Metallurgy is, without a doubt, the true driving force of the entire manufacturing industry. It covers the entire process of converting raw metals into finished products through the use of various industrial processes.
In this article we answer the question of what metal processing is. The discussion focuses on different types of metallurgical processes, common raw materials, and an overview of metallurgical trends in the 21st century.
What is metallurgy?
Let's start the discussion with a formal definition of metallurgy. It is the process of constructing metal structures through methods such as cutting, bending and assembly. Any manufacturing process that fits this brief definition is a machining process.
Now we can talk about the workflow that metal fabricators follow in their projects.
Metal Processing Workflow
The metallurgical industry covers a wide range of activities. Manufacturing companies follow a sophisticated workflow for their projects and each step contributes to the overall success. Below we briefly summarize the usual workflow for metal processing.
1. Conception and design of ideas
Every product starts as an idea. Different teams come together and decide how the product should look and work. At this stage, input comes from professionals such as product designers, engineers and, of course, manufacturers. The creative use of technologies such as CAD (Computer Aided Design) and CAE (Computer Aided Engineering) is important in the idea conception and design phase.
2. Prototyping phase
The next step is to give the concept a physical form to test its viability. Metal processing plays an important role at this stage in developing functional metal prototypes for testing and feedback. However, modern rapid prototyping technologies such as CNC machining are becoming increasingly popular in manufacturing at this stage due to their advantages such as speed and cost.
3. Metal processing process
Once the design team agrees on a prototype, usually after a few iterations, the machining phase begins. Engineers and technicians work out the final details, create manufacturing drawings, and produce the product in its final form. This phase can include a variety of machining processes depending on the project.
4. Post-processing
During metal processing, raw materials are shaped into the desired structural shape. However, some fine work may still be required, for which engineers use post-processing techniques such as metal surface finishing (painting, polishing, etc.).
Types of metallurgy processes
The above discussion shows that metallurgy is a very broad field. Although it is not possible to explain all the processes in detail, we will talk about some of the most common ones to give you a clear idea of what metallurgy is.
1. Editing
During machining, a body is given the desired shape by removing material from its surface. Material removal is generally achieved through the use of sharp-edged cutting tools that cut material in the form of chips or metal powder from the workpiece.
It is an important branch of metal processing and the manufacturing potential of a material is often evaluated by its machinability.
Machining processes generally include milling, turning, drilling, grinding, etc. Each of these methods is based on the same metal cutting principle, but they have fundamental differences. For example, milling is incredibly versatile and can perform a variety of operations on a part, while drilling is strictly a drilling technique.
Machining is popular in metal fabrication shops because of its versatility in manufacturing options and material compatibility; With the right tools and skills, any metal can be cut. Furthermore, the machining processes are characterized by high dimensional accuracy (up to +/- 0.001 mm) and smooth surface finish.
2. Extrusion
Extrusion is a machining process used to produce prismatic shapes such as pipes/tubes, window frames, grilles, casings, etc.
In this process, the raw material is pressed through an opening that gives the product the desired transverse shape. When passing through the opening, the metal plastically deforms (permanent deformation) and assumes the shape of the opening.
In general, there are two other types of extrusion processes. Hot extrusion is a hot working process in which metals are heated to a high temperature before passing through the extrusion die. This helps preserve the properties of the material, but it is an expensive process. Cold extrusion, on the other hand, is a room temperature process that results in higher strength and better surface finish, but cannot process complex cross-sections.
Overall, many metal products around us are made by extrusion. The process is popular because it offers high throughput and can process complex geometries. In addition, products with good surface quality are also produced.
3. Occupation
Metal casting is one of the oldest machining processes. The metal is heated to its melting point to transform it into liquid form. This molten metal is then poured into a mold (which is also a metal product) that has an internal cavity with a specific shape.
The molten metal then solidifies within the die in the hollow mold. Finally, an ejection mechanism ejects the part from the die, which is then ready for post-processing.
Smelting is undoubtedly a useful metallurgy process on our list. It is compatible with all metals, produces nearly true-to-form products that require almost no post-processing, and processes very complex geometries. Furthermore, the material properties of raw metals are often improved through heat treatment. In short, it is a productive and highly profitable manufacturing technique.
4. Cut
Cutting is perhaps the most intuitive concept in metallurgy. It is a simple application where processors use various cutting tools to cut material into specific shapes.
Traditional cutting techniques use sharp tools such as saws and scissors. In recent decades, techniques such as laser cutting, plasma cutting, waterjet cutting and oxyfuel cutting have gained popularity due to their greater efficiency, power and speed.
Cutting processes are extremely useful for sheet metal fabrication shops. This is because larger pieces are cut to custom sizes for further processing or to be marketed as standard size material.
5. Welding
Welding is one of the most common manufacturing processes in metal processing companies. It works on a simple principle: different metal parts are joined together by fusing them at a common intersection and allowing both to solidify again into a single piece. This creates a permanent connection between the two workpieces.
