Metal Forming Processes

Hot Working vs. Cold Working

Casting and Joining
Metal Fabrication Processes
Forging

⚫It involves the application of a

compressive stress which exceeds the
flow stress of the metal
Forging

⚫The stress can be

applied quickly or
slowly
⚫The process can be
carried out hot or cold;
Over 90% of forging
processes are HW
Products of Forging
Rolling
⚫process of reducing the
thickness of a material
passed between a pair of
revolving rolls
Rolling
⚫ May be done hot or cold
⚫ possible to achieve rapid and
cheap change of shape (HW)
⚫ production of good surface
finish (CW)
⚫ More metal is rolled than the
total treated by all other
processes!
Products of Rolling
Extrusion

⚫block of metal reduced

in cross section by
forcing it to flow through
a die orifice under high
pressure
Products of Extrusion
Tubes

Beams

Heatsinks
Drawing
⚫pulling metal through a
die by means of a
tensile force applied to
the exit side of the die
⚫The deformation is
caused by compression
which arises from the
reaction of the metal
with the die
Products of Drawing

Tubes

Wires

Rod Stocks
Metal Fabrication Processes
Casting

⚫metal object obtained by allowing

molten metal to solidify in a mold
⚫the shape of the object
is determined by the
shape of the cavity
Advantages of Casting
⚫ The most intricate shapes, both
external and internal, may be cast
⚫ some metals can only be cast to
shape since they cannot be hot-
worked into shapes from ingot
form
Advantages of Casting

⚫Mass and rapid

production
⚫Extremely large, heavy
metal objects may be
cast
Sand Casting

⚫ Use of sands with binders for the mold

 Green-sand molds
 Dry-sand molds
Die Casting

⚫Uses reusable permanent metal molds

⚫Accuracy in dimensional tolerances
Investment Casting

⚫a.k.a. Lost Wax

Method
⚫“investment” refers to
slurry mold
surrounding a wax
pattern
⚫a pattern must be
made for every
casting
Continuous Casting

⚫ the molten metal is cast directly in a

continuous strand which may have either a
rectangular or circular cross-sectional area
Metal Fabrication Processes
Powder Metallurgy

⚫Processing of metal
powders
fabrication
conversion of metal
powders to products
Advantages of Powder Metallurgy

⚫economy of process
⚫alloyed metals are formed below melting
temperature; avoids segregation and other
casting problems
⚫unique property for some products (e.g.
porous metals for filters)
⚫processing of reactive and refractory
metals for which melting is impractical
Key Steps in Powder Metallurgy

⚫Powder Production
⚫Shaping and Compaction
⚫Sintering
Types of Powder Production

⚫Mechanical Process
⚫Atomization
⚫Chemical Process
⚫Electrolytic Fabrication
Shaping and Compaction

⚫Shaping – forming
powders to a
desired shape
Molding
Casting
Extrusion
Sintering

⚫thermal process which

creates inter-particle
welds
Joining of Metals
Advantages from joining processes depends
upon:
Complexity of the part
Number of pieces
Material
Joining Processes, by phase

Mechanical Solid- Solid Liquid

Rivets Liquid Friction Chemical
Nuts, bolts Adhesives Diffusion ⚫ Oxyfuel
G-clips Soldering Explosion ⚫ Thermit
Pressure Brazing Ultrasoun
fits d

Arc Welding
Resistance
⚫ Spot
Consumable Non-Consumable
Electrode ⚫ Seam
Electrode
⚫ Shielded Metal Arc ⚫ Flash
⚫ Gas Tungsten
⚫ Submerged Arc ⚫ Plasma Arc
⚫ Gas Metal Arc ⚫ E-Beam / Laser
Advantages / Disadvantages
⚫ Many steel parts can be
produced more economically
by joining than by casting or
forging
⚫ joining processes do not
require specialized tools /
machineries
⚫ Additional labor is required
for assembly
Mechanical Processes

⚫Oldest methods for joining metals

⚫Practically any material, geometry
⚫In their simplest form, these methods
require minimum equipment usage
⚫Reversibility
Soldering

⚫ bonding two or more pieces

of metals using another
metal whose TM < 8000F,
<TM of metals to be joined
⚫ Involves only the melting of
the bonding material (most
common general purpose
solder: 60-40 lead-tin)
Brazing
⚫ bonding two or more pieces of
metals using another metal
whose TM > 8000F, < TM of
metals to be joined
⚫ No melting of parent metal;
bonding is by interfacial
diffusion of filler metal to parts
⚫ general classes of brazing
alloys: Ag-base and Cu-base
alloys
Welding

⚫the work pieces are joined

using a filler material w/c are
heated to >Tm
⚫upon solidification, the filler
material forms a fusion joint
between the two pieces
Adhesive Bonding
⚫ Use of organic, inorganic
compounds to bond metals
together
⚫ Quick and non-invasive
⚫ Good damping and insulating
properties
⚫ Weak to tensile loading,
strong in shear, compressive
⚫ Least equipment-intensive
process