INTRODUCTION TO

MATERIALS
MATERIAL PROCESS
Blast Furnace

(IRON ORE) (CHARCOAL (PIG IRON) (GASES)

/COKE)

Lime stone: gathers impurities and make it liquid light

Charcoal: 1) add molecule carbon in iron
2) reduce the combustion temperature *see video
INGOT CASTING PROCESS

Pig Iron
INGOT
• The "hot top" is usually
cropped off to remove most
of the discontinuities before
the ingot is further
processed.

• However a few
discontinuities still remain in
the ingot.
ROLLING PROCESS
• After the top of the ingot is cropped, it is called bloom.
Bloom can be rolled into smaller size called slabs
(rectangular) or billets (square).

• The rolling process also reduced the large grain into

small grain and stretched out in the direction of roll.
 CASTING PROCESS

Casting process is a commonly used method for forming

metal objects of complex shapes by pouring molten
metal into a mould in which it sets to the required shape.
 FORGING PROCESS

• Forging is the working of metal into a desired

shape by hammering or pressing the metal
while is hot and soft condition.
• A forged part gains strength due to the grain
flow taking the shape of the die.
Forging process divided by two type:
1-Open Die Forging
2-Close Die Forging
Open Die Forging
- shaping is done by manipulation using tools of simple
shape.
- 3 dimensional forming process:
a) elongation
b) reduction in thickness
c) stretching

*see video
Closed Die Forging

The impression dies are used and the metal is shaped by

being forced into the die impressions
WELDING PROCESSES
Welding is the process of joining two or more
pieces of material together by bringing the atom
of each piece into such close contact that an
atomic bond take place.
- Welding divided by two category:
a) Forge welding
b) Fusion welding

Forge Welding
- The method involves heating the pieces of iron to be joined
to red heat and hammering them together.
Fusion Welding
- Material at the joint is heated to the molten state and
allowed to solidify to make the joint, without the
application of pressure.
COMMON FUSION WELDING
PROCESSES

1. MMA (SMAW)
2. TIG/TAG (GTAW)
3. MIG/MAG (GMAW)
4. Oxy-acetylene
5. Sub-arc (SAW)

*see video
1. MMA/ Shielded Metal Arc Welding (SMAW)
• The oldest, simple arc welding, also known as
stick welding.
• The electrode is a metal rod or stick held in the
torch with a small clamp.
• The heat of the arc melts the flux at electrodes
which generates a gaseous shield to keep air
away from the molten pool.
2. Tungsten Inert Gas Welding (TIG)/
Gas Tungsten Arc Welding (GTAW)
- The TIG welding process was first developed in
the USA during the 2nd world war for the
welding of aluminum alloys.
- Uses a tank and inert gas to shield the weld.
- The tungsten electrode carries the arc, but is
not consumed.
- The process produces very high quality welds.
No slag produced during welding.
- The process requires a high level of welder skill
 3. MIG/MAG-
Gas Metal Arc Welding (GMAW)
- The MIG/MAG welding process was initially
developed in the USA in the late 1940’s for the
welding of aluminum alloys
- The process uses a continuously fed wire
electrode.
- The weld pool is protected by a separately
supplied shielding gas.
- The process is classified as a semi-automatic
welding process but may be fully automated.
- The wire electrode can be either bare/solid wire
or flux cored/hollow wire.
4. Oxy-Gas Welding

*see video
- Heat source-Fuel gas flame
- Shielding — products of combustion
- Application — light fabrications, motor
vehicle repair
5. Sub-arc (SAW)

*see video
• Submerged arc welding is a process of formation
of an arc between a continuously fed electrode and
the work piece.
• The arc is shielded by a blanket of granular fusible
material on the work.
• Filler metal is obtained from the electrode or from a
supplementary welding rod.
• Major advantages are high quality metal weld,
extremely high speed and deposition rate and
smooth, uniform finished weld with no spatter.