Copper, Aluminum, Titanium & Alloys – Contents

1.0	Copper and Copper Alloy	1 – 70
1.1	Copper	2 – 3
1.1.1	Copper in General	2
1.1.2	Origin	3
1.1.3	Production Quantity	3
1.2	Refinery of Copper	3
1.3	Copper and Copper Alloy Flow Chart	4
1.4	Copper Based Alloy Constituents Chart	5
1.5	Copper	6 – 8
1.5.1	Oxygen free high conductivity Copper – OFHC	6
1.5.2	Tough Pitch Copper	6
	Copper Oxide	6
	Globules Formation	6
	Disadvantages of Globules in Copper	6
	Advantages of Globules in Copper	6
1.5.3	Electrical Conductivity of Copper	7
	100%Conductivity
	Over 100% Conductivity
	Oxygen free high conductivity copper
1.5.4	End Usages of Copper	8
1.6	Water Tube	9 – 13
	Advantage of Water Tube	9
	Rules	9
	Conduit size	9
1.6.1	Simple Principal of Calculating pipe size	10
1.6.2	Minimum Copper Tube Sizes for Short Branch Connections to Fixture	10
1.6.3	Packing Method	10
1.6.4	Ordering	11
1.6.5	Chemical Composition of seamless copper water tube (to ASTM B88)	12
1.6.6	Mechanical Properties of seamless copper water tube to ASTM B88	12
1.6.7	Joining of Copper Tube for water and non-corrosive gases	12
1.6.8	Copper Seamless tube – Standard Size, Working Pressure and Weight	13
1.7	Turner Grooved Copper Tube	14
	Groove Shape
	Standard Sizes
1.8	Copper, Arc Tube	15 – 16
	Chemical Composition and Hardness	15
	Mechanical Properties	15
	Standard Sizes, Weights and Tolerances	16
	Packing Method	16
	Ordering	16
1.9.1	Floor Heating Copper Tube	16
1.9.2	Plastic-sheathed Copper tube	17
1.10	Finned Tube	17
1.11	Pure Copper Casting for General Use to JIS H5100	17
	Copper Alloy	19 – 68
1.12	Brass – Type , Zinc Properties, Working Method, Colour, Hardness & Tensile Strength and Ductility Chart	20
	Brass	21 – 24
1.13	Brass	21
	Solidus Temperature and Zinc Dissolution Ratio	21
1.13.1	Free Cutting Brass	21
1.13.2	High Tensile Brass	21
1.13.3	Commercial Brass	22
1.13.4	Naval Brass or Admiralty Brass	23
1.13.5	Brass Ingot for Castings (to JIS H5101)
1.13.6	High Strength Brass Ingots for Castings to JIS H2205	23
	Bronze	24 – 25
1.14.1	Bronze, metal ingredients	24
1.14.2	Phosphor Bronze	24
1.14.3	Zinc Bronze	24
1. 14.4	Leaded Bronze	25
1.14.5	Phosphor-bronzes, Tin Bronzes and Red Brass -Chemical composition, mechanical properties, end usage & characteristic	26
1.15	Aluminum Bronze	27 – 28
1. 15.1	Features	27
1.15.2	Casting Problem	27
1.15.3	Type and End Usage	27 – 28
	(a-Phase, Cold-working alloy) (a+ y2 (gamma) phase Hot-working and casting alloy)
1.15.4	Aluminum Bronze Ingots for Castings to JIS H2206	28
	Nickel Copper	29 – 30
1.16.1	Nickel Sliver	29
1.16.2	Nickel Copper Alloys for Marine Purpose	29
	Advantage
	End Useage
1.16.3	Cupro Nickel	29
1.16.4	Copper Nickel Alloys to BS2870/5, 3072/6 & NES824,condition, chemical properties feature & end usages	30
1.17	Chromium Copper	31
1.18	Zirconium Copper	31
1.19	Silicon Copper	31
1.20	Hot-dip tinned copper or alloy strip	31
1.21	Contour – miller copper alloy strip	32
1.22	Heat-Treatable Copper Alloy	33
(a)	Beryllium Copper	33
(b)	Titanium Copper	33
(c)	Shape Memory Copper Alloy	33
