Group 2

Title: Hot Work Process

Name: Gan Kai Lun Lee Jia Liang Haridas A/L

06DEM10F1034 06DEM10F1019 06DEM10F1008

Lec.Name: Puan Maya Sofa Binti

DEFINITION OF HOT WORK PROCESS

HOT WORK is any process that can be a source of ignition when flammable material is present or can be a fire hazard regardless of the presence of flammable material in the workplace. Common hot work processes are welding, soldering, cutting and brazin g. When flammable materials are present processes such as grinding and drilling become hot work processes.

FORGE & SMITH FORGE

A forge is a hearth used for forging. The term "forge" can also refer to the workplace of a smith or a blacksmith, although the term smithy is then more commonly used. The basic smithy contains a forge, also known as a hearth, for heating metals. The forge heats the workpiece to a malleable temperature (a temperature where the metal becomes easier to shape) or to the point where work hardening no longer occurs. The workpiece is transported to and from the forge usingtongs. The tongs are also used to hold the workpiece on the smithy's anvil while the smith works it with a hammer. Finally the workpiece is transported to theslack tub, which rapidly cools the workpiece in a large body of water. The slack tub also provides water to control the fire in the forge.

Type Of Forge
Coal/coke/charcoal forge: A forge of this type is essentially a hearth or fireplace designed to allow a fire to be controlled such that metal introduced to the fire may be brought to a malleable state or to bring about other metallurgical effects (hardening, annealing, and drawing temper as examples). The forge fire in this type of forge is controlled in three ways: amount of air, volume of fuel, and shape of the fuel/fire. Gas forge:
A gas forge typically uses propane or natural gas as the fuel. One common, efficient design uses a cylindrical forge chamber and a burner tube mounted at a right angle to the body. The chamber is typically lined with refractory materials, preferably a hard castable refractory ceramic. The burner mixes fuel and air which are ignited at the tip, which protrudes a short way into the chamber lining.

The air pressure, and therefore heat, can be increased with a mechanical blower or by taking advantage of the Venturi effect. Gas forges vary in size and construction, from large forges using a big burner with a blower or several atmospheric burners to forges built out of a coffee can utilizing a cheap, simple propane torch. A small forge can even be carved out of a single soft firebrick. A gas forge is simple to operate compared to coal forges, and the fire produced is clean and consistent. They are less versatile, as the fire cannot be reshaped to accommodate large or unusually shaped pieces. It is also difficult to

heat a small section of a piece. A common misconception is that gas forges cannot produce enough heat to enable forgewelding, but a well designed gas forge is hot enough for any task. Finery forge:
A finery forge is a water-powered mill where pig iron is refined into wrought iron.

HOT ROLLING
Is a metalworking process that occurs above the recrystallization temperature of the material. Usually start with large piece of metal, such as billets. Worked the temperature must be monitored to make sure it remains above the recrystallization temperature, usually 50 to 100 C (122 to 212 F) above the recrystallization temperature. This Process is used mainly to produce sheet metals or simple cross sections, such as rail tracks.

FORWARD AND INVENTED EXTRUSION

Forward Extrusion- Is a most common extrusion process. Here the billet is placed properly in the container and pushed along the die by using ram pressure. Direct extrusion has very popular applications. They are typically used in the manufacture of solid rods, bars, hollow tubes, solid sections etc. In direct extrusion, the direction of metal flow is in the identical direction as that of ram travel. In this process, the billet is slided relative to the walls of the container. The ensuing frictional force increases the ram pressure substantially. Conventionally, the process of direct extrusion has been described as having three distinct phases or regions:

Billet is upset, and the pressure rises quickly to its peak value The pressure decreases, and the 'steady state extrusion commences As the pressure attains its minimum value it is followed by a acute rise as the discard gets compacted Invented extrusion- Is the opposite of forward extrusion and is where metal is forced to flow in the opposite direction to the ram.The ram can be recessed to create a mirror image of the recess in the material as required .The die is held in place by a "stem" which has to be longer than the container length. The maximum length of the extrusion is ultimately dictated by the column strength of the stem. Because the billet moves with the container the frictional forces are eliminated. This method produces shorter lengths than the forward extrusion process

ADVANTAGES & DISANVANTAGES OF HOT WORK

AdVantages Decrease in yield strength, therefore it is easier to work and uses less energy or force Disadvantage Undesirable reactions between the metal and the surrounding atmosphere (scaling or rapid oxidation of the workpiece) Less precise tolerances due to thermal contraction and warping from uneven cooling

Increase in ductility

Elevated temperatures Grain structure may vary increase diffusion which can throughout the metal for remove or reduce chemical various reasons inhomogeneities Pores may reduce in size or Requires a heating unit of close completely during some kind such as a gas or deformation diesel furnace or an induction heater, which can be very expensive