Lead and Lead Alloys

Lead is the first and oldest metal was known to man. The first figure made about 3000 BC. All civilizations, have used lead for many ornamental and structural purposes

Compositions and Grades
The Unified Numbering System (UNS) designations for various pure lead grades and lead-base alloys:

Grades of lead
Grades are Corroding lead (pure lead), common lead both containing 99.94% min lead, and chemical lead, acid-copper lead both containing 99.90% min lead. In commercial quantities Lead of higher specified purity (99.99%) is also available. Specifications other than ASTM B 29 for grades of pig lead include federal specification QQ-L-171, German standard DIN 1719, British specification BS 334, Canadian Standard CSA-HP2, and Australian Standard 1812.

Corroding Lead: Most lead produced in the United States is pure lead (99.94% min Pb) Corroding lead which exhibits the outstanding corrosion resistance typical of lead and its alloys. Corroding lead is used in making pigments, lead oxides, and a wide variety of other lead chemicals.

Chemical Lead: Refined lead with a residual copper content of 0.04 to 0.08% and a residual silver content of 0.002 to 0.02% is particularly desirable in the chemical industries and it is called chemical lead.

Copper-bearing lead: provides corrosion protection in most applications that require high corrosion resistance. Common lead, which contains higher amounts of silver and bismuth than does corroding lead, is used for battery oxide and general alloying.

Lead-Base Alloys
Lead is normally used commercially as lead alloys because it's very soft and ductile. Antimony, tin, arsenic, and calcium are the most common alloying elements. Antimony generally is used to give greater hardness and strength, as in storage battery grids, sheet, pipe, and castings. Antimony contents of lead-antimony alloys can range from 0.5 to 25%, but they are usually 2 to 5%. Unalloyed lead has poor wetting characteristics.

Lead-calcium: alloys have replaced lead-antimony alloys in a number of applications, storage battery grids and casting applications. These alloys contain 0.03 to 0.15% Ca.

Aluminum has been added to calcium-lead and calcium-tin-lead alloys as a stabilizer for calcium.

Tin gives the alloy the ability to wet and bond with metals like steel and copper; tin combined with lead and bismuth or cadmium forms the principal ingredient of many low-melting alloys.

Arsenical lead (UNS L50310) is used for cable sheathing. Arsenic is often used to harden lead-antimony alloys and is essential to the production of round dropped shot.

Adding tin to lead or lead alloys increases hardness and strength, but lead-tin alloys are more commonly used for their good melting, casting, and wetting properties, as in type metals and solders.

Properties of Lead
The properties of lead that make it useful in a wide variety of applications are density, malleability, lubricity, flexibility, electrical conductivity, and coefficient of thermal expansion, all of which are quite high; and elastic modulus, elastic limit, strength, hardness, and melting point, all of which are quite low. Lead also has good resistance to corrosion under a wide variety of conditions. Lead is easily alloyed with many other metals and casts with little difficulty.

The high density of lead makes it very effective in shielding against x-rays and gamma radiation. Lead is an excellent material for deadening sound and for isolating equipment and structures from mechanical vibrations, Because of it combination of high density, high limpness, and high damping capacity makes Malleability, softness, and lubricity are three related properties that account for the extensive use of lead in many applications.

When designing lead components the low tensile strength and low creep strength of lead must always be considered. The principal limitation on the use of lead as a structural material is not its low tensile strength but its susceptibility to creep. Lead continuously deforms at low stresses and this deformation ultimately results in failure at stresses far below the ultimate tensile strength. The low strength of lead does not necessarily preclude its use.

Lead products can be designed to be self-supporting, or inserts or supports of other materials can be provided. Alloying with other metals, notably calcium or antimony, is a common method of strengthening lead for many applications. Consideration should always be given to supporting lead structures by lead-covered steel straps. When lead is used as a lining in a structure made of a stronger material, the lining can be supported by bonding it to the structure. Composites of lead with other materials can be made cause of the development of improved bonding and adhesive techniques. Composites have improved strength yet also retain the desirable properties of lead.

Products and Applications
The most significant applications of lead and lead alloys are: lead-acid storage batteries (in the grid plates, posts, and connector straps), ammunition, cable sheathing, and building construction materials (such as sheet, pipe, solder, and wool for caulking). Other important applications include counterweights, battery clamps and other cast products like bearings, ballast, gaskets, type metal, tern plate, and foil.

Battery Grids: The largest use of lead is in the manufacture of lead-acid storage batteries. it consist of a series of grid plates made from either cast or wrought calcium lead or antimonial lead that is pasted with a mixture of lead oxides and immersed in sulfuric acid.

Type metals : a class of metals used in the printing industry, generally consist of lead-antimony and tin alloys. Small amounts of copper are added to increase hardness for some applications.

Cable Sheathing : the most durable protection against moisture, corrosion damage, and mechanical protection of the insulation can be provided by Lead sheathing extruded around electrical power and communication cables. Chemical lead, 1% antimonial lead, and arsenical lead are most commonly employed for this purpose.

Sheet : because lead resists attack by a wide range of chemicals Lead sheet is a construction material of major importance in chemical and related industries. It is also used in building construction for roofing and flashing, shower pans, flooring, x-ray and gamma-ray protection, and vibration damping and soundproofing. Sheet for use in chemical industries and building construction is made from either pure lead or 6% antimonial lead. Calcium-lead and calcium-lead-tin alloys are also suitable for many of these applications.

Pipe : Seamless pipe made from lead and lead alloys is readily fabricated by extrusion. lead pipes finds many uses in the chemical industry and in plumbing and water distribution system, Because of its corrosion resistance and flexibility. Pipe is made from either chemical lead or 6% antimonial lead.

Solders: Tin-lead solder alloys can be obtained with melting temperatures as low as 182 °C and as high as 315 °C. Except for the pure metals and the eutectic solder with 63% Sn and 37% Pb, all tin-lead solder alloys melt within a temperature range that varies according to the alloy composition. in the tin-lead system are the most widely used of all joining materials. The low melting range of tin-lead solders makes them ideal for joining most metals by convenient heating methods with little or no damage to heat-sensitive parts.

Lead-base bearing alloys (lead-base Babbitt metals)

It can be categorized into two groups:

Ammunition : Large quantities of lead are used in ammunition for both military and sporting purposes. Alloys used for shot contain up to 8% Sb and 2% As; those used for bullet cores contain up to 2% Sb.

Tern Coatings : Long tern steel sheet is carbon steel sheet that has been continuously coated by various hot dip processes with tern metal (lead with 3 to 15% Sn). Its excellent solder ability and special corrosion resistance make the product well-suited for this application.

Lead foil : composition metal foil, is usually made by rolling a sandwich of lead between two sheets of tin, producing a tight union of the metals.

Fusible Alloys : Lead alloyed with tin, bismuth, cadmium, indium, or other elements, either alone or in combination, forms alloys with particularly low melting points. Some of these alloys, which melt at temperatures even lower than the boiling point of water, are referred to as fusible alloys.

Anodes : made of lead alloys are used in the electro winning and plating of metals such as manganese, copper, nickel, and zinc. Rolled lead-calcium-tin and lead-silver alloys are the preferred anode materials in these applications, because of their high resistance to corrosion in the sulfuric acid used in electrolytic solutions. Lead anodes also have high resistance to corrosion by seawater, making them economical to use in systems for the cathode protection of ships and offshore rigs.