1.23	Copper Alloy – Sheet and Strip, Alloy Name, Physical Properties, Tensile Strength and Elongation	34 – 35
1.24	Copper and Copper Alloy – Strip and Sheet Classification, Industrial Standards, Class , Chemical Composition, Application and Characteristics	37 – 39
1.25	Copper and Copper Alloy – Strip and Sheet, Thickness and Width Tolerance	40
1.26	Copper and copper Alloy Strip, Sheet and Plate Standard Measurement	41
	Sheets and Plates	41
	Strips	41
1.27	Semi-finished Product of Copper and Copper Alloy	41
1.28	Copper and Copper Alloy, Mechanical Properties	42 – 43
1.29	Copper and Copper Alloy – Rod and Bar Classification, Industrial Standards, Class, Chemical Composition, Application and Characteristics	44 – 46
1.30	Free Cutting Brass Rod and Bar – Mechanical Properties	47 – 49
1.31	Copper and Copper Alloy Strip, Sheet and Plate Standard Measurement	50
	Rods and Bars	50
	Wires	50
1.32	Semi-finished Product of Copper and Copper Alloys	51
	Semi-finished	51
	Advantages	51
1.33	Copper and Copper Alloy – Wire Classification, Industrial Standards, Class, Chemical Composition, Application and Characteristics	52 – 54
1.33.1	The dimensional tolerances of diameter and length of Round, Hexagonal, Rectangular and Square Rods and Bars.	54
1. 34	Copper and Copper Alloy Wire Diameter Tolerance	55
	Round Wire	55
	Square Wire	55
	Hexagonal Wire	55
1.35	Copper and Copper Alloy, Grain Size	56
1.36	Copper and Copper Alloy, Mechanical Properties	56
1.37	Deep Drawing Purpose (non-earing) strip & sheet, Non-directional	57
	Earing	57
	Calculation of earing percentage	57
1.38	Deep Drawing Material	57 – 58
	Deep Drawing Quality (DDQ) Strip / Sheet	57
	Limits of deep drawing in Practice of Various Metal
	Reduction Limit Ration	58
1.39	Material with Speical Feature	58 – 59
	Stress	58
	Freedom from Flow Line	58
	Soft temper	58
	Etching	59
1.40	Copper Alloy Strip & Sheet End Usage (classified by trade)	59 – 60
1.41	Direct and Indirect Extrusion	61
1.42	Cladded and Plated Metal Alloy	62 – 68
	The Method of Cladding	62
	Cladding included Base & Cladding Metal	62
1.42.1	Types of Cladding	62
	Over lay	62
	In lay	62
	Corner lay	62
	Edge lay	62
	Top lay	62
	Multi-layer inlay	62
1.42.2	Plating	63
1.42.3	Flow Chart of Claded & Plated Metal	63
1.42.4	Various Base Metals’ Other Claded Metal	64 – 65
1.42.5	Plating Position & Example	66
1.42.6	Coiling Direction	66
1.42.7	End Usages	67
1.42.8	Claded, Inlet or Plated Stainless Steel Strip	68
1.43	Indentification of Copper and head Alloy by Physical and Chemical Test	69
1.44	Electroplating Purpose Copper Materials Alloy	70
2.0	Aluminum and Aluminum Alloy	71 – 121
2.1	Aluminum in General	73
2.2	Origin	73
2.3	Refinery	73
2.4	IOutstanding Characteristics of Aluminum	73 – 74
2.5	Production Method & Production Flow Chart	75 – 77
2.5.1	Production of Ingot	75
2.5.2	Production of Aluminum and Alloy Material	76
2.5.3	Aluminum Surface Treatment	77
2.6	Corrosion Resistance Properties	78
2.7	Corrosion Resistance of Aluminum Against Chemical	79 – 82
2.8	Classification of Aluminum & Aluminum Alloys	83 – 84
2.8.1	Comparison of Heat-treatable and Non-treatable Alloy	83
	Tensile Strength
