NON FERROUS METALS

ALUMINIUM

MAN U FACTU R E O F ALU M I N I U M

The aluminium occurs in abundance on the surface of earth. It is
available in various forms such as oxides, sulphates, silicates, phosphates, etc.
But it is commercially produced mainly from bauxite, which is hydrated oxide of
aluminium.

The aluminium is extracted from bauxite ores as follows:

i)

The bauxite is ground and then it is purified.

ii) It is then dissolved in fused cryolite which is a double fluoride of aluminium

and sodium.
iii) This solution is then taken to an electric furnace and the aluminium is
separated out by electrolysis.

PR O PERTIES O F ALU M IN IU M
i)

It is a very good conductor of heat and electricity.

ii) It is a silvery white metal with bluish tinge and it exhibits bright lustre on a
freshly broken surface.
iii) It is a non magnetic substance.
iv) It is rarely attacked by nitric acid, organic acid or water. It is highly resistant to
corrosion.
v) It is light in weight, malleable and ductile.
vi) It is very soft.
vii) It melts at 660C and its boiling point is 2056C.
viii) It possesses great toughness and tensile strength.
ix) It readily dissolves in hydrochloric acid.

x) Its specific gravity is about 2.70

U S E S O F ALU M I N I U M
The metal is chiefly used for making parts of aeroplane, cooking utensils,
electric wires, window frames, glazing bars, corrugated sheets, structural members,
foils, posts, panels, balustrades, bathroom fittings, precision surveying instruments,
furniture, etc. Its other uses can be mentioned as follows :

i)

It is used as a reducing agent in the manufacture of steel.

ii) It is used for making aluminium alloys, automobile bodies, engine parts and
surgical instruments.
iii) It is used for casting of steel.
iv) It is used in the manufacture of electrical conductors.
v) It is used in the manufacture of paints in powder form.

A L L O Y
An alloy is an intimate mixture of two or more metals. The process for making an
alloy is as follows :
i)

The more infusible material is first melted in a fire clay crucible.

ii) The other metal or metals are then added subsequently in order of their
infusibility.
iii) The contents are continuously stirred to form a homogenous mass.
iv) The molten mixture is then cast into suitable moulds and it is allowed to cool.
The product so obtained is called the alloy. The metal which is present in the
alloy in the largest proportion is called the base metal and all other elements are
called the alloying elements.
It may however be noted that an alloy does not merely indicate a mechanical
mixture of two or more metals. As a matter of fact, the properties of an alloy are
entirely different from those if its constituents.

ALU M I N I U M ALLOYS
These are preferred to pure aluminium for constructional purposes. They are
hard and strong. They contain copper, silicon, magnesium, manganese, iron and
nickel in various combinations.

Following are the important alloys of aluminium :

i)

Aldural

ii) Aluminium bronze

iii) Duralumin
iv) Y-alloy

ALD U RAL & ALU M I N IU M B R O N Z E

Aldural : This is also known as the Alcad and it is duralumin with a thin coating of
pure aluiminium.
The thickness of layer of pure aluminium is about 5 per cent of thickness of core
and such a layer prevents corrosion due to salt water.

Aluminium Bronze : This is in fact copper alloy. It consists of 10 to 22 per cent of

aluminium and 90 to 78 percent of copper.

It is very strong, hard, light, elastic and malleable yellowish brown alloy.
It is corrosion resisting alloy and has many applications for die casting, pump
roads, etc.
It is a substitute for brass.

D U RALU M IN
Duralumin : This is a very important alloy of aluminium. Its composition is as
follows
Aluminium . . . . . . . . . . . . . . . . . 94.0 %
Copper . . . . . . . . . . . . . . . . . . . . . . 4.0 %

Magnesium . . . . . . . . . . . . .. . . . . . 0.5 %
Silicon . . . . . . . . . . . . . . . . . . . . . . . 0.5 %
Iron . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 %
Its specific gravity is about 2.85.
It possesses the property of age hardening i.e. it acquires hardness after about 2 to
3 days when quenched in water from 500C.
It is quite strong and it has high electrical conductance.
It is used in aircraft and automobile industries, for making electric cables, in surgical
and orthopaedic implements or gadgets, etc.

