Why Should You Use Metal Alloys Instead of Pure Metals?

Metal alloys and pure metals have a lot in common, and people frequently argue about which is the best to utilize. Metal alloys can provide a number of advantages that pure metals cannot. Learn about the benefits of using metal alloy castings rather than pure metals castings.

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The Advantages of Using Metal Alloys Instead of Pure Metals

Metal Alloys Are More Flexible Than Pure Metals

Pure metals are what they are and do not allow for much modification or alteration, whereas metal alloys are composites of several metals and non-metals. This allows for even greater customization and improvement of features that are more desirable in specific applications. There are more options than pure metals when it comes to obtaining the right metal alloy for your project.

Metal Alloys Are More Durable Than Pure Metals

Metal alloys are mixtures of metals that take the good qualities of one metal and leave the bad ones behind. This results in a compound that is more durable than the parent material, the pure metal. Because pure metals are often soft, they are alloyed to make a more robust combination.  Unlike pure metal, where all of the elements are the same, metal alloys are made up of a variety of elements. Metal alloys are often significantly stronger and harder than pure metals because the atoms in them have a harder time moving around.

Metal Alloys Are More Corrosion Resistant Than Pure Metals

Metal alloys are usually far more corrosion resistant than pure metals. This is because metal alloys are composites of several metals and non-metal components that work together to generate a stronger and more durable alloy.  Alloys can be constructed to withstand corrosion, but pure metals are chemically reactive and easily corrode. Corrosion may swiftly eat away at metals, resulting in a pricey repair. Metal alloys aid in delaying and avoiding the problem of continual corrosion.

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The term ‘alloy’ refers to a substance that is produced through the amalgamation of two or more metallic elements. Alloys may also be generated through the combination of metallic substances with non-metallic elements. The properties displayed by alloys frequently differ significantly from those of their constituent elements. It is often the case for alloys to exhibit enhanced strength and hardness in comparison to their pure metal counterparts. A typical example of an alloy is red gold, which is formed through the process of combining copper and gold.

Metal alloys

Alloys, in general, exhibit enhanced mechanical properties such as increased strength, hardness, durability, and occasionally improved resistance to corrosion when compared to their respective pure metal constituents. The precise composition of an alloy is subject to variation, contingent upon the specific base metal and the alloying elements employed. Some examples of alloys are steel, brass, and aluminum alloys. Alloys find extensive utilization across diverse domains, encompassing construction, transportation, jewelry, and art.

Alloys can exist in two forms: solid solutions comprising metallic elements with uniform composition in each grain or crystal, and mixtures of metallic phases consisting of at least two distinct solutions. The latter type of alloy exhibits microstructures that contain various crystal types within the material.

Interesting Science Videos

History of alloys

• The utilization of alloys dates back to as early as 3000 BCE. The earliest documented alloys consisted of brass, which is a fusion of copper and zinc, and bronze, which is a fusion of copper and tin.
• These artifacts were predominantly utilized for the production of tools and weaponry. During the 16th century BCE, the process of producing wrought iron and cast iron, which are two types of iron-carbon alloys, involved the practice of heating iron and subsequently shaping it through hammering.  The carbon emitted by the flame underwent diffusion and permeated the iron structure. These two alloys served as precursors to carbon steel.
• Nevertheless, it was not until the advent of the Industrial Revolution during the 18th century that numerous alloys, which are widely employed in contemporary times, were actually formulated. The isolation of metallic elements such as manganese, nickel, and chromium, facilitated by advancements in the field of chemistry, has played a pivotal role in the development of various alloys including stainless steel, aluminum, titanium, nickel, and numerous others that are widely utilized in contemporary applications.

Definition of Alloys

An alloy is defined as a combination of materials composed of two or more metallic elements, or a metallic element combined with one or more non-metallic elements. The resultant alloy exhibits distinct characteristics compared to the constituent elements, such as enhanced strength and hardness. A common example of this phenomenon occurs when elemental iron is chemically combined with non-metallic elements such as silicon or carbon, resulting in the formation of steel or silicone steel.

In simple words, A mixture of two or more elements having a predetermined fixed composition is called an alloy, and at least one of the elements must be a metal. Brass, for example, is an alloy of the two metals copper and zinc. A metallic element (iron) and a trace amount (up to 2%) of a non-metallic element (carbon) are alloyed to form steel.

