Mr.S.A.

Howal

ALLOY

Que 1. Define Alloy. What is the Purpose of making an alloy?

Answer- An alloy is a homogeneous mixture of two or more elements out of which one must be metal.
alloys can be formed by combination of metals with non-metals and metalloids. In alloys the element
which present in largest amount is known as principal constituent (base metal). The other elements either
metals or nonmetals are called alloying elements/articles.

examples- i) Steel -An alloy of iron (ferrous alloy)

ii)Duralumin- An alloy of aluminium. (Non-ferrous alloy)

Purpose of Making an Alloy- pure Metals are soft having less corrosion resistance, with high
melting point and more Chemical reactivity. They do not possess properties required for engineering
purpose. Hence the purpose of making an alloy is to improve Hardness, Tensile strength, castability,
machinability and Corrosion resistance properties of metal. Also, the purpose of alloying is to moderate;
physical constants, chemical reactivity, malleability and ductility.

i) To Increase Hardness of metal- pure metals are generally soft. By alloying we can make them
Hard. Example, Gold and silver are alloyed with copper to make them hard to use in ornament.
ii) To increase corrosion resistance- pure metals have less corrosion resistant hence by alloying
corrosion resistance property can be improved. Example, Pure iron is alloyed with carbon and
chromium to form stainless steel which resist corrosion.
iii) To increase tensile strength- By alloying tensile strength can be increased. Example, steel by
alloying with trace carbon tensile strength can be increased.
iv) To moderate physical constants-By alloying physical constant can be altered.
Example, -lead alloys (woods metal) acts as solders due to low melting point.
v) To modify chemical reactivity- By alloying chemical reactivity may be increased or decreased.

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ALLOY

FERROUS ALLOYS NON-FERROUS ALLOY

Plain carbon steel [Fe+C] Alloy steel (Fe+Metal)

1.Mild carbon steel(C=0.15-0.3%) Metal=Ni, Cr, Mo, W, V, Mn, Mg etc.

2.Medium carbon steel(C=0.3%-0.8%)

3.High carbon steel(C=0.8%-1.5%)

Alloy of Aluminium Alloy of Copper Alloy of Lead

Duralumin Magnalumin Brasses (Cu+Zn) Tinman Metal Woods Metal

Al=95% Al=70% 1. Dutch Metal Brass Sn=66% Bi=50%

Cu=4% Mg=30% 2. German Silver Pb=34% Sn=12.5%

Mg=0.5% Bronze(Cu+Sn) Pb=25% ,Cd=12.5%

1. Gun Metal

Mn=0.5% 2.Nickel Bronze

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Que2. Write not on Ferrous Alloy. Explain Plain Carbon steels?

Ans-In Ferrous alloys Iron is major constituent. They are important in engineering construction
materials. Ferrous alloys have Wide applications in construction and various industries. There are two
types of ferrous alloys namely i) Plain Carbon Steels And ii) Alloy Steels.

1. Plain Carbon Steels- plain Carbon Steels are alloys of iron and Carbon. They contain carbon from
0.15%-1.5%. The carbon plays an important role in various functions of steel. As percentage of carbon
increases Hardness, tensile strength, workability, ductility, heat treatments changes. Depending upon
percentage of carbon in steels they are classified in three categories.

i)Mild carbon steel ii) Medium carbon steels iii) High carbon steels.

i)Mild carbon steel-Mild carbon steels are known as soft steels or low carbon steels. They contain
carbon from 0.15% to 0.3% .

Properties -They are tough, ductile, shock resistant. They are not affected by saline water.

limitations- Undergoes Corrosion quickly.

Application- i) Used for manufacturing of bolts, nuts, rivets, screws, plates for boilers and ships.

ii)Mild steels are used in RCC cement concrete. (Reinforced cement concrete)
iii)Mild steel is used in manufacturing of rail tracks, cranes, transmission towers, industrial building
structure, and in roof covering.

2)Medium carbon steel- In medium carbon steel carbon content is from 0.3% to 0.8%.

Properties-i) They are harder and tougher steel and exhibit greater strength than mild carbon steel.
ii)They are shock resistant.

Limitations-i) Due to hardness not easily weldable like mild steel.

Applications-i) They are used to prepare Boiler, turbines, marine shafts.

ii)They are used in manufacturing of Wheels, hammers, hydraulic fittings like cylinders.

iii)Used for manufacturing of Gun parts, wire ropes, casting for automobile engine parts.

