive than iron or steel, zinc will attract almost all oxidation until corrosion completely erodes the coated sheet. What is left is a surface protection layer of oxide and carbonate. This protection even functions after minor scratches and dents and can survive for many years. Galvanization is used on metal roofing, bridges, guard rails, light posts, heat exchangers and most visible to the consumer: car bodies. Coating zinc on another metal is accomplished by electrolytic plating of the metal – much like chrome plating a metal – or dipping it into molten zinc.

24. 2. Intricate machine parts An alloy made of very high grade zinc and aluminium is used to create die-cast parts which require little machining before they are used in an assembly. By injecting the alloy under pressure into the cavity of a two-part steel die, it fills the entire void within the mold. After the metal cools and the die halves are taken apart, the resulting zinc-alloy part is very close to the desired shape. Die-casting is used, among others, to create parts for aircraft, medical instruments and car parts like emblems and doorhandles. 3. Electrodes An unique application of zinc uses its ability to transfer its corrosion resistance properties by electrical contact. In this manner, zinc is used as a sacrificial electrode. An example application for this kind of electrode is when it is attached to aluminium marine engines.

25. Especially in salt water, the oxidation process of the metals on the ship forms a weak electrical current, which may lead to corrosion of the hull and engine parts. By having a zinc sacrificial electrode present, it sacrifices itself by corrosion, negating the electrical current and thus protecting the  aluminium  hull and/or engine. ​ 4. Alloys One widely used alloy which contains a large amount of zinc is brass. Brass is an alloy of copper mixed with 3% to 45% zinc, depending on the type of brass. Brass is superior to copper in areas like ductability , strength and corrosion resistance. This makes it useful in water valves, musical instruments and communication equipment. Other used alloys that contain substantial amounts of zinc include aluminium solder, commercial bronze and nickel silver. It is also the primary metal used in producing one cent coins in the United States. The zinc coin is coated with a layer of copper to give the false impression of a copper coin.

26. Galena is the primary ore of lead, and is often mined for its silver content, such as at the Galena Mine in northern Idaho. Color: Lead gray and silvery Streak: Lead gray Category: Sulfide mineral, octahedral subgroup Other characteristics: Natural semiconductor LEAD ORE:

27. There are many different uses of Lead. It may be used as a pure metal, alloyed with other metals, or as chemical compounds. Various Uses of Lead: 1. Lead Acid Battery: The principal consumption of Lead is for the Lead-Acid storage battery in which grid or plate is made of Lead or Lead with other metal more commonly with antimony. 2. Rolled Extrusions: Lead Sheet is used in the building industry for flashings or weathering to prevent water penetration & for roofing and cladding. By virtue of its resistance to chemical corrosion, Lead Sheet also finds use for the lining of chemical treatment baths, acid plants and storage vessels.

28. 3. Lead Pipes: Lead pipes due to its corrosion resistant properties are used for carriage of corrosive chemicals at chemical plants. Also Lead pipe of appropriate composition is still extruded for cutting into short length 'sleeves' for use in the jointing of Lead sheathed cables. ​​ 4. Pigments: ​​ Used extensively in paints, although recently the use of Lead in paints has been drastically curtailed to eliminate or reduce health hazards. White Lead, 2PbCO3 • Pb(OH)2, is the most extensively used Lead pigment. Other Lead pigments of importance are basic Lead sulfate and Lead chromates.​​ ​​

29. 6. Ammunition Use of ammunition with Lead Bullets, which are commonly used in sport shooting with small arms 7. Lead Alloys: Lead forms alloys with many metals. Alloys formed with tin, copper, arsenic, antimony, bismuth, cadmium, and sodium are all of industrial importance. Lead is used to make bearings, solder, antifriction metals, and type metal. Soft solders are largely Lead-tin alloys with or without antimony while fusible alloys are various combinations of Lead, tin, bismuth, cadmium and other low melting point metals. Shot Lead is an Alloy of Lead, Antimony, and Arsenic. Lead Foil is made with Lead alloys.

30. 8. Lead Weights for Scuba Diving​: Shot Lead is an Alloy of Lead, Antimony, and Arsenic. Lead Foil is made with Lead alloys. Lead is added to brass to reduce machine tool wear.​

31. Tin is a soft, pliable, silvery-white metal. Tin is not easily oxidized and resists corrosion because it is protected by an oxide film. Tin resists corrosion from distilled sea and soft tap water, and can be attacked by strong acids, alkalis and acid salts. Tin Ore: 

32. Applications: Tin is used in for can coating: tin-plated steel containers are widely used for food preservation. Tin alloys are employed in many ways: as solder for joining pipes or electric circuits, pewter, bell metal, babbit metal and dental amalgams. The niobium-tin alloy is used for superconductiong magnets, tin oxide is used for ceramics and in gas sensors (as it absorbs a gas its electrical conmductivity increases and this can be monitored). Tin foil was once a common wrapping material for foods and drugs, now replaced by the use of aluminium foil.

33. What Is Tin? Tin is a very light, soft metal. It's a silvery-white color and is easy to melt. Tin is too soft to use by itself, so it's often mixed with other metals to form an alloy. Alloys combine more than one metal so that the resulting alloy has the helpful properties of each one. Tin resists corrosion, it's very useful. This means that it doesn't have a chemical reaction when it's combined with air or water. Tin is also easily molded into different shapes

34. Copper is a chemical element with symbol Cu (from Latin: cuprum) and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; a freshly exposed surface has a reddish-orange color. It is used as a conductor of heat and electricity, a building material, and a constituent of various metal alloys. Copper ore

35. Copper is found as native metal and in minerals ie . cuprite, azurite, chalcopyrite and bornite. Sulphides , oxides and carbonates are the most important ores. Properties of Copper: As mentioned, copper is prized for its many useful properties. It’s no wonder copper & brass sales have never seen a significant decline in the last few years. Copper alloys turn out to be extremely useful for the exact same reason. Let’s take a look at some of copper’s more valuable properties. Workability Copper is a malleable and ductile metal. It can be hammered or rolled into thin sheets and drawn into small wires without breaking. In its purest form, copper can be worked cold, but a copper sheet supplier may have to hot work it if it’s combined with another much less pliable metal, such as zinc or lead.