Metals alloys (Source: https://www.online-sciences.com)

Alloys demonstrate the principle of collaborative effort, as each constituent material contributes its distinct properties to the resulting solution or mixture. Certain alloys possess the ability to combine the most desirable characteristics of each constituent element, resulting in a composite material that exhibits enhanced hardness, increased durability, and/or heightened resistance to corrosion.

Moreover, an alloy is a composite material formed through the process of melting and combining two or more elements, with the requirement that at least one of these elements is a metal. Upon undergoing the cooling process, an alloy undergoes crystallization and transforms into a solid solution, mixture, or intermetallic compound. The constituents of alloys are not amenable to physical separation methods. An alloy is a homogeneous substance that maintains the characteristic properties of a metal, despite the potential inclusion of metalloids or nonmetals in its composition.

Characteristics of alloys

The characteristics of alloys can vary significantly depending on the specific type of alloy. However, the following are the general characteristics associated with alloys:

• Properties: Alloys are produced through the combination of multiple metals or elements.  The resultant material generally exhibits enhanced properties in comparison to its individual components. As an illustration, it is worth noting that steel exhibits superior strength and durability compared to iron in being alone, while bronze demonstrates heightened hardness and enhanced resistance to corrosion when compared to pure copper.
• Customizability: The utilization of alloys allows for the development of useful features that are absent in the initial pure metals. As an example, it can be observed that aluminum alloys exhibit significantly enhanced strength and hardness in comparison to pure aluminum, which possesses inherent characteristics of softness and malleability.
• Diversity: There is currently a wide range of several hundred distinct alloys in existence. Alloys have been developed to fulfill a wide range of applications. Continual advancements are being made in the development of novel alloys.
• Strength: Alloys exhibit enhanced mechanical strength when compared to their respective pure metal constituents. The incorporation of supplementary components within the lattice structure of the base metal impedes the mobility of atoms, thereby enhancing the material’s strength.
• Thermal conductivity: Alloys generally exhibit reduced thermal conductivity in comparison to their constituent pure metals. The thermal conductivity of a metal is based on the number of unbound electrons present within its atomic structure. The introduction of atoms possessing varying charges within the lattice arrangement of the fundamental metal can impede the movement of electrons within an alloy. 
• Electrical conductivity: Alloys generally exhibit lowered electrical conductivity in comparison to their constituent pure metals. The introduction of atoms possessing varying charges into the crystalline arrangement of the fundamental metal may hinder the movement of electrons within an alloy. 
• Resistance corrosion: Alloys exhibit a higher degree of resistance to corrosion when compared to their pure metal counterparts. The presence of additional alloying elements facilitates a chemical reaction with atmospheric oxygen, resulting in the formation of a protecting oxide layer on the alloy’s surface.

Classification of alloys

In the field of alloy chemistry, the classification of an alloy can be determined based on its atomic arrangement, specifically as either substitutional or interstitial.

• Substitutional alloys: A substitutional alloy is generated through the process of atom exchange mechanisms. The metallic constituents exhibit comparable atomic radii and chemical bonding capacities, enabling the atoms of one metal to occupy corresponding positions within the atomic metal lattice. Brass and bronze are examples of widely recognized substitutional alloys.
• Interstitial alloys: The formation of an interstitial alloy occurs when smaller atoms from a specific element occupy the voids within the lattice structure of a metal. The atomic constituents of each element do not reside in identical locations. Steel is considered to be an illustrative instance of an interstitial alloy. In the context of steel, the diminutive carbon atoms occupy interstitial gaps amidst iron atoms.

Types of alloy

Alloys are categorized into different classes:

• Based on the Principle Metal of the Alloy: Some examples of alloys include copper alloy, iron alloy, and lead alloy. A copper alloy is primarily composed of copper, such as the case of bronze.
• Based on the phase: Single-phase alloys are characterized by a uniform face, while double-phase alloys consist of two distinct phases. An example of a single-phase alloy is brass, which consists of 30% zinc and 70% copper. An illustration of a double-phase alloy is muntz metal, composed of 60% copper and 40% zinc.
• Based on iron content: Alloys are categorized into two groups, namely ferrous alloys and non-ferrous alloys, based on their iron composition. Alloys that include iron (Fe) as a constituent are commonly referred to as ferrous alloys, while non-ferrous alloys are those that do not contain iron (Fe) as a constituent. An example of a ferrous alloy is stainless steel, which consists of iron (Fe) combined with chromium (Cr). A typical example of non-ferrous alloys can be found in the composition of Solder, which consists of a combination of lead (Pb) and tin (Sn).

