ALLOYS

Definition
An Alloy is a homogeneous solid solution made up of two or more elements
out of which at least one is a metal.
Ex. i. Tungsten carbide, high hardness (used in military application)
ii. Woods metal (Made up of 12.5 % Sn, 25 % Pb, 50% Bi,12.5% Cd )
Low melting point (70oC and used in fire alarms and automatic
sprinklers).

Purpose of making alloys

To improve the mechanical / physical / chemical property

To modify the colour (Physical Property)
Ex. Brass an alloy of Cu (red) and Zinc (white) is yellow in colour.

To increase the hardness of the metal. (mechanical - generally pure

metals are soft but their alloys are hard)
Ex. Gold and silver are soft metals. They are alloyed with copper to
make them hard.

To lower the melting point of the metal. Alloying makes the metal
easily fusible (Physical ).
Ex. Woods metal an alloy of Sn, Pb, Bi & Cd melts at 70 0C which
is far below the melting points of any of these constituent metals

To resist corrosion of the metal ( Chemical reactivity)

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Ex. Pure iron gets rusted but when it is alloyed with carbon or
chromium forms stainless steel which resists corrosion.

To modify chemical activity of the metal. Chemical activity can be

increased or decreased by alloying
Ex. Sodium amalgam is less active than sodium
Aluminium amalgam is more active than aluminium

To get good casting of metal (mechanical).
Ex. An alloy of lead with 5% tin and 2% antimony is used for
casting .The addition of these metals produce lead alloys which are
hard, fusible and expand on solidification and gives good casting.

Function / Effect of Alloying Elements.

Element

Nickel

Effect on properties
Fine grains are

Uses of alloys

produced

For making balance

Increases corrosion

wheels

resistance
Improves thermal
stability

Chromium

Improves resistance to

For making surgical

corrosion , tensile

instruments, cutlery and

strength and hardening

connecting rods

Increases high
Molybdenum

VSG & KY

temperature strength

For high speed tools

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Improves resistance to
pitting and crevice
corrosion

Manganese

Increases abrasion

For making grinding

resistance

wheels, steering
spindles

Vanadium

Tungsten

Increases Tensile

For making heavy

strength and abrasion

locomotive forgings,

resistance

piston rods

Grain structure is

For making cutting

refined

tools, permanent

Cutting hardness is

magnets etc.

increased
Increases corrosion
Nickel and Chromium

For stainless steel alloy

resistance and tensile

strength

ALLOY : STEELS
Plain carbon steel finds only limited use. Addition of small amounts of one
or more metals (such as nickel, chromium, cobalt, etc) imparts special
properties to the steel.
Such steels are called Alloy Steels or Special Steels.
For example, Addition of nickel improves the tensile strength, ductility,
toughness, elasticity, heat and corrosion resistance.

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Ferrous Alloys or Alloy Steels

Alloy

Stainless Steel
(CorrosionResistant steel)

Composition

Chromium &
other elements
such as nickel,
molybdenum.
Chromium is
effective if the
content is 16 %
or more

Properties

Protection
against corrosion
due to formation
of non porous,
self healing
tough film of
chromium oxide
at the metallic
surface.

Uses

Utensils,
Implants

Two types of stainless steel:

i) Heat treatable
stainless steel

C =1.2%
Cr = less than
18% (generally
12-16%)

ii) Non- heat

Based on
treatable stainless composition,
steel
Divided into two
types:
a) Magnetic type
b) Non-Magnetic
type
a) Magnetic type

VSG & KY

Cr = 12-22 %
C = less than
0.35%

Magnetic,
Tough,
Can be worked in
cold state,
used up to 800oC
Satisfactory for
resisting weather
& water.

Making surgical
instruments,
scissors, blades,
cutlery etc.

Show less
strength at high
temperature
More resistant to
corrosion

Can be forged,
rolled, or cold
drawn,&

Making chemical
equipments &
automobile parts

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machined with
specially
designed tools
Resist corrosion
better than heattreatable ones

b) Non-Magnetic Cr = 18-26% ,
type
Ni = 8-21% ,l
C = up to 0.15%
(18% Cr & 8%
Ni is called as
18/8 stainless
steel)

Maximum
resistance to
corrosion
To increase
corrosion
resistance further
a little quantity
of Molybdenum
is added

Making
household
utensils,
decorative
pieces, sinks,
dental
instruments,
surgical
instruments etc.

Nichrome

Ni = 60%
Cr = 12%
Fe = 26%
Mn = 2%

In making parts
Can be used up
o
to 1000 1100 C of boilers, steam
lines, stills,
Chemical & heat gas-turbines,
resistant
aero-engine
valves, retorts,
High electrical
annealing
resistance
boxes, and other
machineries
/equipments
exposed to high
Temperatures.

