AMBC Lecture 2

Advanced Building Materials & Composites
Topic 2
Non ferrous metal (Aluminium, Copper, Zinc, Lead)
Non Ferrous
- Non-ferrous metals are metals that do not contain any amounts of Iron.
- Key properties: light weight (aluminium), high ductility, high conductivity (copper),
non magnetic properties, resistance to corrosion (zinc) etc.
Summary of Key Properties:

• Thermal Conductivity
• They are softer, malleable, ductile
• High corrosion resistance
• Low density (less mass)
• Non-magnetic
• Colorful, lustrous
Most Commonly Used Non-ferrous Metals
ALUMINIUM COPPER ZINC

Properties: ductile, flexible, Properties : high conductivity, Properties : fairly strong and durable.
light-weight, good strength to ductile durable. Application : coatings for screws and
weight ratio. Application : electronics, pipes or bolts, can be die cast for small high
Application: building parts, pan bottoms. detail pieces.
panels, cladding.
NON-FERROUS METAL ALLOYS
Nickel-Copper BRONZE BRASS

Appearance: silvery white Appearance: starts browny Appearance: golden in
lustrous metal /gold weathers into greens. colour.
Properties: Strong and Properties: fairly strong and Properties: durable.
durable under varying durable. Use- For decorative
temperature range ,high Use: for decoration, interior work, door knobs, locks
resistance to corrosion detailing etc.
Use: Cladding, panel work
OTHER APPLICATIONS
WELDING BRAZING RIVETING

-used to join together sheet -used to join sheet
-join pipes or tubular
materials and fusing of metals together such as
pieces of metal.
different shaped metals. Pop Rivet and Solid
Rivets.
Material: Iron-free (nonferrous), and special alloys

Properties of aluminium
• Aluminium is also the base metal in many alloys.

• The best known aluminium grades are duralumin,
Y-alloy and magnalium.
➢ Corrosion resistant
➢ Good conductor of heat and electricity (but less
than copper) Micro structure of aluminum
➢ High ductility and lightweight
➢ Becomes hard after cold working, so needs
annealing
➢ In combination with ductility and malleability
replaces copper in some instances
➢ Melting point: 660.4 °C
➢ Density: 2.7 g/cm3 at 20 °C
Aluminium Foil Insulation
As the experiment depicted above shows,

fiberglass is ineffective at stopping radiant heat,
but the reflective foil redirects the intense rays
from the heat lamp and keeps the chamber a cool
78º.
www.steelbuilding.com/buildings/accessories_foil.htm
Aluminium Foil Insulation
Sheets made up of layers of polyethylene bubble film and aluminium foil
insul.net/prod_astrofoil_all.html
Use of aluminium in Architecture
• Aluminium in building because of properties of lightness and corrosion resistance.

• Application: external facades, roofs and walls, in windows and doors, in staircases, railings, and
several applications.
1931 2013
1935
New York City's Empire State Building Balancing Barn
Aluminaire House, usa
tower structure and spire are built from aluminum Thorington, UK
Façade
Uses of aluminium in building and construction:
Exterior Aluminium cladding Panel cladding Aluminium doors and windows

Chimney Rainwater Gutter Curtain wall

Shading Device Framing for PV Panel

Properties of copper
• High thermal conductivity – heat

exchangers, heating vessels and
appliances etc
• High electrical conductivity – used as an
electrical conductor in wiring and motors
• Good corrosion resistance – beautiful but
expensive roofing
• High ductility – makes the material very
easily formable and suitable for making
statues
• When oxidised, copper turns green
Melting point 1,085 °C

Density 8.96 g/cm³
Use of Copper in Architecture
• Copper in architecture can be linked to its durability, corrosion resistance, prestigious

appearance, and ability to form complex shapes.
• Uncoated copper and copper alloys have strong intrinsic antimicrobial properties
with efficacies against a wide range of disease-resistant bacteria, molds, fungi and
virus.
1528
1280 AD 2004
roof at Kronborg
The copper roof of Hildesheim Cathedral, Klaukkala church
Renaissance castles
Copper has higher life span than other material so used in churches
Use of copper in building services
Hot water pipes cooling refrigeration plant Air conditinoner

Properties of zinc
• After aluminium, iron and copper, it is the fourth

most-used metal in the world.
• Good tensile strength, malleability and load
bearing capacity. Zinc sheet and plate develops a
natural patina when exposed to carbon dioxide-
rich air.
• Galvanising materials with alloying elements offers
them a greater resistance to rust, affording it uses
for chain-link fencing, guardrails, suspension
bridges, lampposts, metal roofs, heat exchangers.
Galvanized metal roofing

