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LIA1A769
J, Lead Industries Association, Inc.
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New Yortu N. Y. 10017
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Octobsr 5# 197*
I 8TTBJTCT: WgKDrr - *I*AD * MOCCTI MATERIAL*
TO IB* KSKBfflS 0* TK* LEAD DSUSTXXCS ASSOCIATION DC.
Bidoaad 1* the lUt edition of our publication *IM) A HOPES* MATERIAL". t Written for design engineer* and upper level engineering and Bate riala
students, It describes the uultltude of applications of the netal and lta nuse roue fores. Ccenonly referred to physical propertlee are aleo listed. <t
* If you would Ilka to have additional copies of this booklet for distribution to your staff or cue tone re, please do not hesitate to contact us.
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LEAD OFFERS THESE OUTSTANDING PROPERTIES...
cormiM resistance . . . Lead is a permanent metal unbar varying condition* of weether. exposure to most typos of SO>l. marina and industrial anvironmants. and action of corrowt chemical*.
r4i*tioA resistance . . . The most impervious of alt com mon metals to X ray and gamma radiatdA, toad is the accepted standard of rafaranca. ft occupies frommum space and adds the least weight.
rlbrefion control . . . Massive without being stiff, lead is a poor conductor of vibration. Its ability to effectively block vibraton ma^es it a popular maternal for use under build* mgs and mechmery.
lubricity .. . Few metals have the low coefficient of friction of lead and lewd alloys under lading loads. This feature la used to advantage m tmy bearings as well as under the massive supporting slabs of the Niagara Power Project conduits.
sotid state properties ... hi the field of sold state physics, lead shows outstanding promise. Lead tehunde is used commercially m a thermoelectric power generator; lead xirconate titanate *% highly efficient as a p*exoeiectrc ma terial in both ultrasonics and electrical energy generation.
sound control ... In products ranging from home appli
ances to submarines, lead and leaded materials act to deaden ringing vibration and insulate against airborne
other unique propertiee ... The most dense common metal ... low melting point. .. easily fabricated . . . unde range of forms available ... easily alloyed.
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TO BENEFIT THESE INDUSTRIES
olecfrkef Storage batteries, thermoelectric generators, pyroelectric elements, solder, cable sheathing, ceramics
transportation Storage batteries, solder, sound and vibra tion proofing, shielding for mobile reactors, bearings, anti knock compounds, marine anodes
manufacturing Free machining leaded steels, brasses and bromes. tern# plate, solder, coatings, castings, machinery, noise control
chemical Tanks, reactor vessels, process equipment and piping, valves, chemical compounds and intermediates, scrubbers, preciprtatort
coftsfrucfroft Sound proofing, vibration proofing, and water proofing, flashing, roofing, piping, catkk^. ceram ics. paints, bearing plates, coatings
nuclear Gamma ray shielding for shipping containers, reactors, laboratories, plants, industrial and medical radio graphy, non destructive testing instruments
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lead Is mere readPy arid Tnw.pahslvaly' fabricated into a greater variety of useful form* than almost any other common metal. These readily available forms, combined with lead's interesting variety of properties--high
...as a modern design material
density, low melting point, corrosion resistance, malleability, lubricity, unusual electrical properties, and ability to form use<ul alloys and chemical compounds-- provide a unique material for the solution of " a wide range of design problems.
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LEAD/FORMS AVAILABLE
aheet and fod Because of its malleability. toed can be rolled to any desired thickness down to 0.0078 tn. Foils on be readily rolled to 0 000$ in. Sheets or* produced in standard widths up to 8 ft., with larger sifts available lor sptcisi requirements.
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extrusion* Lead ts eesily extruded in the form of pipe, rod. wire or practically any desired cross section. Com mercially available extrusions rang# in sot from 12 m. ptpt down to solder wire 0.010 m. diameter.
castings Lead <s on# of tht simplest metals to cast. Typemetal. renowned for its thirty to reproduce minute detail, and battery grids srt example* of common toad castings. Small d castings srt produced wrth wall thickness as low
as 0 0$ in. and "as cast" dimensions art reproducible to
0.001.
taminationa Originally developed for X ray protection, a large family of lead laminates is now used for noise control. Typical examples include lead plywood, lead gypsum board, lead-cinder block, leaded plastic and glass fiber com binations.
bonded sheet* Lead in thicknesses from Vi in. to a fool or more may be bonded to other metals to impart special qualities. For example, lead may be combined with steel, copper or aluminum tor corrosion resistance and Strength or for gamma shielding and heat transfer.
powder Particles and flakes of lead from 4 micron di ameter up. impart special properties when added to greases, paints and pipe joint compounds. Powdered lead is also used as a constituent of bearings, brake and dutch (song*.
