Module 5.

Fabrication of Metals
1. Introduction
2. Deformation/Forming
3. Casting
4. Powder Metallurgy
5. Joining

Dept. Metallurgy and Materials Engineering

University of Indonesia
Fabrication of Metals

Dept. Metallurgy and Materials Engineering

University of Indonesia
 METAL FABRICATION METHODS-I

FORMING CASTING JOINING

• Forging • Rolling
(wrenches, crankshafts) (I-beams, rails)
force
die roll
Ad
Ao blank Ad often at Ao
elev. T
roll
Adapted from
force Fig. 11.7,
• Drawing • Extrusion Callister 6e.
(rods, wire, tubing) (rods, tubing)
Ao
die Ad container
die holder
Ao tensile force
force ram billet extrusion Ad
die container die
Dept. Metallurgy and Materials 6Engineering
University of Indonesia
 Forging
Forging
the process by which metal
is heated and is shaped by
plastic deformation by
suitably applying
compressive force.
Forged Flange Hot Forging Product
Penempaan
proses di mana metal
dipanaskan dan dibentuk
hingga terdeformasi plastis
dengan mengaplikasikan
gaya tekan ( compressive
force).
Forged Pipe Fittings
Dept. Metallurgy and Materials Engineering
University of Indonesia
 Forging

Closed die forging

Closed die forging

Open die forging

Dept. Metallurgy and Materials Engineering
University of Indonesia
 Extrusion
Extrusion
is done by squeezing metal in a
closed cavity through a tool,
known as a die using either a
mechanical or hydraulic press to
get required cross-sections.
Ekstrusi
menekan logam dalam rongga
tertutup melalui alat, disebut juga
cetakan menggunakan tekanan
mekanik atau hidrolik untuk
mendapatkan bentuk penampang
yang diiinginkan
Dept. Metallurgy and Materials Engineering
University of Indonesia
 Extrusion

Extrusion
products

Extrusion dies

Extrusion machine
Dept. Metallurgy and Materials Engineering
University of Indonesia
 Sheet Metal Forming
• The shaping of thin sheets of
metal (usually less than ¼ in.
or 6 mm) by applying
pressure through dies.
• Sheet forming is
accomplished basically by
processes such as stretching,
bending, deep drawing,
embossing, bulging, flanging,
roll forming, and spinning.
• In most of these operations
there are no intentional major
changes in the thickness of
the sheet metal.
• Pembentukan lembaran tipis
logam ( biasanya < ¼ in. atau
6 mm) dengan memberi
tekanan melalui cetakan.
• Sheet forming diselesaikan
dengan proses-proses seperti
stretching, bending, deep
drawing, embossing, bulging,
flanging, roll forming, and
spinning
• Kebanyakan dalam operasinya
tidak ada perubahan besar
pada ketebalan dari lembaran
logam.
Dept. Metallurgy and Materials Engineering
University of Indonesia
Sheet Metal Forming

Dept. Metallurgy and Materials Engineering

University of Indonesia
Sheet Metal Forming

Dept. Metallurgy and Materials Engineering

University of Indonesia
 METAL FABRICATION METHODS-II

FORMING CASTING JOINING

• Sand Casting • Die Casting
(large parts, e.g., (high volume, low T alloys)
auto engine blocks)

Sand Sand

molten metal
• Continuous Casting
• Investment Casting (simple slab shapes)
(low volume, complex shapes
molten
e.g., jewelry, turbine blades)
plaster solidified
die formed
around wax wax
prototype
Dept. Metallurgy and Materials 8Engineering
University of Indonesia
Casting Furnaces

Dept. Metallurgy and Materials Engineering

University of Indonesia
Sand Casting

Dept. Metallurgy and Materials Engineering

University of Indonesia
Sand Casting

Dept. Metallurgy and Materials Engineering

University of Indonesia
Die Casting

Dept. Metallurgy and Materials Engineering

University of Indonesia
Investment/Wax Casting

Dept. Metallurgy and Materials Engineering

University of Indonesia
Investment/Wax Casting

Dept. Metallurgy and Materials Engineering

University of Indonesia
 METAL FABRICATION METHODS-III

FORMING CASTING JOINING

• Powder Processing • Welding

(materials w/low ductility) (when one large part is
impractical)
pressure
filler metal (melted)
base metal (melted)
fused base metal
heat
heat affected zone
area unaffected unaffected
contact piece 1 piece 2 Adapted from Fig.
11.8, Callister 6e.
densify (Fig. 11.8 from Iron
Castings Handbook,
• Heat affected zone: C.F. Walton and T.J.
point contact densification Opar (Ed.), 1981.)
at low T by diffusion at
(region in which the
higher T microstructure has been
changed).
Dept. Metallurgy and Materials 9Engineering
University of Indonesia
Welding
Welding
Pengelasan
• Is the process of
permanently joining • Proses penyambungan
two or more metal permanen 2 tau lebih
parts, by melting both bagian logam, dengan
materials. melelehkan materialnya

• Spot welding and • Spot welding dan seam

seam welding are two welding adalah 2 metode
very popular methods yang populer digunakan
used for sheet metal untuk logam lembaran

Welded area

Dept. Metallurgy and Materials Engineering

University of Indonesia
 Submerged Arc welding
Welding
Arc welding

Dept. Metallurgy and Materials Engineering

University of Indonesia
Copyright 2008 Motivating Moments LLC
http://www.MotivateUs.com Dept. Metallurgy and Materials Engineering
University of Indonesia
Copyright 2008 Motivating Moments LLC
Dept. Metallurgy and Materials Engineering
http://www.MotivateUs.com
University of Indonesia
Happy Lunch!