3) High carbon steel- In high carbon steels carbon content is from 0.8% to 1.5%.if carbon content is
more than 1% then the steel is known as cast steel.

Properties-i)They are very hard and possess high strength.

ii)shock resistant

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iii)They have granular shapes and can be permanently magnetised.

Limitations- Difficult to forge.

Applications-They are used in manufacturing of boring tools, metal cutting tools blades, hammers, srew
divers.

All Plain Carbon Steels has Limitations Due to presence of carbon-

1)The corrosion resistance of all plain Carbon Steel is Very low; therefore, they cannot be used in
manufacturing of various machine parts.

2)They are brittle and less ductile.

3)At higher temperature their mechanical properties get deteriorated therefore they are not used at higher
temperature.

Que3) Write note on alloy steels. Explain effect of following alloying elements on
steels.

(i)W, (ii)Mo, (iii)Ni ,(iv) Cr, (v) Co

Ans-There are two types of ferrous alloys namely i) Plain Carbon Steels And ii) Alloy Steels. Plain
carbon steels has only limited applications.Addition of small amounts of one or more metals like Nickel,
Chromium, Cobalt, Tungsten ,Molybdenum, Vanadium, Manganese etc Imparts special properties to
Steels. Such steels are called Alloy Steels.

Main Purposes of Alloying steel are as given- To Improve; Tensile strength, ductility, Toughness,
Elasticity, Hardness, Heat-resistance, weldability. Also to improve Forgeability, Shock resistance, red
hardness and magnetic properties.

To minimise coefficient of expansion along with improving oxidation resistance.

Effects of Alloying elements on Steels.

(i)Tungsten(W)-Addition of W increases the red hardness, toughness, and Shock resistance of steel.

(ii)Molybdenum (Mo)- Addition of Mo in steel will improve Strength at high temperature. improves
corrosion resistance with decrease in brittlement.

(iii)Nickel (Ni)- Addition of Ni in steel improves Tensile strength, ductility, toughness, elasticity.

(iv)Chromium (Cr)-Addition of chromium improves high corrosion resistance mainly. Chromium is

added up to 18%. trace Cr (1.5%) improves tensile strength.

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(v)Cobalt (Co)-Addition of cobalt moderate magnetic properties of steel along with drilling and cutting
abilities at high speed.

vi) Manganese (Mn)- Addition of 1% to 1.5% Mn increases strength, toughness and Brittleness. More
addition up to 14% increases high degree of hardness.

vi)Vanadium(V)- Addition of V increases shock resistance with ductility.

❖ Applications of Specific Alloy steels.

1.Heat Resisting steels- Example (Nichrome)

These are heat resistance Steels suitable for making equipment’s exposed to high temperature. example
is Alloy steel containing Tungsten, Molybdenum, chromium Nickel elements.

Molybdenum gives strength along with heat resistance capacity. Steels containing 3.5% Molybdenum
are known as Heat resistance steels.

Chromium- This element mainly resist corrosion but more than 12 % Cr addition gives Heat resistance.

Nichrome is a steel alloyed with 60% nickel and 12% chromium mainly Used as Corrosion resistance
and also used as Heat resistance Steel at 1000 0C to 1100 0C.

Nickel -Addition of nickel also improves heat resistance of an alloy. Steels containing nickel around 18
% may tolerate temperature around 900 0C.

2.Stainless Steel- (Major Constituent is chromium)

These Steel alloys resist all type of corrosion. Due to excess content of chromium (more than 16%)
dense tough film of chromium oxide forms which resist further atmospheric or chemical corrosion.

Depending upon percentage of chromium stainless steel classified in two steels.

(i)Heat Treatable Stainless steel. - In these steels along with trace carbon (1.2%) chromium percentage
is below 18%. (generally, upto16%). They are used in manufacturing of surgical instruments, scissorrs,
etc. They can tolerate temperature up to 8000C.

(ii)Non-heat treatable stainless steel- These steels Show less Strength towards heat. They are more
corrosion resistance than heat. They are classified in two types.

(a)Magnetic type -These steels contain Cobalt element with about 12 to 22% Chromium Addition. Due
to trace amount of carbon (0.35%) they can be forged or rolled. They are used in manufacture of specially

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designed tools, machines and chemical equipments.