Examples of alloys

Some of the common examples of alloys are:

Steel

Steel is an iron-carbon alloy. Its lower price and increased tensile strength make it a popular alloy. Iron and a negligible quantity (2%) of carbon are the fundamental ingredients for all steels. Manganese, nickel, chromium, and vanadium are also added to steel on purpose to improve or change its qualities. It’s possible that several more elements, either intentionally added or present as residuals, could be involved.

Although its specific qualities may vary depending on its chemical mix, steel is often stronger, harder, and tougher than pure iron, but also less ductile. Corrosion resistance is a property shared by some steel alloys, including stainless steel. These days, steel is among the most widely employed metals. Construction materials, ships, cars, medical devices, home appliances, and even tools frequently make use of it.

Bronze

Bronze is recognized as an alloy composed of 12% tin and 88% copper. In certain cases, supplementary constituents such as aluminum, phosphorus, manganese, and silicon may be incorporated. It finds widespread application in heavy machinery, gears, currency, commemorative items, and various types of electrical equipment. The mechanical properties of bronze exhibit variability due to the specific composition of alloys employed in the alloying process.

Brass

Brass is a metallic alloy consisting of approximately 66.6% copper and 33.3% zinc. Nevertheless, numerous brass alloys that exhibit variations of this fundamental composition have been formulated. These alloys may potentially incorporate additional elements such as aluminum, antimony, iron, or silicon. In a general context, brass exhibits superior strength, hardness, lower density, and enhanced machinability when compared to pure copper. Brass is frequently employed in various applications, including the manufacturing of buttons, hardware components, ammunition cartridge cases, and marine settings.

Aluminum alloys

Aluminum alloys are produced through the incorporation of aluminum with trace quantities of elements including manganese, copper, magnesium, silicon, and zinc. There is a wide range of aluminum alloys, numbering in the several hundred. In contrast to pure aluminum, aluminum alloys exhibit enhanced mechanical properties, including increased strength, which can occasionally rival that of steel, heightened hardness, improved durability, and enhanced resistance to corrosion. Aluminum alloys find extensive utilization across diverse domains, encompassing but not limited to the automotive, aerospace, medical, consumer goods, electrical wiring, and electronics industries.

Nichrome

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Nichrome is a metallic compound composed of the elements chromium and nickel. Nevertheless, it is frequently observed that nichrome alloys often comprise iron and other analogous elements. The primary application of nichrome is in the manufacturing of resistance wires. Furthermore, this technology finds practical use in various electrical devices, such as bread toasters and space heaters. Dental fillings also employ the utilization of Nichrome alloys.

Titanium

Titanium alloys consist of a primary titanium base metal combined with additional elements, including aluminum, manganese, zirconium, chromium, and cobalt. Although pure titanium is known for its strength, titanium alloys exhibit even greater strength. Moreover, titanium alloys exhibit enhanced flexibility and corrosion resistance. These materials find frequent utilization in various domains such as aircraft and automotive industries, marine applications, as well as medical devices and equipment.

Beryllium copper alloy

Beryllium copper, also referred to as Alloy 25 or BeCu is a copper-based alloy containing a beryllium content ranging from 0.5% to 3%. The material exhibits weldability, and ductility, and possesses non-magnetic and non-sparking characteristics. The material exhibits resistance to oxidation, corrosion, and non-oxidizing acids. Furthermore, it is worth noting that beryllium copper exhibits exceptional properties in terms of thermal and electrical conductivity. This material finds frequent application in various areas, including electronic connector contacts, small springs, musical instruments, and computer components, as well as tools designed for hazardous environments such as aerospace engineering and metalworking.

Nickel alloys

Nickel alloys consist of a primary nickel component combined with additional elements, including iron, chromium, and copper. Nickel alloys possess enhanced strength and demonstrate favorable magnetic and thermal characteristics in comparison to pure nickel. Nickel alloys are frequently employed in the fabrication of electrical components and electronic devices.

