POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

COLLEGE OF ENGINEERING
STA. MESA MANILA
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MATERIAL SCIENCE AND ENGINEERING FOR ME

ACTIVITY 01

Question
Cold working is done in ambient temperature while hot working is done at around 600°C
for steel. Differentiate the effect of the two process in steel, and the reason for using one
from the other.
Answer: The process between these two does not depend solely on temperature alone of
course, but rather the processing temperature. When the processing temperature of the
mechanical deformation is above the recrystallization temperature, the process is known as hot
working, but if not, then it is called cold working.
When to use cold working: Use cold working when you want to improve the ultimate tensile
strength, yield and fatigue strength of metal. But take not that it reduces the corrosion resistance
of the metal. In addition, the surface finish of the component is better because no oxidation
takes place during the process since it worked on low temperatures.
While for hot working, unlike in cold working, the ultimate tensile strength, yield point, corrosion
resistance are unaffected. But instead, there is a decrease in yield strength, therefore it is easier
to work and uses less energy or force. And in addition, it also improve some mechanical
properties like impact strength and elongation and that any impurities in the metal are
disintegrated and distributed throughout the metal.
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Question
Besides the mold used, differentiate the three metalworking processes: die casting, sand
casting, and investment casting
Answer:
First Die Casting: Die casting is a manufacturing process of which molten metal is poured or
forced into steel molds. These molds, are also known as tools or dies, at which are created
using steel and are specially designed for each project. This allows each component to be
created with accuracy and repeatability. Aluminum, zinc, and magnesium are the most
commonly used die casting alloys.
Second Sand Casting: In sand casting, molten metal, usually iron, steel, bronze, brass,
aluminum, magnesium, and other non-ferrous alloys, is poured into a two-piece mold. The
molds are created by compacting sand—most often mixed with clay as a bonding agent and
moistened with water—around a pattern or model of the final product. The mold is split apart
and the pattern removed. The two halves of the mold are put back together and the void is filled
with molten metal. Once the metal cools sufficiently, the mold is opened, the sand removed, and
the part taken out. In other words, Its where molten metal gets poured into the sand-based
molds during sand casting, is what sand casting really is.
Third Investment casting: Investment casting, also called lost-wax casting, makes parts from
molten metal, usually stainless-steel alloys, brass, aluminum, and carbon steel. this casting can
be done in 3 ways.
1. Form a gelatin mold around a solid, 3D model of the final product.
2. Create a metal mold of the final product, and then fill it with hot wax.
3. Carve and machine a replica of the product out of wax.

This process (investment casting) is also done in the Anime Dr. Stone in the creation of a steam
engine, where they used wax as models to cast for the parts of the steam engine.
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Question
Metal 3D printing is a new technology in making parts, what is its difference/similarity
with powder metallurgy?
Answer:
Differences
1) In metal 3D printing, they print or create the object layer by layer, similar to that of a
normal 3D printer, and the printed product in its early stage is called a ‘green part’ where its
strength is only sufficient for handling purposes and could crumble if not washed and sintered..
Meanwhile, in powder metallurgy, instead of creating it layer by layer, they compress the
material used (fine metal powder) in a mold at which they call a ‘green state’, and this green
state the part has the so called green strength, which is sufficient only for handling purposes
and for the part to reach the sintering process, since it’s not that sturdy enough and could
crumble anytime, all the more reason as to why it needs to go through the sintering process
where it will be subjected in high temperatures so that the metal powders will stick together.
2) Unlike in powder metallurgy, in 3d printing, they have the process called washing. Where
in this process, removes the first stage of the binding material where the green part is
taken from the printer and placed into the wash basket, which is then lowered into the
solvent. Then after that, we now have what they call a ‘brown part’ that is now ready for
sintering process.
Similarity
1) Both the 3D printing and powder metallurgy process has 1st process where the product
formed is in a state where it still needs to undergo sintering process so that the 1st stage of
material hardens up.
2) They both use fine powder metal to create their product.
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Question
When do we use extrusion? Give at least 5 examples of its application in metalworking.
Answer:
We use extrusion when we need a material to be formed in a desired shape that
hammering or bending process can’t be used since the material to be formed is either too brittle
or too soft for said process. Extrusion is done by pushing the material to be formed in a
container through what they call a ‘die’, and that the shape of the formed material can change
depending on the pressure applied and the shape of the die.
The 5 examples of its application in metalworking:
1) Aluminum cans
2) Collapsible tubes
3) Deck railings
4) Doors and Windows in automotive industries
5) Hollow pipes
References
APA 6th Edition
Difference between Hot Working and Cold Working (May 17, 2017) retrieved from
https://mechanical-engg.com/notes/manufacturing-technology/difference-between-hot-working-
and-cold-working-r17/
Difference Between Hot Working and Cold Working. Retrieved from
https://alldifferences.net/difference-between-hot-working-and-cold-working/ -
Die Casting. Retrieved from https://www.dynacast.com/en/specialty-die-casting/die-casting -
https://study.com/academy/lesson/extrusion-definition-process-examples.html
Powder metallurgy – tooling U-SME (June 20, 2014) https://www.youtube.com/watch?v=N4-
kfSD6XJI
Extrusion Process : Working, Types, Application, Advantages and Disadvantages. Retrived from
https://paulmurphyplastics.com/2019/09/25/extrusion-process-working-types-application-
advantages-and-disadvantages/