When it comes to manufacturing, choosing the right materials can make or break the success of your product.
Quality metal components, for example, ensure better performance, durability, strength and resistance to environmental hazards. The wrong material, on the other hand, can lead to poor performance, higher maintenance costs, product failure and, ultimately, lost sales.
Most manufacturers turn to alloys when choosing metal components.
An alloy is a substance that includes a metal combined with one or more other elements – either metallic or non-metallic. Alloys tend to be stronger and harder than pure metals, along with many other advantages.
Today’s advanced processing techniques allow elements to be combined in precise amounts to achieve desired properties with a high degree of specificity. Many different types of alloys are widely used across industries, from tiny electronic components to large industrial equipment.
Why Choose Advanced Alloys?
A quality alloy is specially tailored to give you advantages over pure metals.
Strength
For starters, you can often boost the strength of a pure metal by adding one or more addititonal elements to the mix. Combining elements impedes the mobility of atoms, which increases the hardness of the material. Many alloys are known for their tensile strength, which is the maximum stress that a material can tolerate when being stretched or pulled. Alloys can be designed for maximum impact resistance and hardness.
Customizability
Whether your product calls for strength, electrical conductivity, malleability or corrosion resistance, advanced processing techniques allow a wide degree of customization. Today’s engineers can design unique alloys with highly specific application requirements. This enables manufacturers to achieve unique features to gain an advantage over competitors in the marketplace.
Corrosion Resistance
For products that are exposed to moisture and harsh chemical environments, corrosion resistance is a must. The alloying process facilitates a chemical reaction that adds a protective layer on the surfaceof many metals. As a result, the finished material resists oxidation and rust, leading to a longer service life and improved aesthetic appearance.
Efficiency
Fuel efficiency is a top priority in automotive, aerospace and similar industries. Lightweight alloys containing aluminum or titianium allow vehicles to move faster and reduce fuel consumption. This lets end users enjoy lower operating costs and reduced environmental impact.
Additional Properties
Many alloys have lower electrical and thermal conductivity than pure metals That’s because combining elements restricts the movement of electrons within the material. Some alloys are also known for lower ductility and recyclability.
How Are Advanced Alloys Used?
Here are just a few examples of industries that use metal alloys in manufacturing products.
Aerospace
This industry requires metal components with a high strength-to-weight ratio, which means they can withstand a high degree of stress without failure. Strong, lightweight titanium and aluminum alloys are common.
Automotive
Cars, trucks and busses require efficiency, safety, durability and corrosion resistance. While steel is widely used for vehicle frames, aluminum and titanium are also common thanks to their lower weight.
Electronics
Copper-nickel alloys work well in batteries and other electronic components thanks to good electrical conductivity and thermal performance.
Medical
Artificial joints, prosthetics, surgical instruments and other medical devices must possess biocompatibility. This means they are safe to come into contact with, or to be implanted in, the human body. Strength and corrosion resistance are other important criteria. Steel and titanium alloys are good options here.
Construction
Structural components, roofing systems, siding and other building materials containing metal must be strong and durable for use in residential and commercial buildings.
Steel
Steel is an iron-carbon alloy that contains about 2% carbon. It may include other elements depending on the desired properties. These include manganese, chromium and nickel. Steel alloys are customized for strength, hardness, corrosion resistance and other characteristics.
Carbon Steel
Commonly used in constructive, automobiles and machinery, carbon steel is a strong and affordable alloy made of iron and carbon.
Stainless Steel
Stainless steel includes chromium, which is added to the mix for extra corrosion resistance. This popular alloy tolerates moisture and harsh environments well. Common applications include motor vehicles, ships, kitchen appliances, medical equipment and architectural components.
Alloy Steel
Other steel alloys may include a variety of elements such as chromium, nickel and molybdenum for use in tools, machinery and other industrial applications.
Aluminum
Aluminum can be combined with other materials such as manganese, copper, magnesium, silicon and zinc. Common properties of aluminum alloys include light weight, strength, hardness, durability and corrosion resistance. Applications span a number of industries from automotive and aerospace to medical, consumer goods, electrical wiring and electronic devices.
Copper
Copper is known for good electrical and thermal conductivity. It can also be combined with other materials for a wide range of uses.
Brass
Brass contains about 66.6% copper and 33.3% zinc. It may also include aluminum, antimony, iron or silicon. Its properties include strength, hardness, low densibility and machinability, which means it is easy to fabricate into a variety of shapes. Brass also offers good corrosion resistance.
Applications for brass include hardware components, ammunition cartridges and marine equipment. Other common uses include plumbing fittings, electrical components and decorative structures.
Bronze
Bronze contains 88% copper and 12% tin. Other elements may include aluminum, phosphorus, manganese and silicon. Applications include heavy machinery and electrical equipment. This alloy has been widely used for thousands of years and is known for its durability and corrosion resistance.
Beryllium Copper
Also called Alloy 25 or BeCu, beryllium copper is a non-magnetic and non-sparking alloy known for its weldability, ductility, thermal conductivity and electrical conductivity. It resists corrosion, oxidation and acids. Common applications include springs, computer components, electrical components, aerospace engineering and metalworking.
Titanium
Titanium is a strong, corrosion-resistant metal that tolerates harsh conditions. It forms a number of useful alloys when combined with other materials including aluminum, manganese, zirconium, chromium and cobalt. Applications for titanium alloys include aircraft, motor vehicles, marine vehicles and medical equipment.
Nickel
Because of its strength at high temperatures, nickel is useful for gas turbines, chemical processing, aerospace and other applications that include hot conditions.
Elements that combine well with nickel include iron, chromium and copper. Properties of nickel alloys include strength, magnetism and thermal conductivity. These materials are often found in electrical components and electronic devices.
Copper-Nickel
Copper-nickel may also include materials such as silicon, iron, manganese and zinc. Important properties include electrical conductivity, corrosion resistance and high tensile strength. Applications include electronics, mechanical engineering and pipeline construction.
Nichrome
This chromium-nickel alloy may include other elements such as iron. Common uses include resistance wires, medical applicatoins and electrical appliances such as toasters and space heaters.
How Do You Choose the Right Alloy?
Material selection depends on the specific needs of your project, such as mechanical performance and environmental conditions. Careful research ensures that the alloy you choose will meet the minimum quality standards for your product.
Mechanical & Chemical Properties
Mechanical properties include things like strength, hardness and ductility. For example, alloys used in load-bearing structures must possess high strength, while others prioritize flexibility and ductility. Metal components that will be exposed to extreme weather, marine environments, harsh chemicals or high temperatures require materials with good temperature- and corrosion-resistance.
Certification
Certification enables manufacturers to ensure the quality and authenticity of selected alloys. Certified materials must meet stringent standards and regulatory requirements. The certification process includes testing by accredited laboratories. Performance criteria include reliability, consistency, regulatory compliance and liability risk reduction.
Traceability
Traceability refers to the ability to document the origin, processing and handling of your selected alloy. Like certification, being able to trace the materials in your products helps with regulatory compliance, safety and overall quality assurance. It also facilitates maintenance and repairs whenever replacement parts are needed.
Work with Experts in Custom Metal Fabrication
At Metaltech, our design engineers and fabricators have the knowledge and experience to create quality metal components for your product. We work closely with customers to select the very best materials, including advanced alloys for superior performance and quality.
If you need custom metal parts, you can request a quote online at any time. You may also get in touch with us through our online form or call us at 417-426-5577 if you need more information.
