Processes Used to Form Metallic Materials

These flashcards cover essential vocabulary related to the processes used to form metallic materials, including definitions and key characteristics.

Forging

The process of shaping metal by successive hammering (compressive force) until the desired shape is attained, resulting in strong and tough parts due to a dense and fine grain structure.

Coining

A manufacturing process where metal shapes are squeezed in a closed set of dies to produce parts with detailed surface features.

Roller Forming

A rotary forming process where cold metal is shaped by passing through a set of rolls, typically used to create channels, tubes, and structural shapes.

Thread Rolling

A process where cold stock is rolled between two dies to create threads, enhancing the metal's strength without removing material.

Extrusion

A process in which metal is pushed through a die to take on a new shape, commonly used for creating tubing.

Upsetting (Cold Heading)

A fast process used to thicken parts of stock to make products such as nails, bolts, and rivets.

Stamping

A cold forming process that involves compaction under pressure to make shapes, cuts, and indentations in metal, usually requiring a die set.

Embossing

A technique that produces raised areas on flat sheet metals and is commonly used for items like credit cards and military dog tags.

Drawing

A metal forming process that compresses and stretches metal simultaneously using various methods including hydroforming and explosion forming.

Sand Casting

A method of creating molds by compacting sand around a pattern, highly utilized in the metal casting industry.

Permanent Mold Casting

A casting process that uses reusable molds made from materials like graphite or steel, resulting in better metal properties than sand casting.

Diecasting

A highly automated casting process using high-pressure to push nonferrous metals into reusable molds.

Investment Casting (Lost Wax)

A method where patterns are made from materials like wax and cannot be reused; used to produce high-quality, dimensionally accurate castings.

Centrifugal Casting

A casting process where liquid metal is poured into a rotating cylindrical mold to create parts with a uniform density.

3D Metal Printing

A revolutionizing process that melts metal powders into droplets to build solid parts, expected to shape the future of manufacturing.

Electromagnetic Forming

A process that utilizes electromagnetic forces and molecular heating for fast, automated metal forming, especially for joining tubular shapes.

Shot Peening

A process that strengthens metal surfaces by blasting them with steel, iron, or glass shot to induce surface compression.