METAL MANUFACTURING

PROCESSES
Warm-up
Task 1: Listen to a recording about different manufacturing processes and
complete the table with NO MORE THAN THREE WORDS.
MANUFACTURING PROCESS Welding Process of  Gas welding
The production of goods (1)…………………………… joining two
using machines.  (8)
Processes Definition Examples metallic ………………
Casting N/A  Sand casting workpieces by ……….
 (2) applying (7)
…………………  Resistance
…. …………………
welding
 Permanent mould if required.
casting  Soldering
 Die casting  Brazing
 Centrifugal Material Process of  Drilling
casting
(3) Process of  Drop forging removal removing any (9)  Milling
…………… changing the shape (Machini …………...
 (5)
…… of (4) …………………  (10)
………………… ng) ……………….
….. ………………
……. from the
 Upset forging ….
workpieces.
 Wire drawing  Broaching
 (6)
Warm-up
Task 1: Listen to a recording about different manufacturing processes and
complete the table with NO MORE THAN THREE WORDS.
MANUFACTURING PROCESS
in large quantities
The production of goods (1)……………………………using machines.
Processes Definition Examples
Casting N/A  Sand casting
 (2)…………………….
investment casting
 Permanent mould casting
 Die casting
 Centrifugal casting
(3)………………… Process of changing the  Drop forging
shape of (4)  (5)……………………..
forming ………………………. press forging
a preheated metal  Upset forging
 Wire drawing
 (6)……………………..
rolling
Warm-up
Task 1: Listen to a recording about different manufacturing processes and
complete the table with NO MORE THAN THREE WORDS.

Welding Process of joining two metallic  Gas welding

workpieces by applying (7) electric arc welding
 (8)……………………….
………………… if required.
 Resistance welding
heat and pressure  Soldering
 Brazing
Material removal Process of removing any (9)  Drilling
(Machining) …………...……………….
unwanted material  Milling
from the workpieces.
 (10)………………….
grinding
 Broaching
 Turning
Processes
• Casting
• Powder processing
• Deformation
• Heat treatment
• Machining
• Joining
• Finishing
Casting
• Heating to melt metal - pouring a liquid material
into a mold (containing a hollow cavity of the
desired shape) – allowing to solidify.
• Iron/ steel: ingot casting; continuous casting
(unit 7).
• Sand casting, lost foam/ lost wax (investment)
casting, die casting, centrifugal casting …
Sand mold casting

• Mold is made of
sand.
• Mold making 
clamping 
pouring 
cooling 
removal 
trimming.
 Enclose the model
with clay

Lost foam/ wax

(investment)
casting

Make a wax model

Pour molten metal

Remove & trim

Die casting

• forcing molten metal under high

pressure into a mold cavity.
• two hardened steel dies (halves)
which have been machined into
shape.
• Using plunger to force molten metal
in.
Centrifugal casting
• a permanent mold is rotated continuously at high speeds (300 to 3000
rpm) as the molten metal is poured.
• molten metal spreads along the inside mold wall, where it solidifies after
cooling
Powder processing
• Treat powdered metals with pressure (pressing, compacting) and heat
(sintering) to form different shapes.
Deformation
• mechanically manipulates workpiece into a desired shape using tension,
compression, shear ….
• Bulk deformation: changing thickness, cross-section … (rolling, forging,
extrusion, drawing ... )
• Sheet deformation: changing shape, but not the thickness (bending, shearing …)
Forging
• the shaping of metal using localized compressive forces (hammer, die)
• Drop forging - a hammer is raised and then "dropped" into the
workpiece
• Press forging - slowly applying a continuous pressure or force.
• Upset forging - increases the diameter of the workpiece by
compressing its length.
Drawing
• metal is stretched and
formed using tensile
force.
 Rolling
• Press the metal (workpiece)
using a Rolling mill with
rollers
• Two-high, three-high, four-
high, universal mill
Heat treatment
• Heat up and cool down
• Quenching - a process of heating a
metal and cooling it at a rapid rate.
• Annealing - heating a metal to a
specific temperature and then cooling
at a rate (usually slow) that will
produce a refined microstructure.
• Tempering – heating steel below the
lower critical temperature (often from
205 to 595 ˚C, depending on the
desired results).
• Normalizing ….
Machining
• also known as material removal processing
• Cutting, Shearing, Punching, Stamping …
Joining
• Joining, or assembly: Join parts together
• Welding, Brazing, Bolting, Riveting, Adhesives
Finishing
• Brushing, Buffing/polishing, Hot/cold blackening, Metal grinding,
Galvanizing, Metal plating, Painting, Powder coating …
 Molten metal

(1)
Processing (2) (3)
_______________ into powder _______________ _______________

Powder
consolidation (4)
_______________

(5) (6)
_______________ _______________

Joining Machining

Semi- or fully
finished part