(b)Non-Magnetic -These steels contain 18 to 25 % Chromium ,8-21% nickel and 0.15 % carbon. These
are mostly known as Stainless steel. As the percentage of Chromium to Nickel is 18 to 8 %, they are
called as "18/8 Stainless steel."

3.Shock resist steel- In this steel along with chromium Vanadium or molybdenum are added to
absorb shock or vibrations. These types of steel are used where sudden Shock absorption is required.
They possess high elastic limits.

Chrome-Vanadium steel containing 0.8 % to 1.1% chromium, 0.25% vanadium and 0.35 to 0.9% carbon
possess great impact resistance. These are used in making laminated Springs ,leaf springs ,so mostly
known as spring-steels.

Q4. What is Non-Ferrous alloy? Explain composition properties & uses of

Duralumin & Magnalium (Magnalumin).

Ans-In Non-Ferrous alloys Iron is not the main constituent. The main components in these alloys are
Aluminium, Copper, Lead, Zinc, Tin, Nickel etc. These alloys have low melting point than ferrous alloys

Examples- Duralumin (alloy of aluminium), Bronze (alloy of copper).

Properties of Non-ferrous alloys as given- These alloys are soft compare to ferrous alloys. They have
good castability, they possess good atmospheric corrosion resistance, They have low coefficient of
friction, They have low Physical constants, They have low density.

Duralumin-Duralumin is an alloy of aluminium. Aluminium is major constituent in this alloy. It is

widely used and Most important alloy of aluminium.

Composition- Aluminium (Al) =95%

Copper (Cu) =4%

Manganese (Mn)=0.5%

Magnesium (Mg)=0.5%

Properties-(i)It is light, tough, Highly ductile ,easily castable, Good conductor of heat and electricity.

(ii)It is lighter than Steel. it has same strength as steel but density is very low.

(iii)It possess high Machinability

(iv)Tensile strength can be increased by heat treatment without affecting ductility.

Applications of Duralumin.

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(i)It has extensive use in Aircraft industry in the form of Clad.

(ii)It is used in the making of Automobile and locomotive parts.

(iii) It is used in making surgical instruments and fluorescent tube caps.

(iv)It is used in cables due to its high ductility and good electrical conductivity.

Magnalumin;it is an important alloy of aluminium. With the modern advancement of aircraft and
automobiles, the utility of light-weight alloy has increased.

Composition- Aluminium(Al)=70-90%

Magnesium(Mg)=30-10%

Properties- It possesses mechanical properties similar to brass. Strong, tough and lither than
aluminium.

Uses-It is used in preparation of scientific instruments. for making cheap balances, and airplane parts

Que.5) Give composition properties and application of Wood`s metals.

Ans-Wood`s metal is an alloy of Lead. In wood`s metal along with Lead (Pb), Bismuth (Bi), Cadmium
(Cd) and Tin (Sn) are present. Due to low melting point Lead alloys are commonly known as Solders.

Composition- Bismuth (Bi)=50%

Lead (Pb)=25%

Tin (Sn)=12.5 %

Cadmium (Cd)= 12.5%

Properties-(i) Very low melting point (710C)

(ii)Incompatible with Acids, oxidizing agents, halogens interhalogen compounds.

(iii)Due to low melting point readily fusible.

Applications/Uses-(i)It is used as a solder for joining two metallic parts/articles.

(ii)It is used for making fire alarms and automatic sprinklers.

(iii) It is used for safety plug for cookers, Milk pots.

(iv) It is used for castings for dental works.

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Que.6) Give composition properties and application of Tinman`s metals.

Ans- Tinman`s metal is an alloy of Lead.In Tinman`s metal principle constituent is Tin(Sn). Due to
low melting point Lead alloys are commonly known as Solders. Tinman`s metal is known as quick
solder.

Composition- Tin (Sn) = 66%

Lead (Pb)= 34%

Properties -low melting point melts at constant temperature 1830C.

Applications/Uses--(i)It is used as a solder for joining two articles of tin in tin smith`s work.

(ii) It is used for sealing of Tin cans.

Que.8) Give the composition properties of German silver and Dutch metal

Ans-German silver is an alloy of copper. It comes under category of special Brass.

