Metal Manufacturing Processes

Contents page Page no

Tongue and slot…………………………………………….. 2
Spot welding………………………………………………… 10
Sheet bending………………………………………………. 19
Sand casting………………………………………………… 24
Roll forming…………………………………………………. 33
Punching and blanking…………………………………….. 41
Plasma cutting……………………………………………… 46
Pipe bending………………………………………………… 59
Metal injection moulding…………………………………… 67
Low pressure vacuum casting…………………………….. 73
Investment casting…………………………………………. 76
Dip brazing………………………………………………….. 82
Die casting………………………………………………….. 89
Deep drawn…………………………………………………. 99
Curling……………………………………………………….. 105
Copper tube bending………………………………………. 111
TONGUE AND SLOT
ASSEMBLY
 FUNCTION
Tongue and slot assembly is a way in which we
Tongue
join metal pieces together similar to that of
wood joints.
Slot

It consists of a tongue/tab and slot.

It can be joint either by friction fit, bent to

fasten or welded once in place.
 MATERIALS Basically any metal that
can be laser cut , plasma
cut or cut via hack saw
• Stainless steel
• Mild steel
• Titanium
• Copper
• Aluminum
• Carbon steel
It can be trick to make because you need
to make sure your dimensions are right

1) It all starts with the design.

2) Then you cut it out, through laser,

plasma or hacksaw but the hack saw is
not advisable.

3) You then fit the tab/tongue into the slots

and either weld it , or bend it to fasten it.
ADVANTAGES DISADVANTAGES
• No fasteners like bolts and nuts • not very appealing at times
needed
• Can be difficult to design
• Easy assembly
• Cant be bent fastened if material
• Cheap process is too thick

• Can be used on a lot of different • CAD is needed

metals
• If it is not welded, its fasten is not
• Can make small and large objects strong (can be wobbly)
PRODUCTS
Spot welding
Where it is used
The most common application of spot welding is in
the automobile manufacturing industry
Function of the proses
The function of spot welding is to
join two pieces of metal together it
leaves behind a spot as a mark
Materials that can be used

• Steel
• Copper electrodes
• Carbon steel
• Carbon
• Alloy metals
What is spot welding
Resistance spot welding is a process in which
contacting metal surfaces are joined by the heat
obtained from resistance to electric current.
How it works
Work‐pieces are held together under pressure
exerted by electrodes. Typically the sheets are in
the 0.5 to 3 mm thickness range. The process uses
two shaped copper alloy electrodes to
concentrate welding current into a small "spot"
and to simultaneously clamp the sheets together.
Forcing a large current through the spot will melt
the metal and form the weld
Prose and cons
Prose
• It is quick
• It is cheap
• And more energy efficient
• Easley understood

Cons
• It can be weak
• It needs a lot of space
• It can look ugly
• It is lastly dangerous if not handled
with care
Finishes that can be applied
The surface can be powder coated but it
might not hide all of the defects so normal
they will try to hide the spot weld and if that
is not possible the a coating of body filler and
some sanding will fill it up and make it ready
for coating
 Sheet bending
Sheet bending in a manufacturing process that produces a v‐shape ,u‐
shape or a
Chanel shape along a straight axis in ductile materials normally sheet
metal.
Sheet bending
Product identified: Chair made from sheet
Bending.

Function: To be sat on.

Material: The chair is made from 1,2 mm

16 gauge CR4 mild steel sheet

Finish
Corroded sheet with a layer of clear gloss.
Manufacturing process

The net of the chair is firstly cut on the laser cutting machine and then the chair is bent by
Hand to form the overall shape which is secured by a double sided VHB foam tape. Then the
Chair is left outside so that it can corrode which gives it the rusted finish.
Advantages
Sheet bending is a cost effective process when used for low to medium quantities.
Thin sheets are much more easier to bend.
Sheet bending can be used to achieve complex bends.
It can make a product look more appealing.