	Alloy
	Corrosion Resistant
	Jointing
	Machining
2.8.2	Not-heat-treatable Wrought Aluminum Alloy	84
2.8.3	Not-heat-treatable Cast Aluminum Alloy	84
2.8.4	Heat-treatable Wrought Aluminum Alloy	84
2.8.5	Heat-treatable Wrought Aluminum Alloy	84
	Industrial Standards of Aluminum & Alloys	85 – 113
2.9	American Standards	85 – 99
2.9.1	Typical mechanical properties of Aluminum & Aluminum alloy (Alloy Designation)	85
2.9.2	(Temper Designation)	86 – 88
2.9.3	Visual Inspection	88 – 89
2.10	Japan Industrial Standard (JIS)	90
2.11	British Standard (BS)	91
2.11.1	Heat-Treatable & Non Hea-Treatable Alloy	91
2.11.2	Materials Shape	91
2.11.3	Purity	91 – 92
2.11.4	Condition	92 – 93
2.12	Engineering Aluminum Under British Standard	94 – 95
2.13	Other Standards	96
2.14	Aluminum – Type, Industrial Standard, Chemical Composition, Characteristic & end usage of the most commonly used Stainless Steel	97 – 108
2.15	U.S. Aluminum Plate Standard	109
2.16	Weight of Aluminum Plate (For 2024 and 7075 alloy)	109
2.17	Comparison of Aluminum Bars Standard	110
2.18	Aluminum Rounds (2024 and 7075 alloy)	111 – 113
2.19	Aluminum Square (2024 and 7075 alloy)	114
2.20	Aluminum Rectangle (2024 and 7075 alloy)	115 – 119
2.21	Aluminum Hex (2024 and 7075 alloy)	120 – 121
3.0	Titanium and Titanium Alloy	125 – 173
3.1	Titanium in general	125 – 127
3.1.1	Application	125
3.1.2	Example of Application	126
3.1.3	Supply of Titanium	127
3.1.4	Origin of Titanium	127
3.2	Refinery	128 – 129
3.2.1	Titanium Spongy Manufacturing Flow Chart	128
3.2.2	Flow Chart of Titanium Finishing Material	129
3.3	The Outstanding Characteristic of Titanium	130
3.4	Grain Structure of Titanium Alloy	130
3.5	Comparison of Properties of Titanium Steel, Stainless Steel and Aluminum	131
	Working Methods	132 – 143
3.6	Working on Titanium Alloy	132 – 135
3.6.7	Comparison of Working Speed of Titanium, High Speed Steel and Carbide	134 – 135
3.6.8	Forming & Deep Drawing	136 – 137
	Forming	136
	Forming Temperatures for Unalloyed Titanium and Titanium Alloys	136
	Deep Drawing	136
(a)	Lubrication	136
(b)	Comparison of physical and mechanical properties of Titanium, Stainless Steel (304 & 403) and mild steel	137
(c)	Bending test	137
3.6.9	Drilling	138
3.6.10	Grinding	139
	Coolant	139
	Suitable Wheel Speed	139
	Vitrified bond (Vitrified Bond) A60 wheel	139
	Wheel Designation , Speed and Feeding of Materialµ	139
3.6.11	Milling	140
3.6.12	Turning	141
	Tool Geometry for Turning Titanium	141
3.6.13	Jointing	142
3.6.14	Welding & Soldering	142
	Welding	142
	Bending	142
	TIG	142
	Soldering	143
	Typical Solders and Soldering Temperatures	143
3.6.15	Bending	143
	Titanium Bending
3.7	Treatment	144
3.7.1	Surface Treatment	144
(a)	Nitriding	144
(b)	Glow Discharge Nitriding	144
(c)	Chromium Plating	144
(d)	Hard-facing Welding	144
3.8	Increasing Corrosion Resistance	144 – 145
3.8.1	Electroplating	144
	Platinum Plating	144
	Pd O/T.o Coating	144
3.8.2	Decorative Colour	144
3.8.3	Interference of colour by Atmospheric Oxidation	145
3.8.4	Interference of colour by Anode Oxidation	145
3.8.5	Lubricily	145
3.9	Heat Treatment	146