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shot Produced in abundance in this form, over 30.000 tons of lead each year go into shotgun ammunition in sites ranging from 0.04 to 0.44 in. Lastly handled, shot is also useful for packing when mass or shielding is required inside an irregular enclosure.
wool By passing molten lead through a fine sieve and allowing it to solidify in the air. a loose rope of fibers is
produced, weighing about 0.4 tbs. per foot. When this is driven under pressure into a crevice, the fibers are cotd welded into a homogeneous mass forming a solid metal seel. This jo*ntmg procedure is especially useful where temperature or explosion hazards prohibrt other methods which reqmre heet.
aOoye The extremely wide range of lead alloys permits only limited coverage here. Scores of fusible alloys and solders are available with melting temperatures from 117 to S88*F. A number of bearing alloys--the most familiar of which is bebbtt--make use of lead. Small quantities of antimony and arsenic are frequently added to lead for hardening and strengthening such products as type metal. Calcium has also been alloyed with lead for use in battery plate* and roohng.
Tetraethyl lead controls the flame propegstion rate m Internal combustion engines resulting in greater efficiency and even combustion. Litharge (PbO) is used In storage batteries, crystal glass (and leaded glass radiation shielding windows), in pigments, and to vulcanize rubber. Newer chemical derivatives of lead with the same basic action--ere also being used. Other lead components stabil ize modem plastics. Lead oxide (Pb,00 is the ubiquitous red lead valued for its corrosion resistance, and lead chromates--y*How, orange, and red--ere similar pig ments. Lead carbonate is the familiar white lead for house paint and racreoul coatings; lead azide is a standard ex plosive detonator; lead arsenate is an insecticide and hertxctds; lead silicates are peint pigments snd enameling fnts.
mixtures Lead powder and paraffin mixtures combine the gamma shielding ability of lead with the neutron capturing quality`of an organic to produce a removable shield with a meltmg point of about 200*F. Many lead organic mixtures are similarly used. Lead plastic mixtures show unusual sound attenuation properties. A mixture of lead and polyethylene has been used to mold precision parts with substantial mass, and lead shot in neoprene forms a com bination acoustical, antifouling, antiturbulence coating for submarines.
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LEAD INDUSTRIES ASSOCIATION, INC.
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Zb/* radiation control
Coatings of toed and toad attoyi over steel and other metal* re available In thicknesses from a few thousandth* of an
inch to several Inches. Tama (15% ho/65% toed). other hot dipped coating*, electroplate, flam# sprayed load and soWer, art soma of th* common form*. Tama 1* an aspecially versatile material. The TV chassis shown 1* mad* from tarn* bacausa. 1} die lift Is extended by th* coatinf's A tubricrty. 2) tem# #fmin#ta* th# naad for additional cor* ro**on protective maajura*, 3) ft l* ***Uy soldered and
Joined.
epphcattont; automotive |M tanas* *tr Mara, fa&tdor
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head tubes, oil filters, *netrume<rt*. 4 pant, redtotor part*. va\w rocker ami coiom. gaskets, car heetar*. wash**, vacuum actuators
This feed shielded cat* is used for the safe shipment of nu clear waste* or span* fuel alaments horn an atonwc reactor.
air handling and heating o*l stoves and heaters. fbmacee. a*r cfeener*, radiators, ** condAJonert
far rediatto* cewtrel
* laad is first in materials to be considarad in any design for
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In an impressed currant system tha electrical power it expended to forca tha corrosive action to tiii place largely at tha anoda. Under thasa conditions, lead hat baan par ticularly successful as an anoda material, initial penefrafion of the lead is stopped by tha formation of a heavy him of lead peroxide which offers food electrical conductivity
X-ray or gamma radiation shielding Whan other materials re considarad. "comparisons are usually expressed to terms of lead bacausa A represents tha bast practical gamma shield material for most applications." (Quoted from AECt authoritative "Reactor Shielding Design
Manual**)
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without permitting corrcshrc penetration to the lead. Suc cessful applications have been made on salt water ships and
Although lead's primary quality is massiveness, th* us* of lead in shielding almost invariably saves weight and
pers. in brackish water, and in several types of soil. High
space. Its low cost, density, and the ease with which it can
current density can be attained without sacrificing anoda
be cast, extruded, rolled, machined or otherwise formed,
bf*. combine to make it on* of th* most efficient of shielding
material*.