Disadvantage
Thick sheet is much more harder to bend.
The more complex the bend the more expensive it will be.
Small bends are more harder to achieve than large bends
Sand casting is a most widely used process that utilizes
expandable sand moulds to from complex parts that
can be made of almost an alloy. It has a low
production rate, because of the sand mould that
needs to be destroyed to remove the casted product.
• Produce variety of metal components with complex
shapes
• Products include; Gears, pulleys, crankshafts and
engine blocks, cylinder heads and transmission cases
(automotive components)
Engine Block
An engine block is an essential part of the
structure of an internal combustion engine. It
contains the crankcase and all its parts, including
gaskets, valves and seals. The engine block
contains cylindrically bored holes for the pistons
and ways to attach other components such as the
cylinder head. It is a solid, sturdy and heavy piece
of equipment usually made of cast iron, or
sometimes, aluminium alloy.
This engine block is made up of aluminum alloys. Its main
advantage is because it is low weight, making the weight of
the engine lighter.
• But it’s very expensive as compared to engine blocks casted
with grey iron.
• Two main aluminum alloys namely; 319 and A356.
• Aluminum has good machinable properties compared to grey
cast iron.
 Comparison of the two Aluminum
alloys
Alloy 319 Alloy A356
Contains 91.5% Aluminum, 6.5% silicon, Contains 93.3% Aluminum, 7.5% silicon,
4% Copper, nickel 0.25%, 0,5% 0.45% magnesium, 0.2% titanium, 0.2%
manganese and 1% of iron and zinc. iron and 0.1% of zinc.
Has good casting features Good casting features
Corrosion resistance Corrosion resistance
Good thermal conductivity Also a good thermal conductor
Under heat treatment, it generates high Under heat treatment, generates higher
strength and rigidity for the engine block. strength than 319, but has lower modulus
of elasticity.
 Pattern Making‐ the first step taken to produce the shape of
the final product.
 Cores Making – forms which are inserted into the mould to
create interior contours of the casting. Made of a sand
mixture (sand + water + organic adhesives (binders))
 Moulding – contains a 2 piece frame called a flask. Upper
portion is called a cope and lower portion a drag. Moulding
sand is packed into a flask around the pattern.
 Melting & Pouring ‐ Melting is the preparation of the metal
for casting, and its conversion from a solid to a liquid state in a
furnace. It is then transferred in a ladle to the molding area of
the foundry where it is poured into the molds. After the metal
has solidified, the molds are vibrated to remove the sand from
the casting, a process called shakeout.
 Cleaning ‐ Cleaning generally refers to the removal of all
materials that are not part of the finished casting. Rough
cleaning is the removal of the gating systems from the casting.
Initial finishing removes any residual mold or core sand that
remains on the piece after it is free of the mold. Trimming
removes any superfluous metal.
Advantages Disadvantages
Produces large and complex Poor material strength
parts

Many material options to choose High porosity possible

from

Low tooling and equipment costs Poor surface finish and tolerance

Recycling of scraps Low production rate

Short lead time High labour costs
Roll forming – Curtain rails
Specified product -Metal curtain rails
Hospital curtain rails Shower curtain rails Window curtain rails
The function of the product?
• To provide an easy and ergonomic way
to hang a curtain from.
• The curtain is easily opened and closed
because of the roller design used.
• The rail itself can be made aesthetically pleasing.
• The curtain rails is stronger then extrusion rails
because they have been cold-hardened.
The material it is made from?
• Ferrous metals – has iron in metal.
Steel, stainless steel and galvanized sheet steel.

• Non-ferrous metals – has no iron in metal.

Aluminium, brass, copper, lead and composites.

All of these materials have to be soft metals because of the process that is used, the finished
Product will get its toughness from the cold forming that will harden the material.
The material also gets rigidity from the bends that is put into the product to make it stronger.
The manufacturing process?
• It typically begins with a large coil of sheet metal, between 25 mm to 510 mm,
that is supported on an uncoiler.
• The strip is fed through an entry guide to properly align the material as it
passes through the rolls, each set of rolls forming a bend until the material
reaches its desired shape.
• The sheet or strip is deformed along a linear axis in a room
temperature environment.
• Each stand in the roll forming process has a specific job in the
fabrication of the piece, and every stage involves minor changes in
the configuration of the metal. The size of the stands used depends
on the metal’s type, thickness, and formability.
• Side rolls and cluster rolls may also be used to provide greater precision and
flexibility and to limit stresses on the material.
• The shaped strips can be cut to length ahead of a roll forming mill, between
mills, or at the end of the roll forming line.
The advantages of using this process?
• Roll-formed sections may have advantages over extrusions of a similar shapes.
• Roll formed parts may be much lighter, with thinner walls possible than in the extrusion process,
and stronger, having been work hardened in a cold state.
• Parts can be made having a finish or already painted.
• In addition, the roll forming process is more rapid and takes less energy than extrusion.