	Solution Treatment & Aging (STA)
	Duplex Solution Treatment & Aging (STSTA)
3.10	Descaling	146
3.11	Titanium – Type, Industrial Standard, Chemical Composition, Characteristic & end usage of the most commonly used Titanium & Titanium Alloy	147 – 150
3.12	6Al-4V ELI & 6Al-4V Alloy	151 – 157
3.12.1	End Usages, Available Forms and Chemical Composition
3.12.2	Mechanical Properties	152 – 153
3.12.3	Physical Properties	154
3.12.4	Fabrication	155
3.12.5	Heat Treatment	156
3.12.6	Smallest Bending Radius (r)	157
3.13	CP GR4 & GR2 Alloy	158 – 161
3.13.1	Mechanical Properties	158
3.13.2	Physical Properties	159
3.13.3	Fabrication	160
3.13.4	Heat Treatment	160
3.13.5	Technical Data	161
3.14	Titanium & Titanium Alloy Specifications Available Forms	162 – 163
	Available Forms	162
	General Specifications	163
	Grading	163
3.15	Titanium Alloy Military Use	164
	Bar and reforge Stock (MIL-T-9047G)	164
	Sheet-Strip-Plate (MIL-T-9046J)	164
3.16	Surface finish	165
3.17	Titanium Wire and Shaped Wire	165 – 169
3.17.1	End Usages	165
3.17.2	Size Available	165
3.17.3	Chemical Comparison and Mechanical Property(Annealed Condition)	166
3.17.4	Tolerance of Round Wire Diameter	166
3.17.5	Dimensional Profile of Flat and Half Round Wire	167
3.17.6	Chemical Composition of Titanium Wire and Rods for Welding	167
3.17.7	Comparison of Physical Properties of Titanium, Stainless Steel, Iron and Aluminum	168
3.17.8	Corrosion Resistance of Titanium	168
3.17.9	Weight in kg per one meter	168
3.18	Diameter of Mother Wire to Draw Hexagons or Square Wire	169 – 170
3.19	Weight Formula for Titanium	171 – 172
	Rounds	171
	Squares	171
	Rectangles	171
	Hexagons	171
	Octagons	171
	Circles	171
	Sheet / Plate	172
	Round Seamless Tube	172
	Square Seamless	172
	Rectangular (Seamless Tubing)	172
	Ring	172
3.20	Fire Preventive	173
	Supplement
4.0	Nickel	187 – 195
4.1	Nickel in General	187
4.2	Origin	188
4.3	Refinery	188
4.4	Nickel Pellet	188
4.5	Monel	189
4.6	Constantan	189
4.7	Nichrome Wire	189
4.8	Permalloy	189
4.9	Nickel Silver	190
4.10	Nickalloy	190
4.11	Physical and Mechanical Properties of Nickel	190
4.12	High Nickel Alloys	191 – 193
4.13	Indentification of Copper and Lead Alloy by Physical Test	194
4.14	Electroplating Purpose Nickel	195
5.0	Zinc	199 – 208
5.1	Introduction	199
5.2	End Usages	199 – 200
(a)	Coating	199
(b)	Zinc Oxide	199
(c)	Die-casting	199
(d)	Alloying	200
(e)	Super Plastic Alloy	200
(f)	Roofing & Cladding	200
(g)	Nutrition
5.3	Origin	200
5.4	Refinery	201
5.5	Production	201
5.6	Properties of zinc	201
5.7	Zinc Die-Casting Alloy
5.8	Battery Grade Zinc Alloy (for making dry cell cans)	202
5.9	Special Zinc Anodes > 99.995% Zn	203
5.10	Special Highgrade Zinc > 99.995% Zn	204
5.11	Gravity Casting Alloy Zinc No.12	204
5.12	Gravity Casting Alloy Zinc No.12
5.13	American Standard of Zinc	206
5.14	European standard (EN) of Zinc	206
5.15	Zinc Chemical composition to EN 11749(% ps mm2)	206
5.16	The Zinc trading in LME	207
5.16.1	Purity	207
5.16.2	Ingots – slabs & Jumbo	207
5.17	Nickel and other metal for Electroplating purpose	207 – 208
6.0	Cadmium	209
6.1	Cadmium(99.99% Cd minimum)	209
