metal alloys

metal fabrication

the process consists of combining raw materials to form products or structures into its desired shape and using forced compression.

Cutting

The process involves removing unnecessary pieces from the metal scraps — which can be ferrous or non- ferrous.

Metal stamping

This process is used to process specific sheet metals and combines with other fabricating metal methods to have a desired result.

Automotive component manufacturing and assembly

metal stamping is popular to be used in what?

• die assembly

• Compound die

• Combination die

• Progressive die

metal stamping technique

Die assembly

is designed to operate a single task per stroke. It is commonly used in manufacturing process for low - volume production.

Compound die

can execute by several cutting processes, such as blanking and piercing in a single press stroke. It is suited in producing multiple cuts and complex designs more efficiently.

Combination die

are advanced tools that designed to perform a multiple cutting and forming processes in a single stroke.

combination die

improve the production of efficiency and reducing the processing time.

Progressive die

are designed to cut or shape a workpiece step by step through a series of stations arranged within the die, following the sequence of fabrication steps.

• gas tungsten arc

• Gas metal arc

• Flux cored arc

• Electron beam

• Atomic hydrogen

Welding technique Types

Gas tungsten arc

Welding where Two Metal are joined together through an electrode.

Gas tungsten arc

In this welding type, non - consumable

tungsten is used. It is also considered

to be one of the most difficult welding

techniques.

Gas metal arc

Uses consumable piece of an electrode

in order to incorporate the two

materials together.

Gas metal arc

The electrode wire does not have a

coating and it is heated up until the

melting point.

Flux cored arc

Can be conducted with or

without the presence of

shielding gas because the flux

is important to prevent the

welded workpiece from

external contamination.

Electron beam

The Material is much less exposed to

contamination due to oxidation.

Electron beam welding

It is a high - precision welding technique, its’ usually done with the use of computer - controlled or an automated machine.

Atomic hydrogen welding

Involves the use of two non -consumable tungsten electrodes in which the welder has more freedom in adjusting the distance of electrodes from the workpiece to modify and control the amount of heat.

Extrusion technique

This process can be used in different

production not only in metals but also in

plastic - based products like polymer. It has a wide range of uses in the process for steel or aluminum beams, or sectional components

aluminum

MOST POPULAR EXTRUSIONS

longer - lasting and aesthetically -

appealing

Aluminum is adding another layer of powder

coating where it will make the quality of

having What because the aluminum consists of a

non - corrosive properties — which is not

easily damaged by the chemicals such as

acids.

Forging

The blade undergoes being hammered on a solid block of anvil which is the metal being shaped using compressive forces and the temperature can be classified on how the method will be performed.

cold forging

shapes and process the metals at a room temperature or at a constant temperature. This method is uses in the process for soft metals like aluminum and copper.

Hot forging

has a capacity to create complex shapes with high precisions.

results to have excellent ductility , can be extensively deformed and reshaped, enhancing their resistance to tensile stress.

Results of hot forging

Open die or drop forging

it is where the workpiece shapes

without fully enclosing the metal within this

die. the workpiece is heated before being

placed on the anvil for shaping. Then the

workpiece is heated and hammered to achieved

its desired shape.

metal casting

It is the process where it undergoes heating a

metal until its melting point and poured in an

empty cavity mold that has a specific design —

and allows the metal to cool until it fully hardens

and removes the minor defects to finish the metal.

Thermal processing of metals

It is used to enhance the desired performance and characteristics of the metals.

Annealing

It uses high temperature to soften the metal

and slowly cools down to reduce stresses and

increase the ductility.

Annealing

It helps eliminate the effects of cold working,

such as hardness and decreased ductility.

Recovery stage of annealing

Initial stage of annealing.

The metal is heated below

the recrystallization

temperature.

Dislocation moves and

rearrange, relieving internal

stresses.

Recrystallization

The temperature is beyond

the recovery stage

temperature but below the

melting temperature of the

metal.

Distorted grains are

replaced by new, strain-free

grains.

The metal becomes softer

and more ductile.

Grain growth

Occurs when there is

continuous heat.

New strain-free grains will

continue to grow.

As grain size increases, the

grain boundary decreases.

Full annealing

• It is used on higher alloy or carbon steels.

• This process heats the alloy or metals above their upper critical temperature and then cools gradually.

process annealing

• It uses a temperature that is lower than the full annealing temperature.

• This process aims to restore the ductility of cold-worked metals without breaking them.

• Usually used on low-carbon steels.

Stress relief annealing

It removes internal residual stresses formed due to plastic deformation processes

and nonuniform cooling.

Spheroidizing annealing

• It is an annealing process where spheres of carbide form after heating and cooling

• The formation of these spheres helps improve ductility.

Steel

A ferrous metal that contains iron as its base metal, carbon, and other elements.

Heat treatment of steel

What treatment can produce martensitic steel, which is considered to have high strength and more durable properties.

Jominy end-quench test

used to determine

the hardenability of the steel by using water to quench the end of the specimen.

Hardenability

It measures the steel’s ability to be hardened to its given depth.

Hardenability curbe

It demonstrates the steel’s hardness level with the distance from the quenched end of the specimen.

Increase of distance as the cooling rate decreases

causes the steel's hardness to diminish.

Precipitates

are used to enhance the

properties of metal alloys, such as strength

and hardness.

Alfred wilm

A German metallurgist who discovered precipitation hardening in 1906 which led to the development of Duralumin.

Duralumin

An aluminum alloy that consists of copper, manganese, and magnesium. It is used in aircraft manufacturing and structural components.

Solution heat treatment

The solute atoms of the metal alloy are heated to form a single-phase solid solution.

Quenching

The solution will undergo rapid cooling to room temperature. This will prevent the

solute from precipitating outside the solution.

Ageing

The solution in this stage will be heated again, but at a lower temperature. The precipitates will start to form.