Major constituent of German silver is copper and Zinc with addition of Nickel (Ni)

Composition: of German Silver -Copper (Cu) = 25-50%

Zinc (Zn)=10=35%

Nickel (Ni)=5-35%

Properties: High tensile strength, Due to presence of nickel high corrosion resistance to salt water. Extremely
improving ductility and malleability, Looks like silver.

. Applications/Uses-- Decorative articles, Utensils and Tableware, Bots & Screws Ornaments, Cutlery
and Coinage

Dutch Metal: Is an alloy of copper and Zinc (Cu+Zn). It is also known as commercial brass

Composition- Copper (Cu) =80%

Zinc (Zn)=20%

Properties/Characteristics:

1. It is Golden in Colour

2. Suitable for all drawing and forming operations.

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Uses: Cheap Jewellery Musical Instruments, Battery Caps, Flexible Hoses, Tubes and Name Plate

Que.9) Give the composition properties of Gun Metal and Nickel bronze.
Ans- These are non-ferrous alloys. Bronze are alloys of copper where Main constituent is copper. These
alloys have low melting point than ferrous alloys.

Bronze are an Alloy of Copper, Tin and Nickel (Cu+Sn+Ni) such as, Gun Metal and Nickel Bronze

Gun Metal Composition:

Copper (Cu) =85%

Tin (Stannous) (Sn) =8%

Zinc (Zn)=4%

Lead (Plumbum) (Pb)=3%

Properties : Tough ,strong to resist the force of explosion.

Uses: Used in heavy bearings, water fittings, hydraulic fittings, marine pump and Gun Parts.

Nickel bronze

Composition: Cu=90%

Ni=9%

Fe=1%

Properties: They are hard, higher in tensile strength and better corrosion resistance than copper.

Use: For rolling purposes, Unhardened shafts, valves and general purpose

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Que10. Distinguish between Brasses and Bronze.
Brasses Bronze

1.Brasses are alloys of copper and Zinc 1.Bronze are alloys of copper and tin.
2.Inferior to Bronze in respect of 2.superior to brass in respect to
corrosion resistance. corrosion resistance.
3.Less strong and harder than bronze. 3.More stringer and harder than brass.
4.Because of high toughness, common 4.They can be machined easily.
grade brasses are difficult to Machine. 5.Bronze are expensive because of tin
5.Brasses are cheap because of zinc content.
content. 6.Gun metal, Nickel Bronze
6.German Silver, Dutch metal, Cartridge Phosphorous bronze are examples of
brass, admiral brass, Muntz metal are Bronze.
examples of Brasses. 7.In Bronze along with copper and tin
7.In Bronze along with copper and zinc other elements like Ni, Al, P, Be, Si are
other elements like Mn, Al, Fe, Pb are present.
present.

Important Brasses Extra.

Name of the alloy Composition Properties Uses

Ordinary Brass Cu=60-70% High tensile strength For making Condensors,
Zn=40-30% Corrosion resistance Brass fittings,Sheet
Readily machinable, ornamental and
decorative purpose
Commercial Cu=90% Golden coloured For making ornaments,
brass/French gold Zn=10% ,Harder and stronger jewellery, Nameplates,
Musical instruments.
Battery caps and
Machine parts.
German Silver Cu=25-50% High tensile strength, For making Utensils,
Zn=10-1-35% Due to presence of decorative articles
Sn=5-35% nickel high corrosion ,ornaments
resistance with
improving ductility and
malleability.
Looks like silver
Muntz metal Cu=60% Harder and stronger For making automobile
Zn=40% than cartridge brass parts.for hot stamping
and fitting.

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Important bronze extra.

Name of the alloy Composition Properties Uses

Gun Metal Cu=85% Tough ,strong to resist Used in heavy
sn=8% the force of explosion. bearings, water
Zn=4% fittings, hydraulic
Pb=3% fittings, marine pump.
Phosphorous bronze Cu=86% They are hard brittle and For making turbine
Sn=10-13% abrasion resistance. blades, bearings and
P=0.4% to 1% They posses low gears, taps, springs,
coefficient of friction.
Aluminium bronze Cu=90-93% It is quite strong, readily For all casting
Al=10-7% fusible, Gives good operations, bushes and
casting and corrosion bearings. which retain
resistance. It looks strength upto 4000C
golden yellow.
Nickel bronze Cu=90% They are hard ,higher in For rolling purposes,
Ni=9% tensile strength and Unhardened shafts,
Fe=1% better corrosion valves and general
resistance than copper purpose

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Numericals on Alloys
An Alloy is composed of 70% Copper (Cu) and 30% Zinc(Zn) by weight. Calculate the atomic % of
each in the alloy.