7.0	Lead	210 – 212
7.1	Lead in General	210
7.2	Corrosion	210
	Alkali corrosion	210
	Condensation corrosion	210
	Lead Attack Aluminum	210
7.3	Lead use in general	211
7.4	Battery use lead	211
7.5	Source and Production	211
7.6	Properties of Lead	212
7.7	Color Marking on Different Thickness of Lead	212
7.8	Melting Point of Lead and Other Materials	212
8.0	Tin	213 – 214
8.1	General	213
8.2	Chemical Composition of Tin Metal to JIS H2108	213
8.3	Tin for Electroplating	213
8.4	Physical Properties of Pure Lead, Tin and Zinc	214
9.0	Magnesium	215 – 217
9.1	General	215
9.2	Physical properties of Magnesium	215
9.3	Mechanical Properties of Magnesium	216
9.4	Casting Magnesium Alloy and Forging Magnesium Alloy	216
9.5	Magnesium Casted Parts to JIS H5203	217
10.0	Gold	218 – 220
10.1	General	218
10.2	Gold Alloy	218
10.3	Evaporation	218 – 219
10.4	Precious Metals & Alloy	220
11.0	Platinum	221
12.0	Heat Resistant Alloys and Stainless Steel	223 – 224
12.1	Heat – Resistance Stainless Steel	223
12.2	Chrome Heat Resistance Stainless Steel	224
12.3	Cr-Ni Heat Resistance Stainless Steel	224
12.4	Superior Heat Resistance Steel	224
12.5	Heat Resistance Super Alloy	224
13.0	Permalloy & Magnetic Alloy	225 – 227
13.1	Magnetic Materials – General	225
13.1.1	Soft Magnetic	225
13.1.2	Hard Magnetic	225
13.1.3	Magnetic Induction	225
13.1.4	Magnetic Permeability	225
13.1.5	magnetic force,magnetic field,electron	226
13.2.1	Soft Magnetic Alloys	226
13.2.2	Usages	226
13.2.3	Semi – Hard Magnetic Alloy	226
13.2.4	Usages	226
13.3	Hard Magnetic Alloys	227
13.4	End Usages of Hard Magnetic Alloys	227
13.5	Magnetostrictions Alloys	227
13.6	Alloys for Semi – Conductors & Electronic Tubes
13.7	Alloys for Semi – Conductors & Electronic Tubes Use	227
13.8	Alloys for Semi – Conductors & Electronic Tubes – Chemical Composition & Characteristic	228
13.9	Anti – Corrosion and Heat – Resistant Spring Alloys	228
13.10	End Usages	228
13.11	Anti – Corrosion and Heat -Resistant Spring Alloys	228
14.0	Bi-Metal(Thermostat Metal)	229 – 231
	Structure	229
	End Usages	229
14.1	Bi-Metal, Chemical Composition and Expansion	230
14.2	Available sizes	231
14.3	Applications	231
15.0	Shape Memory Alloy & Super Elastic Alloy	232 – 236
15.1	Memory Alloy	232
15.2	Features	232
15.3	Memory Characteristics & Super Elastic Characteristics	233
15.4	Comparision of Memory Alloy & Steel	233
15.5	Chemical composition and shape-recovery temperature of shape memory alloy	233
15.6	Physical properties of shape memory alloys in comparison with titanium, copper and stainless steel	234
15.7	Mechanical properties	235
15.8	End usage examples	235
	Control value of evaporated coffee maker
	Joints of Micro-robot
	Heat senser for power supply cable of mass transit system	236
	eye glasses
	Garment Accessories
	Temperature Control Device	236
	Greenhouse window switch
	Medical appliance
	Others
16.0	Tungsten	237
16.1	Tungsten Alloy	237
17.0	Manganese	238
18.0	Chromium	239
19.0	Molybdenum	239
20.0	Cobalt	239
21.0	Vanadium	239
22.0	Antimeny	239
23.0	Bismuth	239
24.0	Mercury	240
25.0	Metal Elements and their Properties	241