The disadvantages of using this process?

• The production rate depends greatly on the material thickness and the bend radius that
is used.
• The set up time must be taken into consideration, because this will take time.
• The equipment and tooling costs is high, because of the amount of rollers used.
• The process requires manual load and unloading of the material and product.
The finish applied to the finished product?
• Since different finishes vary in durability and resistance, you should make your
decision based on how often you’ll be cleaning the metal surface after it’s
painted.
• If the surface does not need frequent or regular washing, you can use the flat
or matte finish, but if the surface needs frequent cleaning, you should go for
a glossier finish.

• Any type of metal finishing can be applied to the surface, but the most
common finish is spray painting these products. It is used with a
spray gun to deliver the required surface texture.

Thank you.
Punching and
Blanking
Blanking and piercing are shearing processes in which a punch
and die are used to modify webs. The tooling and processes are
the same between the two, only the terminology is different:
in blanking the punched out piece is used and called a blank; in
piercing the punched out piece is scrap
 Pros Cons
• excellent dimensional • Slightly slower
control • high equipment costs
• excellent part
flatness is retained;
• Superior finished
• More economical for
large production
Applications
PLASMA
CUTTING
WHAT IS PLAMA
CUTTING?
Plasma cutting is a process that cuts through
electrically conductive materials by means of an
accelerated jet of hot plasma.
PROCESS
The basic plasma cutting process involves creating an electrical channel of
superheated, electrically ionized gas or plasma from the plasma cutter itself, through
the work piece to be cut, thus forming a completed electric circuit back to the plasma
cutter via a grounding clamp.
This is accomplished by a compressed gas (oxygen, air, inert and others depending on
material being cut) which is blown through a focused nozzle at high speed toward the
work piece. An electrical arc is then formed within the gas, between an electrode near or
integrated into the gas nozzle and the work piece itself. The electrical arc ionizes some
of the gas, thereby creating an electrically conductive channel of plasma.
MATERIALS
Plasma cutting is limited to conductive materials only:
• Primarily:
1. Mild steel
2. Stainless steel
3. Aluminium
• Also:
1. Copper
2. Brass
3. Titanium
4. Cast iron
5. Etc.
METAL SURFACE
FINISHES
A list of possible surface finish for plasma cutted products:
• Mechanical finishes
• Cladding
• Dipping
• Arc spraying
• Ion plating
• Immersion plating
• Electroplating/electrolessplating
• Anodizing
• Powdercoating
• Vitreous enameling
• Oxide
• Etc.
PROS AND CONS
Advantages disadvantages
It is very fast Hard edges
Extremely precise The dross(marks left on workpiece
after cutting)
Versatile(can pierce, cut and Extremely high costs due to large
bevel)over 15cm thickness range in quality of cutters, in order
for a cutter to be truly efficient it will
have to be very expensive.
High cut quality
Very easy to operate
Very safe
DESIGN
CONSIDERATIONS
Generally plasma cutting is used to cut 2D shapes from sheet metal ,the
designs are generally not too complex ,here are some design
considerations:

Edges can be rough, especially for thicker material and more so with aluminum than steel.

The cut edge will have an oxide layer.(the dross)

The angle of the edge can deviate from 90 degrees typically by 10 to 20 deg.

Edges may have pits at some points along the edge (with depth typically up to material
thickness).

Some warping can occur on intricate parts.

APPLICATIONS
Example applications include:
• Metal Brackets
• Motorcycle parts
• Auto parts
• Parts for heavy machinery
• Aircraft components
• Signs
• Panels
• Material handling equipment
PLASMA CUT GEARS
Gear:

A toothed machine part, such as a wheel or cylinder,

that meshes with another toothed part to transmit
motion or to change speed or direction.
MATERIALS
Gears and sprockets are made from a vast array of
materials ranging from polymers to cast iron,
however for plasma cutting the most commonly
used materials to manufacture gears are:

• Cast iron
• Carbonized steel
• Hardened iron
APPLICATIONS AND
FINISHES
Gears can increase or decrease the speed of rotation and can easily
be used to reverse the direction of rotation of numerous mechanical
functions