Y ALLOY

Y - Alloy : Following is the composition of the alloy

Aluminium . . . . . . . . . . . . . . . . . 92.5 %
Copper . . . . . . . . . . . . . . . . . . . . . . 4.0 %
Nickel . . . . . . . . . . . . . . . . . . . . . . . 2.0 %
Magnesium . . . . . . . . . . . . . . . . . . 1.5 %

This alloy is a good conductor of heat and it possesses high strength at high
temperature.

It is used for making pistons of engines, cylinder heads, gearboxes, propeller

blades, etc.

ALU M IN IU M

PRODUCTS

The Aluminium as used in the building industry usually takes one of the
following four forms :
Casting based
Extrusion

Foil and powder based

Sheet based
Casting Based : The known applications of this form are as follows :
Baluster head : The cast aluminium baluster heads add elegance to the interior
of buildings and complicated figures can be developed.
Hardware and fittings : The unconventional designs of hardware and fittings can
be produced in casting process.
Security and decorative grills : This application has tremendous potential in our
country.

ALU M IN IU M

PRODUCTS

Extrusion Based : The known applications of this form are as follows :

Door and window frames : This is the major application f aluminium in buildings.
It is possible to make several types of windows to suit the functional requirements
like side hung and fixed, side hung and openable, sliding, top hung, etc.

Fascia panels and curtain walls : A curtain wall is an external non load bearing
wall ,mainly designed to carry its own weight and at the same time, it is sufficiently
strong to resist wind loads in accordance with the normal building regulations. The
larger aluminium fascia panels and curtain walls can be produced by using
interlocking aluminium extrusion.

Geodesic domes and space grids : A geodesic dome is vaulted structure of light
weight straight elements that form interlocking polygons. With aluminium as the
structural material, such architectural marvels have been built.

ALU M IN IU M

PRODUCTS

Green houses and roof top gardens : For cold climate, the aluminium extrusion
are used to provide green houses and roof top gardens.

Hardware and fittings : The aluminium is extruded in the form of hardware items
like handles, tower bolts, aldrops, curtain rails, etc.

North light glazing frames : For industrial sheds, the aluminium frames for the
north light glazing provides an easy and quick way to erection and maintenance
free installation.

Partitions and space dividers : The aluminium structural framework is ideally

suitable for office interiors where high finishing quality is essential.

ALU M IN IU M

PRODUCTS

Foil and powder based : The known applications of this form are as follows:
Decorative laminate : The printed decorative laminates are extensively used as
wall papers, partition panels, etc.

Insulative foils : These can be conventionally used for insulating air conditioning
ducts in large air conditioned systems.

Paints : The aluminium powder based paints are useful to grant protection to the
building against corrosive environment.

Water proofing sheet : The foil based laminates provide a maintenance free
barrier for protection of roof against water leakage.

ALU M IN IU M

PRODUCTS

Sheet based : The known applications of this form are as follows:

Cable tray : The aluminium is fast replacing the galvanized iron trays for carrying
insulated electric cables in industrial complexes particularly in chemical industries.
Planar or flat type false ceilings : The use of such type of false ceilings exhibit
supreme aesthetic appearance.
Prefabricated houses : The use of prefabricated houses can be made for colder
and tropical climates. It can be sandwiched with polyurethane to form a better
material for this type of application. It can also prove to be an effective panelling
material for mobile houses and caravans.
Rain water articles : The non - corrosive aluminium is a natural choice for the
gutter, spouts, etc. for the disposal of rain water,
Ridging and angles of roof : The aluminium can be used for all building
requirements of corner flashings, ridgings, monitor roofs and gable end flashings.
Roofing and siding : The aluminium is an ideal material for roofing and siding of
industrial buildings, workshops and sheds.