Metallurgy (Mech-242)

Lecture Notes
Chapter 12: Industrial Shaping of Metals

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 1. Hot Working Processes:
i. Hot Rolling
Process where metal is passed between rollers at a high temperature which is above the
recrystallization temperature of the metal. It is used to reduce the thickness or change the
shape of the metal. It is used to produce sheet metal, plates, beams etc.

a. Two High Rolling: A simple rolling process metal. Center rolls which are smaller in
where the metal is passed between two size are in contact with metal, while bigger
rolls rotating in opposite directions to rolls are known as support or backup rolls.
reduce its thickness or change its shape. d. Cluster Rolling: Similar to four high rolling,
b. Three High Rolling: Similar to two high it contains two smaller rolls for rolling
rolling, but with an additional roll placed process and four big rolls are present for
between the top and bottom rolls to allow support.
additional reduction in thickness by e. Skew Rolling: A rolling process where the
wrapping the material around the center rolls are tilted or skewed relative to each
mill. other to produce finished products like
c. Four High Rolling: Involves using four rolls balls for ball bearings.
to shape or reduce the thickness of the

ii. Hot Forging

a. Forging: The process of shaping metal by c. Impression Forging (Closed Die Forging):
applying compressive forces using a Metal is forced into a die cavity to achieve
hammer or press. the desired shape, resulting in highly
b. Drop Forging (Open Die Forging): Metal is precise parts.
shaped by repeated blows from a falling d. Upset Forging (Heading): Metal is
hammer or die, typically used for large deformed by compressive forces applied
parts. perpendicular to the length of the
workpiece, commonly used for forming
heads on bolts.

iii. Hot Pressing

It involves applying gradual pressure on a shaped die to deform a piece of metal into a specific
shape above recrystallization temperature.
iv. Hot Extrusion
Process where metal is heated until it is very soft, then it is forced through a die to create a
long, continuous shape. It's like squeezing toothpaste out of a tube, but with metal instead of
toothpaste. This process is used to make things like rods, tubes etc.

a. Direct Extrusion: Metal is forced through b. Indirect Extrusion: The die is stationary
a die to produce long continuous shapes while the workpiece is forced through it. It
like rods, tubes etc. is used for more complex shapes.

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 2. Cold Working Processes:
i. Cold Rolling:
Process where metal is passed between rollers at a low temperature which is less than
recrystallization temperature of the metal, and is usually room temperature. It is used to
reduce the thickness or change the shape of the metal.

a. Thread Rolling/Thread Forming: Threads are formed on a cylindrical workpiece by pressing it

between two dies with thread patterns.

ii. Cold Forging:

Metal is shaped or formed at room temperature or slightly raised temperatures using
compressive forces, normally used for producing high-strength and precise parts.
iii. Cold Pressing:
It involves applying gradual pressure on a shaped die to deform a piece of metal into a specific
shape at room temperature.
iv. Cold Extrusion:
Metal is forced through a die at room temperature to produce parts with complex shapes and
precise dimensions, often used for producing automotive components and fasteners.
v. Drawing:
Metal is pulled through a die to reduce its cross-sectional area and increase its length,
commonly used for producing wires, tubes, and bars.
vi. Deep Drawing:
Sheet metal blank is formed into a hollow shape, such as a cup or container, using dies and
punches.
vii. Coining:
Metal is stamped or pressed between two dies to create accurate features or shapes on the
surface, often used for making coins or creating decoration pieces.
viii. Spinning:
A sheet metal blank is formed into a hollow shape by rotating it on a spinning lathe while
pressing it against a mandrel or form tool, commonly used for producing cylindrical or conical
parts like pots, pans, and lampshades.

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 Production of Pipes
1. Forming Method 2. Casting Method
i. Butt Welded Pipe i. Sand Casting
ii. Lap Welded Pipe ii. Centrifugal Casting
iii. Piercing for Seamless Pipe

1. Forming Method
i. Butt Welded Pipe
They are manufactured by forming flat plates into cylindrical shapes and then welding the seam
using a butt welding process. This method is commonly used for producing pipes of larger
diameters and thicker walls.
ii. Lap Welded Pipe
Lap welded pipes are created by overlapping the edges of two pieces of metal and welding
them together along the seam. This method is typically used for producing pipes with smaller
diameters and thinner walls.
iii. Piercing for Seamless Pipe
Seamless pipes are produced by piercing a solid billet to create a hollow shell. The billet is
heated and pierced with a mandrel to form a seamless tube. This method is used for high-
quality pipes where a seamless construction is required, often for applications where high
pressure or corrosive environments are present.