Generally gears made viaplasma

cutting wil not require any surface
finishes as they will be under
tremendous amounts of stress and
rely on the physical properties of
the material itself.
VIDEO
PIPE BENDING
CAR EXHAUST
EXHUAST PIPE IS DESIGNED TO CARRY TOXIC AND
NOXIOUS GASES AWAY FROM THE USER’S OF THE
MACHINE
STAINLESS STEEL AND ALUMINIZED STEEL
• APPEARANCE
STAINLESS STEEL HAS THE MOST DEFINED LOOK THAN THE ALUMINIZED STEEL .
• CORROSION RESISTANCE
STAINLESS STEEL IS THE WAY TO GO WHEN IT COMES FROM CORROSION
RESISTANCE .
LIVING IN DRY CLIMATES THAT STAYS FAIRLY WARM IN WINTER THEN
ALUMINIZED STEEL IS GOOD FOR THE CAR EXHAUST.
STAINLESS STEEL HAS THE HIGHEST RESISTANCE, AN EXHAUST SYSTEM
MADE FROM 304-GRADE STAINLESS STEEL LAST FOR 20 YEARS.
• DENSITY
STAINLESS STEEL IS LESS DENSER THAN ALUMINIUM STEEL

Aluminized exhaust Stainless steel exhaust

ADVANTAGES OF PIPE BENDING
• 45 OR 90 DEGREES ELBOWS ARE PRODUCED EASILY IN
PIPE BENDING
• PIPE BENDING PRODUCE BETTER FLOW OF
CHARACTERISTICS BECAUSE OF INTERNAL SMOOTH
SURFACES.
• THE INTERNAL DIAMETERS OF PIPE BENDING AND
FITTING ARE NEARLY THE SAME
• REDUCE OVERALL INSTALLED PARTS
PIPE BENDING
• ITS MANUFACTURING PROCESS THAT PRODUCES A V-
SHAPED, U SHAPED OR CHANNEL SHAPED ALONG A
STRAIGHT AXIS

COMMONLY USED EQUIPMENTS

• BOX AND PAN BRAKES
• BRAKE PRESSES
MANUFACTURING PROCESS OF
CAR EXHAUST
CERAMIC COATING
THIS IS A SPRAY ON FINISH THAT’S INFLUSED WITH HEAT INSULATING CERAMICS
AND THISE EXHAUST PARTS ARE COATED AT THE FACTORY.

PROS CONS
PREVENTS RUST AND COATING MAY DULL IN
CORRISION OF THE CERAMIC APPERIANCE OVER TIME
COATED PARTS
LOOKS GREAT CERAMIC COATED EXHAUST
PARTS ARE MORE EXPENSIVE
IMPROVES THE LAMINAR
FLOW OF EXHAUST GASSES
LOW PRESSURE VACUUM
CASTING
Key words; pair of dies and vacuum.
Vacuum casting is a special process where the casting
product is produced using a pair of dies containing
vacuum in it.

Vacuum casting nickel base alloy

used for ultra light aircraft turbine
wheel.
MANUFACTURING
PROCESS
 ADVANTAGES
[Link] surface quality is insured.
[Link] strength is increased.
[Link], thinner, more complex casting are made
possible.
4. Less casting pressure is required.

DISATVANTAGES
[Link] heated casting material

IDEAL APLICATIONS
[Link] of plastic prototype parts for a range of
industries, including consumer goods.
[Link] and medical devices.
[Link] and aerospace parts.

(FINISH)
INVESTMENT CASTING

Small boat propellers

Function of the
part
• A propeller is a type of fan that transmits power by converting
rotational motion into thrust. A pressure difference is produced
between the forward and rear surfaces of the airfoil‐shaped blade,
and a fluid (such as air or water) is accelerated behind the blade
 Material it is made from and
the manufacturing process