36. Electrical/Heat Conductivity One of the most prominent properties of copper is its high electrical and heat conductivity. It is so conductive that 95 percent of all the transformers, cores of electrical wires, and other conductors are made of copper. Silver is the only metal that is more electrically conductive than copper, but it isn’t good at handling heat, which is why copper is still preferred for electrical applications. Durability​ Most metals corrode as they oxidize. Iron, for instance, slowly reduces to rust when exposed to oxygen. Copper, on the other hand, oxidizes by developing a protective layer on its surface, called patina. The longer the exposure, the tougher the patina gets. This green layer of protection can preserve the inside of copper for thousands of years.​

37. Name Formula % Copper when pure Chalcopyrite CuFeS 2 34.5 Chalcocite Cu 2 S 79.8 Covellite CuS 66.5 Bornite 2Cu 2 S·CuS·FeS 63.3 Tetrahedrite Cu 3 Sb S 3  + x(Fe,Zn) 6 Sb 2 S 9 32–45 Digenite Cu 9 S 5 78.1 Malachite CuCO 3 •Cu(OH) 2 57.7 Azurite 2CuCO 3 ·Cu(OH) 2 55.1 Cuprite Cu 2 O 88.8 Chrysocolla (Cu,Al) 2 H 2 Si 2 O 5 (OH) 4 ·n(H 2 O) 37.9 Tennantite Cu 12 As 4 S 13 51.6 Dioptase CuSiO 2 (OH) 2 45.3 Enargite Cu3AsS4 48.4 list of minerals that serve as copper ores in the copper mining process:

38. The copper is manufactured by a laborious method and the treatment to be adopted largely depends on the quality of copper ores. Following is the general outline of the modern process of copper manufacture: ( i ) The ores, usually pyrites, are cleaned and crushed and they are them calcined in a reverberatory furnace.  (ii) The calcined ores are mixed with silica and a small quantity of coke. The evo mixture is then smelted in a blast furnace. (iii) The melted metal is oxidized in the Bessemer converter. It gives blister copper (iv) The impurities contained in blister copper are removed by melting it a reverberatory furnace in presence of air. (v) The slag is removed and pure copper to the extent of about 99.70 percent is obtained. (vi) Very pure copper or 100 per cent copper is obtained by the electrolysis.

39. Anti-Bacterial Copper is also one of the few metals that can produce the oligodynamic effect, a phenomenon in which ions of copper break down certain proteins that make up single-celled organisms, killing them eventually. Recyclable Over 80 percent of all the copper ever mined and manufactured are still in use today, and they are all recyclable. Because of this, copper is considered one of the most eco-friendly metals. There are more things around you that are made of copper or copper-based alloy than you probably know. Part of the reason is that copper alloys come in different colors and shades depending on their composition. This means they don’t have a single identifying feature. Here’s a list of things copper is used for.

40. Kitchen Sink Copper is a good choice for kitchen sink because it is generally resistant to corrosion and it has anti-microbial properties. For those who are not a fan of patina, however, pure copper is out of the question. They prefer copper alloys that take longer to tarnish, let alone develop patina. Table Tops As mentioned earlier, copper is extremely malleable. You can turn it into thin sheets or plates that make a perfect cover for table and counter tops. Copper’s anti-microbial property makes it suitable for this application as well since these are high-touch surfaces

41. Jewelry Copper is also a good material for accessories. Even in the ancient times, those who can’t afford gold jewelry wear copper jewelry instead. It offers design flexibility too due to its high ductility. Door Knobs and Pull Handles Maybe you haven’t noticed this but most, if not all, of the door knobs and pull handles you’ve ever held are made partly of copper. They can only be either brass or bronze.

42. Railings When you’re in the train, at a balcony, or on the stairs, odds are you’ll clutch on to the copper-based railing nearest you. Like table tops, railings are also commonly touched surfaces, which is why they are best made of a metal with antimicrobial property. They are conspicuous, too, so they must be made of a naturally elegant-looking material. Tools Ever wondered what metal your wrenches, pliers, screw drivers, and other house tools are made of? Judging by their physical features, you can easily tell that they are copper-based. Specifically, most of them are made of beryllium copper, a non-sparking and non-magnetic alloy that works well in hazardous workspaces.

43. Musical Instruments Copper alloys are also valued for their acoustic quality, especially brass, an alloy of copper and zinc. There are so many brass-based musical instruments that an entire subset of them was named brass. Wire Copper’s high electrical conductivity makes it the safest and most efficient material for wire cores. Unlike silver, it doesn’t burn up when conducting high voltages. Pipes Copper’s antimicrobial property once again proves extremely useful, and this time in filtration applications. Pipes used to convey water or substances requiring zero-level contamination are often made of copper alloys.

44. Gutter It’s probably not the most frugal choice, but a copper gutter is a great addition to your roofing system. It lasts longer, repels mold and mildew, and looks appealing. However, since copper is a little bit more expensive than its galvanized counterpart, you have to be ready to fork out more cash.

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