as a corrosion proof atotarMi
5 Lead * corrosion resistance is an important factor in its usefulness. Tha statu* will suffer no weathering, even in tha corTOswa atmosphere of the city. Cocroson resistance enables the pipes to carry many thousands of gallons of concentrated sulphuric acid during the many years that they will be m service. This excellent resistance to cor rosives accounts for about 60 percent of the metallic laad used in the United States. Applications indud* cable sheathing, battery grid metal, corrosion resistant lining* to chemical process equipment and roofing for city building*.
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POLLUTION CONTROL
Again, toad's outstanding resistance to SO*. H,S0. and H,S0. makes I! a wise choice as a lining material for electro static and acid mist precipitators and gas scrubbers. A unique passivating layer of insoluble toed sulphate serves to protect the lead from the corrosive action of these chemicals and others yielding longer equipment life and more efficient operation,
SO, -- the gas generated by roasting sulphur hearing ores at high temperature -- can be a critical problem in the non ferrous metals industry, both In air pollution and corrosion. Control of SO, is usually channelled into pro duction of Sulphuric Acid, an important industrial solvent and one to which lead stands up especially well.
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i for sound/vibration control^ _
Noise end VWrattow Control Today load and Waded material* are being used In office equipment. transportation, skyscraper*. and mdutlry to control noise. In typewriter* and sound movie cameras Wadad damping materials art modifying the character of the noise produced. In |et airliner*. military helicopter*, and twrtxne-powerad marina crafL sheet Wad. sheet Wad composite*, and Waded plastic sheets art Nocking out engine noee. lead, by virtu* of Ks high internal damping, is one of the most efficient no*e attenuator* known. Ho other materials tn rts econormc range stop noise per pound or per inch of thickness. Leaded plastics ei sheet tile, or castings are affective in Nockirg airborne noise as wen as damping the ringing of metal structures -- from small stamped metal panels of an ordinary typewriter to steef deckmg of special railroad car*.
b for electrical energy sources
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The power to detect sense, and drive tomorrow's electrical and electronic products will come, W many cases, from source* which utilize some of Wed's inherent characteristics -- thermoelectric activity of Wed alloy semi metal*, piezo etoctnc activity of Wed ceramic*, or from the rehabW Wad acid storage battery.
A large power source employs Wad teAuride to place of thermocouples m thermoelectric generator*. Lead tefluride is selected because it generates so much power from the heel source that no amplification or secondary power source i* needed to dr** control*. It has been a critical power source lor lunar exploration.
lead raoneteritenete ceramics demonstrate remarkable efficiency in producing ultrasonic vibrations or *n g*n#f<mg high outputs of electricity when mechanically stressed. Completely seeled Wed-acid batteries requiring no msW tenance--not even the edddon of water--ere available in a variefy of sizes representing an efficient power source to a compact package.
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One of the Golden Get* Funn. The engine room i* kned with Wed tor acoustical msutehon.
Passengers ee today** luxurious airilners ere well pro tected from the 150 db roar of the engines, thank* to Wed. On passenger aircraft and e*ecutrve aircraft as well. Weded vinyl is sandwiched in the fuselage to effectively insulate the cabin intenor.
The Golden Gat* Ferries, es depicted here, are driven by three aircraft type gas turbine* end Jacuzzi water Jets. Sheet Wad. 2-lto/ft1 ha* been specified for engine room noise treatment
In Industry, harmful noiaa tore** are stopped by Wad sound barrier*. Leeded vtnyf curtain* can block as much as 25 db of noise, if not more. Velcro fastener* ensure e tight, "noise proof" seal. Available in a variety of densities, color*, and finish**, leeded vinyl noise barner* can be specified for practically any installation requiring a flexible, durable, movable pertition.