Investment casting, also called lost wax casting, is a process in which a

pattern, also known as a master or master pattern, traditionally made of
wax, is COVERED WITH A CERAMIC SLURRY (being the outer finish).
The wax pattern is normally produced with injection molding. The wax is
melted out of the ceramic shell, which is pre‐heated before MOLTEN
METAL is poured into it. After the metal cools, the ceramic is vibrated and
blasted from the metal casting.
Investment casting generally provides higher accuracy (+/‐ 0.005 inch
(0.127 mm) tolerance is normal) and surface finish (typically 125 micron
RMS (3.125 micron Ra)) than other casting processes. It is generally used
in applications that have relatively low production quantities and changing
product designs.
 Where this process is used…
• Investment casting is used in the aerospace and power
generation industries to produce turbine blades with
complex shapes or cooling systems.
DIP BRAZING
 Dip brazing
Advantages
Dip brazing process is a process that allows simultaneous  It provides leak-tight EMI and RF shielded Joint
joining of multiple joints with different material thicknesses. The  Reduces coupling of radio waves,
resultant joints are leak-tight and EMI shielded. There are minor electromagnetic fields and electrostatic fields.
distortion results after the parts are uniformly heated.  No restriction on wall thicknesses
 conductivity is clearly better than that achieved
EMI- is the practice of surrounding electronics and cables with with an adhesive bonded or mechanically
conductive or magnetic materials to guard against incoming or attached assembly.
outgoing emissions of electromagnetic frequencies (EMF)  Less distortion better than that of a welded part.
 It’s cost effective
Disadvantages
 The molten flux releases
dangerous fumes which can
cause occupational asthma
 PRODUCT
WHAT IS THE FUNCTION OF THE PRODUCT
This is an aluminium chassis that was manufactured or
machined using precision CNC milling. A chassis is used as the
supporting structure for a military application or to construct
an amplifier.

Material
6061-T6 Aluminium
Thickness: 12 mm The c

Finish applied to product

Chromate Conversion Coating
Priming
Painting
DIE CASTING
PROCESS
Die casting is a manufacturing process that can produce geometrically complex metal
parts through the use of reusable molds, called dies. The die casting process involves
the use of a furnace, metal, die casting machine, and die. The metal, typically a non-
ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into
the dies in the die casting machine

5 STAGES – 2 sec to 1 Min per cycle

• Clamping
• Injection
• Cooling
• Ejection
• Trimming
DIE CAST VIDEO
TYPES OF DIE CASTING
Hot Chamber Die Casting
Used for zinc, some magnesium alloys, and other low-melting alloys that do not readily
attack and erode metal pots, cylinders, and plungers

Cold Chamber Die Casting

Better suited for metals with high melting points such as aluminum, metal is liquefied
and then ladled into a cold chamber where a hydraulically operated plunger pushes
the metal into the die

Injected Metal Assembly

An innovative, one-step manufacturing solution we’ve developed and refined over the
past 50 years, IMA outperforms most adhesives used for small component joining and
assembly production and reduces manufacturing costs
USES

Engine components, pump components,

appliance housing and designer products

MATERIALS
Metals
Aluminum
Lead
Magnesium
Tin
Zinc
ADVANTAGES DISADVANTAGES
Can produce large parts
Trimming is required
Can form complex shapes
High tooling and equipment cost
High strength parts
Limited die life
Very good surface finish and accuracy
Long lead time
High production rate
Low labor cost
Scrap can be recycled
SPECIFIC PRODUCT

KITCHEN FAUCET

Die cast parts are found in many places around the home. The
polished, plated zinc die casting in this kitchen faucet illustrates one
of the many finishes possible with die casting
EXAMPLES

ZINC

ALUMINIUM
FINISHES
■ Abrasive Blasting
■ Sandblasting
■ Burnishing
■ Chemical-mechanical planarization (CMP)
■ Electropolishing
■ Grinding
■ Industrial etching
■ Linishing
■ Tumbling
■ Vibratory finishing
LA FIN.
Press work/Deep drawn Parts
How a saucepan is made:
 Two types of press work