Properties of Lead
• Lead is the heaviest common metal

• As it doesn’t react easily with other
substances, they are still used in
batteries and power cables, acid tanks.
Lead properties are:
• Very heavy
• Resistant to corrosion – doesn’t react
with many chemicals
• Soft and malleable
Use of lead in building material
• Lead was used for making water pipes in the Roman Empire
• From the 13th century, lead was used to create stained glass
• Due to health reasons lead is avoided in building (toxic in nature) ,
but small drops are used in manufacturing of paint and storage battery
Now being replaced by steel pipes

Individual Assignment
Visit the IIT KGP gymkhana building individually and prepare a list of building
materials used in the construction of the gymkhana building through observational
means, including taking photographs, while refraining from disrupting any ongoing
activities.
Submission requirement: Create a PDF report containing your name, roll number,
along with a comprehensive list of the building materials used, supplemented by
images taken by you. It is important to ensure that each picture is appropriately
numbered and labeled with a title containing name of material and location (eg.
Wall, roof, floor window etc.) where it has been used.
Submit the hard copy of report by 22nd of August 2023

Thank you!
Joining of Metals
• Adhesive bonding (being used increasingly but not yet common).

• Diffusion bonding – Solid-state process
• Welding – The material is heated locally to above the melting temperature, additional metal may be
added, and the joint is allowed to cool naturally.
• There should be complete continuity between the parts. However, this is not normally achieved.
• The joining material should have properties that are better than the parent metal.
• Brazing and soldering – Involves the joining of parts by means of a thin film of (filler) material, which
has a melting temperature lower than the parent metal and which flows into the joint (often by
capillary action). The thin film should solidify to give a material with properties comparable to the
parent metal. In soldering, the filler material melts at much lower temperatures (less than 450 °C) than
the brazing filler materials.
Illston & Domone, Schaffer et al.

Oxidation and Corrosion
• Almost all metals occur in nature in the oxidised state, except gold and silver.
• A thin layer of oxide first forms on the metal surface exposed to the atmosphere. Thereafter,
metal ions must diffuse out or oxygen ions should diffuse in for oxidation to progress. The rate
of oxidation depends, therefore, on the thickness and structure of the oxide layer.
• When the oxide occupies less volume than the metal itself, it generally cracks to expose fresh
metal.
• When the oxide occupies more volume than the metal, it will tend to wrinkle and fall off,
exposing fresh metal.
• In some cases, the volume change is not significant leading to thin adherent layers that prevent
further oxidation. This occurs in aluminium, chromium and nickel. Consequently, the last two
are essential components of “stainless steel”.
Illston & Domone

Corrosion Prevention 1/2
Use of Protective Coatings

• A common way of minimizing corrosion is by coating the metal. There are two types of coatings:
• Those that are based on cathodic (galvanic) protection
• Those that simply prevent the contact between the metal and fluid.
• Cathodic protection is done with (anodic) metal coatings. For example, steel can be protected by
Zn coatings, which will continue to protect the steel even after the coating is scratched. (On the
other hand, chromium being more cathodic than steel will not protect it when a small pit
appears in the coating, and the steel underneath rusts quite rapidly.)
Schaffer et al.
Corrosion Prevention 2/2
Use of Protective Coatings

• Non-cathodic coatings such as porcelain enamels, tar, Teflon, paints and lacquers are used to protect
metals. They should limit the diffusion of oxygen and water to be effective. A major problem with
such coatings is the presence of “pinholes” or “holidays” – small exposed areas caused accidentally.
This results in the formation of corrosion cells with high anode-to-cathode area ratios. Many modern
paints incorporate Zn particles in order to combat this problem.
• Passive oxide layers can also protect metals, such as aluminium. This is done by anodizing, which
involves the application of a high corrosion potential to form a thicker than normal oxide layer.
Schaffer et al.

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Advanced Building Materials & Composites

Summary of Key Properties:

ALUMINIUM COPPER ZINC

Nickel-Copper BRONZE BRASS

WELDING BRAZING RIVETING

Material: Iron-free (nonferrous), and special alloys

• Aluminium is also the base metal in many alloys.

As the experiment depicted above shows,

• Aluminium in building because of properties of lightness and corrosion resistance.

Exterior Aluminium cladding Panel cladding Aluminium doors and windows

Chimney Rainwater Gutter Curtain wall

Shading Device Framing for PV Panel

• High thermal conductivity – heat

Melting point 1,085 °C

• Copper in architecture can be linked to its durability, corrosion resistance, prestigious

Hot water pipes cooling refrigeration plant Air conditinoner

• After aluminium, iron and copper, it is the fourth

Galvanized metal roofing

• Lead is the heaviest common metal

Lead properties are:

Now being replaced by steel pipes

Submit the hard copy of report by 22nd of August 2023

• Adhesive bonding (being used increasingly but not yet common).

Illston & Domone, Schaffer et al.

Illston & Domone

Use of Protective Coatings

Use of Protective Coatings

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