2. Casting Method
i. Sand Casting
Sand casting involves creating a mold from a pattern made of sand and then pouring molten
metal into the mold cavity. Once the metal has solidified, the sand mold is broken away to
reveal the cast pipe. Sand casting is suitable for producing pipes with complex shapes and is
often used for smaller-scale production runs.
ii. Centrifugal Casting
Centrifugal casting involves pouring molten metal into a rotating mold. Centrifugal force
distributes the molten metal evenly along the inner surface of the mold, resulting in a dense,
uniform pipe with few impurities. This method is particularly suited for producing pipes with a
uniform wall thickness and is commonly used for manufacturing pipes made of materials like
cast iron or bronze.

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 Metallurgy (Mech-242)
Lecture Notes
Chapter 13: Die Casting
Die Casting:
It involves injecting molten metal into a steel mold, called a die, under high pressure. The metal
solidifies quickly, taking the shape of the die cavity, and the finished part is ejected from the
die. It is used to produce metal parts with high precision and surface finish.
Die (Permanent and Moveable):
 Permanent Die: A permanent die, also known as a stationary die, is a part of the die
casting machine that remains fixed in place during the casting process. It forms one half
of the mold cavity and is typically made of high-strength steel to withstand the high
pressures and temperatures involved.
 Moveable Die: The moveable die, also called the ejector die, is the other half of the
mold cavity that moves to allow for the ejection of the finished part from the die casting
machine after solidification. It also helps in opening and closing the mold during the
casting process.
Die Material:
The die material is usually made of tool steel or other high-strength alloys capable of
withstanding high temperatures and pressures. These materials are chosen for their durability,
thermal conductivity, and resistance to wear and deformation.
Characteristics of Die Material:
 Hardness: Die materials need to be hard to withstand the repeated impacts of injecting
molten metal at high pressure.
 Heat Resistance: They must be able to withstand the high temperatures generated
during the casting process without deforming or losing their shape.
 Wear Resistance: The die material should be resistant to wear and erosion caused by
the molten metal flowing through the mold cavity.
 Thermal Conductivity: Good thermal conductivity helps in dissipating heat quickly,
allowing for faster cooling and solidification of the cast part.
Methods of Die Casting:
 Gravity Die Casting: Gravity die casting relies on gravity to fill the mold cavity with
molten metal. It is suitable for producing parts with simple shapes and is often used for
casting aluminum and zinc alloys.
 Pressure Die Casting: Pressure die casting involves injecting molten metal into the die
cavity under high pressure. It allows for the production of parts with complex shapes
and tight tolerances.

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Further Types of Pressure Die Casting:
 Hot Chamber Die Casting: In hot chamber die casting, the injection mechanism is
immersed in the molten metal. It is used for metals with low melting points like zinc and
magnesium.
 Cold Chamber Die Casting: Cold chamber die casting is used for metals with high
melting points such as aluminum and brass. The molten metal is ladled into the injection
chamber before being injected into the die cavity.
Further Types of Hot Chamber Die Casting:
 Plunger Die Casting Machine: In plunger die casting, a hydraulic-powered plunger forces
the molten metal into the die cavity.
 Air Injection Die Casting Machine: Air injection die casting uses compressed air to inject
the molten metal into the die cavity.
Advantages of Die Casting:
 High precision and dimensional accuracy.
 Smooth surface finish requiring little or no additional machining.
 Rapid production rates.
 Ability to produce complex shapes with thin walls.
Disadvantages/Limitations of Die Casting:
 High initial tooling costs.
 Limited to metals with relatively low melting points (for hot chamber die casting).
 Not suitable for very large parts.
 Limited material choices compared to other casting methods.
Applications of Die Casting:
 Automotive industry for producing engine components, transmission parts, and body
panels.
 Electronics industry for manufacturing casings and connectors.
 Aerospace industry for producing lightweight components with high strength-to-weight
ratios.
 Household appliances for making parts like handles and knobs.