Blanking Piercing
Material Identification
Stainless Steel Copper
Pros: Pros:
• Non-reactive • Excellent thermal conductivity
• Heavy (cooks food evenly).
• Durable
• Dishwasher save Cons:
• Inexpensive for basic models • Reactive with alkaline or acidic
foods (creates a metallic taste).
Cons:
• Copper requires regular polishing
• Poor heat transfer and distribution.
and maintenance.
• Expensive.
Solution Added inner core made of
Solution Look for copper pots
copper or aluminum.
with a stainless steel or tin lining.
Aluminum Cast Iron
Pros: Pros:
• Excellent thermal conductivity • Durable
• Light weight • Inexpensive
• Affordable • Naturally non-stick
• Distributes heat evenly and
Cons: retains heat well.
• Raw aluminum is highly reactive to
alkaline or acidic foods. Cons:
• Very soft and tends to warp in high • Reactive to acidic foods.
heat. • Heavy
• Health concerns for long term use. • Takes long to heat up
• More effort to clean and
Anodized aluminum is a better option maintain.
and is a excellent heat conductor.
Another option is to use
enamelled cast iron which is a
non-reactive metal.
The Manufacturing Process

[Link]
 Pros and Cons of Manufacturing Process
Presswork/Deep Drawn Parts

Pros: Cons:
• Process is advantageous for • Process not valued in small
use in products requiring: quantities.
 seamless elements. • Very high start up costs.
 rapid cycle times. • Requires lots of experience
 complicated axi-symmetric and expertise.
geometries. • Radial drawing stress and
• Minimal labour required for tangential compressive stress
process. are common concerns.
• Process hardens the material.
• The process can be automated.
• Waste material can be recycled
Curling
Manufacturing
What is curling?
• Metal Forming process.
• Forms the edges of a metal part into a hollow ring.
 How does it work
Punch PUNCH PRESS
Knuckle
Tool
tool
Leading
curve

Curl

Stop
curve
Video: Curling of Hinges
Advantages and Limitations

• Curled edges aren’t sharp • Has to curl outwards

• Attractive • Each die is made for a specific
sheet thickness
• Increase the structural strength of
the curled edge by a factor of 4 • High wear process
• Allows for unique functions
References
• Amazon (n.d.). A hairdryer mouthpiece with a curled edge. [image] Available at: [Link]
[Link]/images/I/31uKxCl1QkL._SY355_.jpg [Accessed 22 May 2017].

• An image depicting a curled edge. (2016). [image] Available at: [Link]

[Accessed 22 May 2017].

• An image depicting the curling process. (n.d.). [image] Available at: [Link] [Accessed 22 May 2017].

• Hinges, H. and Heston, T. (n.d.). Hinging Success—on Hinges. [online] [Link]. Available at:
[Link] [Accessed 22 May 2017].

• Revolvy, L. (n.d.). "Curling (metalworking)" on [Link]. [online] [Link]. Available at:

[Link] [Accessed 22 May 2017].

• YouTube. (2012). Forming Hinges in the Punch Press Saves Time, Increases Accuracy. [online] Available at:
[Link] [Accessed 22 May 2017].
COPPER TUBE BENDING
Used in plumbing pipes, product chosen; Antique Taps. PRODUCT
The bending helps direct water in the direction you want.
Used in piping systems to deliver clean and safe domestic drinking water. FUNCTION
Copper – Type M pipe – Has thin walls compared to type L and type K.
Used for general plumbing and heating, available in soft or hard temper. MATERIAL
Bending Techniques
• Sand bending to prevent kinking MANUFACTURING
• Bending using a spring
• Pipe benders PROCESS
Spring Bending
Attach a piece of chord to the spring
And insert it in the copper pipe. Spring must
span evenly in the area you want it to bend.
Once spring is in place, gently bend the pipe
by pulling it around your knee. Remove
spring by pulling rod

Sand Bending
Fill copper pipe with sand, after it has
cooled down and then bend the pipe. This
will not allow kinks on the copper pipe

Pipe bender
Used if pipe is more than 15mm in diameter.
Place copper pipe in correct channel and fit
the ribbed block on the external edge, use
the lever to put pressure on the block and
continue levering till the pipe bends.

STEP BY STEP
Cheaper to bend a pipe instead of using elbows
No joints that could leak
Increased flow through a sweeping bend more than what you would with an elbow
Easy to form
ADVANTAGES
Bending permits savings in installation time, material and overall costs
Failure to support your copper pipes during the process of bending will cause a collapse and pleat

DISADVANTAGES
Different bender is needed for each pipe size when using a pipe bender – can be expensive
Time consuming if sand bending
You need to be quick and skilled as this can get tricky
Fastest and most reliable way is to first apply special reactive paint
Aged using various solutions of acids and salts
Clean using lemon to give it a bright finish
FINISH
Thank You. FIN.