Copper-Nickel alloys

Copper-nickel (Cu-Ni) alloys are predominantly formed by copper and nickel, with occasional inclusion of additional elements like silicon, iron, manganese, and zinc, in order to achieve diverse material characteristics. The properties acquired exhibit variation based on the precise chemical composition of the Cu-Ni alloy. In general, copper-nickel alloys exhibit exceptional electrical conductivity, possess resistance to corrosion, and demonstrate notable tensile strength within the range of 340-650 MPa. Copper-nickel alloys are frequently employed in the fields of electronics, marine engineering, and pipeline systems.

Niobium alloys

Columbium, also known as niobium, is a lustrous and malleable metallic element primarily employed in the production of alloys. It serves to improve the properties of steel and is commonly employed in structural applications, jet propulsion systems, and gas transmission networks. Niobium metal plates, rods, and sheets are employed as sputtering targets and chemical processing machinery owing to their corrosion resistance and high-temperature performance. At extremely low temperatures, it undergoes a transition into a superconducting state. Superconductive niobium wire is utilized to produce highly powerful electromagnets, which find applications in particle accelerators and magnetic resonance imaging.

Examples of metal alloys

What elements make up an alloy?

Alloys are a type of metallic material that consists of a primary metal combined with the inclusion of other metals, non-metals, or a combination of both. The precise composition of an alloy can exhibit significant variation, contingent upon factors such as the primary metal, the alloying constituents, the targeted properties, and the intended utilization.

How alloys are made?

The concept of an alloy being defined as a “mixture of metals” may potentially cause confusion. What is the process for combining two solid metal masses? The conventional method employed for alloy production involved subjecting the constituent elements to elevated temperatures, causing them to liquefy, subsequently amalgamating them, and finally facilitating their solidification into a solid solution, analogous to a solute dissolved in a solvent, such as salt dissolved in water.

An alternative method for alloy production involves converting the constituent elements into powdered form, subsequently blending them, and subsequently consolidating them through the application of elevated pressure and temperature. The aforementioned methodology is commonly referred to as powder metallurgy.

One additional technique for producing alloys involves the utilization of ion beams, which consist of ions possessing either an excess or a deficiency of electrons, directed toward the outermost layer of a metal specimen. Ion implantation also referred to as a highly precise method for alloy fabrication, is employed in this context. One of its most prominent applications is in the fabrication of semiconductors utilized in electronic circuits and computer chips.

Why are alloys useful?

The use of pure metals in manufacturing processes is infrequent due to their inherent malleability, rendering them excessively soft for practical applications. However, the process of alloying a metal frequently results in the improvement of its properties. Certain alloys are engineered to exhibit enhanced resistance to corrosion or improved conductivity, while others are specifically designed to substantially augment their load-bearing capacities.

The physical characteristics of an alloy, including conductivity, reactivity, and density, may not exhibit substantial deviations from those of its individual constituent elements. Nevertheless, the engineering characteristics of an alloy, including shear strength and tensile strength, can exhibit significant variations.

As a result of these factors, there is a significant demand for metal alloys across various sectors and industries, including manufacturing, electronics, domestic goods, architecture, plumbing, as well as the automotive and aerospace sectors.

How do alloys behave?

Alloys are created and utilized by individuals due to the inherent limitations of metals, which often lack the precise properties necessary to fulfill specific tasks.

• Iron is widely recognized as a commendable construction material; however, steel, an alloy formed by incorporating minute quantities of nonmetallic carbon into iron, possesses superior strength, hardness, and resistance to rust.
• Aluminum is characterized by its low density, rendering it a lightweight metal; however, in its unalloyed state, it exhibits a notable degree of malleability.
• By incorporating minute quantities of the metallic elements magnesium, manganese, and copper, an exceptional aluminum alloy known as duralumin can be synthesized, exhibiting remarkable strength suitable for the construction of aircraft.

Alloys consistently exhibit enhancements in one or more crucial physical attributes compared to the primary metal, encompassing strength, durability, electrical conductivity, heat resistance, and other relevant factors. In general, alloys exhibit enhanced strength and hardness compared to their constituent metals, while also displaying reduced malleability and ductility, thereby rendering them more challenging to manipulate and shape.

Are metal alloys really expensive?

There exists a widely held misconception that metal alloys are characterized by high costs, primarily attributed to the multiple stages involved in their production. Numerous metal alloys, such as brass and bronze, have been utilized over an extended period, resulting in the alloys often being available at a more affordable cost compared to their constituent pure metals.

