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Metal Processing

The document outlines various metals processing techniques, including forging, rolling, extrusion, drawing, casting, powder metallurgy, and welding. Each method is described in terms of its process, applications, and advantages, such as casting being economical for large or complex shapes and welding creating strong metallurgical bonds. The document emphasizes the importance of these techniques in manufacturing useful metal products.

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callmeraj38
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8 views

Metal Processing

The document outlines various metals processing techniques, including forging, rolling, extrusion, drawing, casting, powder metallurgy, and welding. Each method is described in terms of its process, applications, and advantages, such as casting being economical for large or complex shapes and welding creating strong metallurgical bonds. The document emphasizes the importance of these techniques in manufacturing useful metal products.

Uploaded by

callmeraj38
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Materials Engineering

Fundamentals

Metals processing
• Metal fabrication techniques are the methods by which metals and
alloys are formed or manufactured into useful products
Forming operations…the shape of a metal piece is changed by
plastic deformation
The deformation must be induced by an external force or stress, the
magnitude of which must exceed the yield strength of the material
Most metallic materials are amenable to these procedures being at
least moderately ductile and capable of some permanent
deformation without cracking or fracturing

Forging
Mechanically working or deforming a single piece of a normally hot metal
Either closed or open die
For closed die a force is brought to bear on two or more die halves having the
finished shape such that the metal is deformed in the cavity between them
For open die, two dies having simple geometric shapes are employed
normally on large workpieces
Rolling
The most widely used deformation process, consists of passing a piece
of metal between two rolls; a reduction in thickness results from
compressing stresses exerted by the rolls
Rolling may be used in the production of sheet, foil with high quality
surface finish
Extrusion
A bar of metal is forced through a die orifice by a compressive force
The extruded piece that emerges has the desired shape and a reduced
cross-sectional area
Rods,pipes

Drawing
Pulling of a metal piece through a die by means of a tensile force that is
applied on the exit side.
A reduction in cross section results with a corresponding increase in
length.
Rod , wire
Casting

A totally molten metal is poured into a mold cavity having the desired
shape..upon solidification the metal assumes the shape of the mold
but experiences some shrinkage

Employed when the finished shape is so large or complicated that any


other method would be impractical…in comparison to other
fabrication processes, casting is the most economical
Sand casting

The most common method, ordinary sand is used as the mold material
A two piece mold is formed by packing sand around a pattern that has
the shape of the intended casting
Die casting
The liquid metal is forced into a mold under pressure and at a relatively
high velocity, and allowed to solidify with the pressure maintained.
A two piece permanent steel die is employed; when clamped together,
the two pieces form the desired shape.
When complete solidification has been achieved the die pieces are
opened and the cast piece is ejected.
Rapid casting rates are possible making this an inexpensive method
A single set of dies may be used for thousands of castings
Relatively small pieces
Investment casting
The pattern is made from a wax or plastic that has a low melting
temperature. Around the pattern is poured a fluid slurry, which sets
up to form a solid mold, plaster of paris is usually used. The mold is
then heated, such that the pattern melts and is burned out leaving
behind a mold cavity having the desired shape.
This technique is employed when high dimensional accuracy..excellent
finish are required
In jewelry and dental crowns
Powder metallurgy
• The process of blending fine powdered materials, pressing them into a
desired shape or form (compacting), and then heating the compressed
material in a controlled atmosphere to bond the material (sintering).
Powder metallurgy

Metals having high melting temperatures are difficult to melt and cast
Parts that require very close dimensional tolerances [gears] may be
economically produced using this technique
Welding
• Welding is a fabrication process that joins
materials, usually metals.

• This is often done by melting the workpieces


and adding a filler material to form a pool of
molten material (the weld pool) that cools to
become a strong joint, to produce the weld.

• This is in contrast with soldering and


brazing, which involve melting a lower-
melting-point material between the
workpieces to form a bond between them,
without melting the workpieces.
Welding
Two or more metal parts are
joined to form a single piece
when one part fabrication is
expensive or inconvenient
Both similar and dissimilar
metals may be welded
The joining bond is
metallurgical [involving some
diffusion] rather than
mechanical as with bolting.
Welding
During welidng the workpieces to be joined and the filler material are
heated to a sufficiently high temperature to cause both to melt upon
solidication, the filler material forms a fusion joint between the
workpieces

• After welding, a number of distinct regions can be identified in the


weld area. The weld itself is called the fusion zone—more
specifically, it is where the filler metal was laid during the welding
process.

• The properties of the fusion zone depend primarily on the filler metal
used, and its compatibility with the base materials. It is surrounded
by the heat affected zone, the area that had its microstructure and
properties altered by the weld.

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