Lead and asbestos anti-vibration pads can also ba used to cut noisa and vibration from intense sources. Accepting static loads up to and above 1000 psi. anti-vibration pads block the structural path by which vibration can get to radiating surfaces where A appears es noise.
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taad-ba etteyt Numerous soldering alloy* of land ara eva.labia for almost any metal foming purpose Tha most widely utad sotter* are the lead tin alloy* Many of theta bee n to melt at 3617. leadtm sotter * compatible tor ute with naarty all bata matt! ctoeher* and fiuaa*. and
heating method*.
Other Laad Setter* Laad tm antimony aftoyt ara fra-
qurntly utad where fleeter mechan*ca( ttrenfth and hifher
operatmf temperaturet are necessary,
AiNrar alloyt
are suitable for application temperature* up to 3S0`F.M<nor
add-i*ons of tm (less than 15%) art sometimes made to
the sitvAf totters to reduce corrosion tutcaptibrfdy.
The FirtibW AAayt These feneralty contam a combma tion of lead, tm. b<tmuth. and cadmium or md.um To acte*e better properties minor addition* of certain other elements are sometimes made One group of these alloys *% bated on the ternary eutect< conu>n<r>f 15 5% tm 52 5% bismuth, and 32% lead. Wood t and lpo witz's alloys are typical of the Quaternary eutectic, con ta*n.r\f teed. tm. bismuth and cadmium. Theta melt around 158 f Tensile strengths for the fuub*# alloys range f.-pm 4.000 to more than 13.000 *b sq m however, mechanical properties of most tend to change oar a period of tme anc care thoutt be taken n therr selection.
Dewf* ConsidarAttORS The designer must tailor each solder h>nt to meet the specific requirements of hes appkot*on if he wishes to lu``f utilize totter * eersabMy a* a joining material He must constter choice of ahoy, base metal*, tiu* artt hui removal, and jor* geometry. Tfug latter includes taking advantage of the mechamcat strength of tv base metal rather than relying solely on the totter't strength.
Paste Setters Powdered sottert b*<tted with fluxes and neutral suspending agents are termed "pest# sotters**. They can save time and money m that flunng and SOtter placement art carried out n one step. Precise amounts of sotter metal can be metered out by automatic dispenser* and nearly any Alloy or flu* can be incorporated into tha pasta.
lead |Umh arfth thalr inherent high volume rasitthrity, high dieiectnc constant and tow toa* factor 11 watt M icellent tow-temperature working properties are wy important tor electrical And electron* applications w |Um And enamels for insulator bodies. U filament supports foe Incandescent bulb*. for high-temperature Ceram* coated wire. #nd a* a (tar* coating for spark plugs. Simple lead silicate fUlMt have been used WCteishjlly a* trireme htfh temperature lubricants At Mtt* MX vetoed** greater than 1000 ft./minute in supersonic aircraft engine* and th like. Faction coefficients of 0.05 to 0 08 at temperature* above 1200'F lit doubtless due to fprmat*on o< A lead ottte glaze in the sitting rone. Of course. htfh density Wad (Uuh (oftan 80% or more teed corUM) hart traditionally bean used in rediettonprotect/ve w*rttot because they retain that/ citeUent transparency while effectrveiy sh*ettmg tha viewer Marty at wail as sheaf toad would do. leads etoctroceram* And magnefoceram* applications Ara of special interest to engineers alto Barium terms parmanant ceram* mag nets modif.ad w*th laod additions, and ptafoeLadnc ceram*s batad on th* Wad rrcon#ta-teed trtanat* *y*tam are be-rtf used increasingly to* their batter design characteristica--end often lower m theproduct cost*. Laad lanthanum i.monate tHanata has a remarkable image storing capacity wh*ch may eventually make tha w*fer-thw tetons** realty.
Fuel level sensmg d*v<ei depend on a perfect seat between tube and cover plate Paste solder provttes the solution.
Automotive appticeUont for mechsrwed paste sotter oper ton* ar many Here n Oil MHr tube on a power steering aitembty receives paste sotter stripe poor to sottermg with o Same
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Automat* rotary soldering machines help to meet high production requirements m the automotive uyjirstry.
Precision in >oining ta a fore most requirement In industry.
Solder It the key for dose tOleranCAA.
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