Welding is compatible with a wide range of materials and there are several types. Common types of metal welding processes include arc welding, tungsten inert gas welding (GMAW), resistance welding, friction stir welding, etc.
Each of these processes has a different mechanism for joining metals and a different set of parameters that govern the process. Some generate heat through the application of electrical current, others use frictional heat, while others use external heat sources. Joint quality and defects vary between these techniques, but they all have the common goal of creating durable bonds between two metal parts.
This list of machining types does not cover the entire metalworking industry. But we also need to keep this article short. With that in mind, below we've published a condensed list of other common metalworking processes that you can explore in your free time.
- Punch
- Stamp
- Forge
- design
- Education
- Punch
- Scissors
- To bend
- Laser engraving
Common metal material for manufacturing
The only limitation on the number of metals compatible with metallurgy is roughly equal to the number of the metals themselves. However, some metals are suitable for their desirable material properties, such as: B. a much more common high metallic strength.
Below you will find a table with the most common metals and alloys for metal processing.
| metal | Characteristics | Forms |
| Steel (mild steel, stainless steel, carbon steel) | • High resistance and hardness • High fatigue resistance • Ductile, malleable |
• Aerospace • Vehicle chassis, transmission • Heavy machinery |
| aluminum alloys | • High strength/weight ratio • Light • Corrosion resistant |
• Spaceships, planes • Motor vehicle engine blocks • Frame window |
| Copper alloys (brass, bronze) | • Electric conductivity • Thermal conductivity • Aesthetic appearance |
• Electrical wiring, motor winding • Musical instruments • Kitchen equipment |
| magnesium | • Strength/weight ratio • Thermal resistance • Corrosion resistance |
• Electrical appliances • High speed machines • Medical devices due to biocompatibility |
| High performance alloys (titanium, Inconel) | • High toughness, hardness, tensile strength • Light • Corrosion resistance |
• High performance components for aerospace engines • Oil and gas production • Naval industry |
Types of Bearings for Metal Processing
Metal products come in all shapes and sizes. However, they are usually made from one of the standard geometric shapes of raw materials found in every well-stocked metalworking shop.
Below is a list of common bearing types for metal processing:
- Bar (square, rectangle)
- Sticks
- Pipe
- sheet
- dishes
- Foundries
Metal processing in the 21st century
The technological boom of the fourth industrial revolution or Industry 4.0 has brought innovative changes to metal processing companies. Today, metal processing is more precise, efficient, economical and dynamic.
In this section, we explore some innovative developments that are redefining the manufacturing industry.
High-precision manufacturing with robots
The use of robots has improved the accuracy of metal processing processes many times over. Robotic arms are now a common technology in high-quality metal fabrication operations, performing important tasks such as machining, welding and assembly. Furthermore, they are not only more accurate but also much faster and more powerful than manual workers.
automation
The transition from manual to automated metal processing is not entirely new, but it is an ongoing development. The introduction of technologies such as computer numerical control (CNC) machines, which can produce complex parts without human intervention, is a prime example of the crucial role that automation will play in the future of this industry.
Companies that rely less on manual labor can focus on upskilling their workforce so they can move on to more meaningful and productive tasks, such as technology management. This improves product quality, profitability and workforce satisfaction.
Real-time monitoring
The use of sensors and data monitoring devices has become prominent in the metalworking industry. The use of sensors allows real-time monitoring of manufacturing processes and allows machines to correct themselves if they detect the slightest deviations from the desired behavior.
Furthermore, preventive maintenance is also a useful monitoring application because problems can be detected long before they lead to failure.
WayKens Metalworking Services
Our experienced engineers also provide the necessary assistance in project preparation, checking for any problems at this stage and correcting them before production begins. This helps make the production process simpler and more economical. Simply upload your CAD files today and receive DFM feedback and a quote.
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Metal processing is an essential part of our economy. Without them, we wouldn't be able to produce the components that keep our companies, our technology and our vehicles running. Furthermore, a variety of metal products are found in everyday life – from bolts and screws, cutlery, pipe fittings and automobile parts to hand tools. Therefore, the intricate details of precision metal processing influence many aspects of our lives.
Common questions
What is the purpose of metal processing?
Metal processing serves the important purpose of giving metal components the desired shape. All manufacturing processes involve manipulating raw materials to shape them into a useful final geometry. This also includes the assembly of finished parts, without which we would not have functional products.
What are the advantages of metal processing?
Metal processing is the driving force of technological and industrial development. It is an extremely versatile tool that includes numerous work steps. Each process has its specific advantages that allow us to add more variety to our metal products and produce complex parts economically and with high precision.
How much does metal processing cost?
Manufacturing costs depend on several factors. The biggest factor is the raw material and manufacturing process. Manufacturing costs also increase with manufacturing precision, surface quality requirements, geometric complexity, and assembly. To find out the specific cost of each project, you can request a quote from the manufacturer.