Alnico
(Aluminum
Nickel Cobalt
Steel)

Al = 8 12 %
Ni = 14 28 %,
Co = 6 35 %
Cu upto 6%
Ti- upto 1%
Fe balance

Highly magnetic

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Making powerful
permanent
magnets in
motors,
generators,
telephone
receivers etc.
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Non - Ferrous Alloys

Alloys

1 Brasses

Composition

Characteristics

Cu = 60-90%
Zn = 40-10%

Posses greater
strength, durability,
& machinability than
pure Cu.
Lower melting point
than Cu & Zn.
Good corrosion
resistant against
water

Uses

The main forms of Brasses are:

(i)Commercial
Brass (Guilding
metal / French
gold)

Cu = 90%
Zn = 10%

Golden color.
Stronger & harder
than pure Cu.

Forgings, rivets,
hardware's, screws,
costumes, jewellery
etc

(ii) Dutch -metal

(Low brass)

Cu = 80%
Zn = 20%

Golden color.
Suitable for all
drawing & forming
operations.

Cheap jewellery,
musical
instruments, battery
caps, flexible hoses,
tubes, name plates.

(iii) Cartridge
Brass
(spinning brass)

Cu = 70%
Zn = 30%

Soft.
Ductile in the
annealed state.
Harder & stronger
than Cu
Can be severely cold

General purpose
brass, cartridge
cases, condenser
tubes, sheet
fabrication,
household articles

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deformed by drawing,
pressing, extrusion &
work hardens quickly

2 Special Brasses - Contain metals other than Cu & Zn

i)German silver

Cu = 25-50%
Zn = 10-35%
Sn = 5-35%

Good strength &

corrosion resistance
to salt water.
Extremely malleable,
ductile, & looks like
silver

Utensils, tableware,
bolts, screws,
ornaments,
corrosion-resistant
implements,
coinage, decorative
articles, etc.

ii) Admiralty
Brass ( Tobin
Brass)

Cu = 59-62% Posses high corrosion Propellers &

Zn = rest
& abrasionmarine works
Sn = 0.5-1.5% resistances

3 Bronzes

Cu = 80-95%
Sn = 20-5%
Besides these,
other metals
are also
added.

Tough, strong,
corrosion resistant,
Can readily be casted
& machined

Types Of Bronzes

i)Coinage bronze Cu = 89-92%

(common bronze) Sn = 11-8%

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Soft, ductile &

durable

Pumps, valves,
wires, flanges,
utensils, coins,
statues, etc.

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ii)Gun metal

Cu = 85%
Zn = 4%
Sn = 8%
Pb = 3%

Hard, tough & strong

to resist the force of
explosion

Foundry works,
Hydraulic fittings,
heavy-load
bearings, parts of
high pressure steam
plants, water
fittings, marine
pumps, etc.

iii) High
Phosphorus
Bronze

Sn = 10 -13%
P = 0.4-1%
Cu = rest

Hard, brittle, abrasion Making bearings &

resistant. Posses low gears, taps, bushes,
coefficient of friction springs, turbine
blades, fuses etc.

iv) Aluminium
Bronze

Cu = 90-93%
Al = 10-7%

Golden yellow color,

Quite strong, readily
fusible, gives good
castings, posses good
abrasion resistance.

For all casting

operations, bushes
& bearings,
jewellery, utensils,
coins, photo frames
etc.

v) Nickel
Bronzes

Cu = 90%
Ni = 9%
Fe = 1%

Hard, higher in
tensile strength, &
better corrosion
resistance than
copper

For rolling
purposes,
unhardened shafts,
valves, & general
purpose semi-hard
bearings

4 Solders - Low melting alloys of Sn & Pb

i) Soft solder

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Pb = 37.67%, Melt at low

Sn = 31-60%, temperature
Sb = 0.12- 2%

Soldering electrical
connections,
sealing tin cans,
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joining lead pipes

ii) Brazing alloys Sn = 92%,

Sb = 5.5%,
Cu = 2.5%

Used for soldering

steel joints by the
process of fusing

iii) Tinmans
solders

Used for soldering

and tinning

Sn = 66%
Pb = 34%

Low melting alloys

Woods Metal

Rose metal

VSG & KY

Bi = 50%
Pb = 25%
Sn = 12.5%
Cd = 12.5%

It is readily fusible
m.p. 70 C.

Used for making

fire-alarms and
automatic
sprinklers ,
Safety plugs for
cookers,
as a soft solder for
joining two metallic
parts, as castings
for dental works
for boiler and
electric fuses.

Bi = 50%
Pb = 28%
Sn = 22%

It is readily fusible
m.p. 89 C

Used for making

fire-alarms, fusewires, castings for
dental works, and
in automatic
sprinklers.

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