Benefits of alloys

• Improved strength: Alloys exhibit enhanced strength compared to pure metals due to the introduction of additional atoms into the lattice structure of the base metal, resulting in lattice deformation that hinders atom mobility.
• Improved hardness: Alloys exhibit enhanced hardness relative to pure metals due to the same underlying mechanisms that confer increased strength in comparison to pure metals. The introduction of supplementary atoms induces strain within the lattice structure of the underlying metal, thereby impeding the dislocation of atoms.
• Versatility: Alloys exhibit greater versatility compared to pure metals due to the presence of desirable properties that are absent in their pure counterparts. Alloys typically exhibit enhanced strength, hardness, and corrosion resistance.
• Cost-effectiveness: Alloys are considered to be a more economically viable option compared to pure metals due to the relatively lower costs associated with alloy production processes in comparison to the refining processes required for pure metals.

Limitations of alloys

• Decreased ductility: The decreased ductility of alloys compared to pure metals can be attributed to the introduction of additional atoms into the lattice structure of the base metal. This results in a decrease in the number of available slip systems for plastic deformation.

• Not Easy to Weld: Alloys exhibit comparatively lowered melting points in comparison to their corresponding pure metal constituents. This phenomenon results in increased difficulty in welding alloys.
• Challenges of Recycling: Since alloys consist of many elements, they are more challenging to recycle than single-element metals.
• Potentially More Vulnerable to Corrosion: Certain alloys exhibit varying degrees of susceptibility to different types of corrosion compared to pure metals.
• Environmental concern: The emission of harmful and dangerous fumes into the environment can occur during the manufacturing process of certain alloys.

Application of alloys

• Electronics: Copper-nickel alloys are commonly employed in the field of electrical engineering due to their exceptional electrical conductivity and minimal electrical resistance. Additionally, these materials find application in batteries, relays, solder frames, and various other electrical components.
• Transportation: Aluminum alloys are extensively utilized in the transportation sector, making them the most prevalent type of alloy in this industry. The aforementioned materials possess a low mass, exhibit a favorable ratio of strength to mass, demonstrate resistance to corrosion, and can be effectively recycled. The utilization of aluminum in automotive applications contributes to the enhancement of fuel efficiency and the reduction of the overall weight of vehicles, all while meeting the necessary strength criteria.
• Construction: Steel and aluminum alloys are extensively utilized in the field of construction due to their exceptional mechanical properties, including high strength and durability. These materials find application in various structural components, roofing systems, siding installations, and other construction-related building materials.
• Medical: Medical devices, including implants, prosthetics, and surgical instruments, commonly employ stainless steel and titanium alloys. These alloys are frequently employed in various applications due to their high strength, resistance to corrosion, and biocompatibility.
• Manufacturing: A wide range of alloys find application in the manufacturing sector for the production of components utilized in various industries such as automotive, aerospace, construction, heavy equipment, medical, consumer products, and others. Steel, brass, aluminum, and titanium alloys are commonly employed in the manufacturing industry for various processes such as machining, casting, or forming. Alloys are commonly employed in the manufacturing industry due to their superior workability and formability compared to pure metals. 
• Jewelry: Various alloys, such as bronze, copper-nickel, nickel-silver, and aluminum, among others, are employed in the fabrication of jewelry. Alloys are frequently employed in various kinds of jewelry due to their enhanced formability and superior durability in comparison to their pure metal counterparts. Furthermore, the utilization of alloys enables the acquisition of diverse color variations that would otherwise be unattainable through the use of pure metals.
• Art: Alloys, such as bronze and brass, are extensively employed in the field of artwork and sculpture due to their distinctive hues, robustness, and malleability.

Conclusion

Alloys are formed by the combination of the metal with either another metal or a nonmetal ingredient. The process of producing a metal alloy commonly involves the melting of its constituent components, subsequent mixing, and subsequent cooling to ambient temperature. Several pure metals, including gold, possess inherent characteristics that render them unsuitable for certain applications. Nevertheless, the incorporation of metals into alloys can enhance their strength and confer additional advantageous chemical properties. The incorporation of an alloy can enhance or introduce desired attributes such as increased hardness, improved machinability, and enhanced resistance to corrosion.

References

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