Solution:

1. Convert percentages to mass fractions

70
Mass fraction of Cu (wcu)= 70% = = 0.70
100

30
Mass fraction of Zn (wzn)= 30% = = 0.30
100

2. Calculate atomic percentages

Assume the atomic masses (Molar masses)

Atomic mass of Cu (MCu)= 63.55 g/mol.

Atomic mass of Zn (MZn)= 65.38 g/mol.

3. Calculate the Molar masses of CU and Zn in the alloy

Malloy = wcu × MCu + wZn × MZn

∴ Malloy = 0.70 × 63.55 g/mol + 0.30 × 65.38 g/mol

Malloy = 44.485 g/mol + 19.614 g/mol

Malloy = 64.099 g/mol.

Calculate actual atomic percentages in an alloy ( xCu and xZn)

𝑤cu × 𝑀Cu
xCu = × 100
𝑀𝑎𝑙𝑙𝑜𝑦

0.70 × 63.55 𝑔/𝑚𝑜𝑙

xCu = × 100
64.099 𝑔/𝑚𝑜𝑙

44.485 𝑔/𝑚𝑜𝑙
xCu = × 100 =𝑥𝐶𝑢 ≈ 69.43%
64.099 𝑔/𝑚𝑜𝑙

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𝑤Zn × 𝑀Zn
xZn = × 100
𝑀𝑎𝑙𝑙𝑜𝑦

0.30 × 65.38 𝑔/𝑚𝑜𝑙

xZn = × 100
64.099 𝑔/𝑚𝑜𝑙

19.614 𝑔/𝑚𝑜𝑙
xZn = × 100 =𝑥𝑍𝑛 ≈ 30.57%
64.099 𝑔/𝑚𝑜𝑙

Therefore, the atomic percentages of Cu and Zn in the alloy are approximately 69.43%
and 30.57 % respectively.

Numerical2.

Problem.

An alloy is composed of 80% nickel (Ni) and 20% Copper (Cu) by weight. Calculate
the density of the given alloy. Given Density of Ni=8.9 g/cm3 and Cu= 8.96 g/cm3.

Solution.

1. Convert percentages to mass fractions

80
Mass fraction of Ni (wNi)= 80% = = 0.80
100

20
Mass fraction of Cu (wCu)= 20% = = 0.20
100

2. Calculate the density of the alloy.

Assume that the volume occupied by Ni and Cu in the alloy are proportional to
their Mass fraction.

∴ Density of the Alloy (𝜌alloy);

(𝜌alloy)= wNi × 𝜌 Ni + wCu × 𝜌 Cu

(𝜌alloy)= 0.80 × 8.9 g/cm3 + 0.20 × 8.9 g/cm3

(𝜌alloy)= 7.12 g/cm3 + 1.792 g/cm3

(𝜌alloy)= 8.912 g/cm3. Therefore density of the alloy is 8.912 g/cm3

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Numerical3.

Problem1. Calculation of weight of components in an alloy.

An alloy sample weighs 500 g and consist of 60% Iron(Fe), 30% Chromium (Cr) and
10% Nickel (Ni). Calculate the weights of each component in the alloy.

Solution.

1. Convert percentages to mass fractions;

60
Mass fraction of Fe (wFe)= 60% = = 0.60
100

30
Mass fraction of Cr (wCr)= 30% = = 0.30
100

10
Mass fraction of Ni (wNi)= 10% = = 0.10
100

2. Calculate The weights of each component.

Given Total mass of the alloy = 500 g.

Wight of Fe = Mass fraction of Fe (wFe) × Total mass of alloy

= 0.60 × 500 g

∴ Weight of Fe = 300 g

Wight of Cr = Mass fraction of Cr (wCr) × Total mass of alloy

= 0.30 × 500 g

∴ Weight of Cr = 150 g

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Wight of Ni = Mass fraction of Ni (wNi) × Total mass of alloy

= 0.10 × 500 g

∴ Weight of Ni = 50 g

Therefore, the weights of Fe, Cr, and Ni the alloy are 300 g, 150 g, and 50 g,
respectively.

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