Rolling (metalworking)In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is known as hot rolling.
Metal castingIn metalworking and jewelry making, casting is a process in which a liquid metal is delivered into a mold (usually by a crucible) that contains a negative impression (i.e., a three-dimensional negative image) of the intended shape. The metal is poured into the mold through a hollow channel called a sprue. The metal and mold are then cooled, and the metal part (the casting) is extracted. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.
Die castingDie casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Aluminium alloyAn aluminium alloy (or aluminum alloy; see spelling differences) is an alloy in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, tin, nickel and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminium is used for wrought products, for example rolled plate, foils and extrusions.
Sand castingSand casting, also known as sand molded casting, is a metal casting process characterized by using sand known as casting sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. In 2003, over 60% of all metal castings were produced via sand casting. Molds made of sand are relatively cheap, and sufficiently refractory even for steel foundry use.
CastingCasting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various time setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay.
Investment castingInvestment casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques. The term "lost-wax casting" can also refer to modern investment casting processes. Investment casting has been used in various forms for the last 5,000 years. In its earliest forms, beeswax was used to form patterns necessary for the casting process. Today, more advanced waxes, refractory materials and specialist alloys are typically used for making patterns.
Casting defectA casting defect is an undesired irregularity in a metal casting process. Some defects can be tolerated while others can be repaired, otherwise they must be eliminated. They are broken down into five main categories: gas porosity, shrinkage defects, mould material defects, pouring metal defects, and metallurgical defects. The terms "defect" and "" refer to two specific and separate things in castings. Defects are defined as conditions in a casting that must be corrected or removed, or the casting must be rejected.
IngotAn ingot is a piece of relatively pure material, usually metal, that is cast into a shape suitable for further processing. In steelmaking, it is the first step among semi-finished casting products. Ingots usually require a second procedure of shaping, such as cold/hot working, cutting, or milling to produce a useful final product. Non-metallic and semiconductor materials prepared in bulk form may also be referred to as ingots, particularly when cast by mold based methods.
ElectromagnetismIn physics, electromagnetism is an interaction that occurs between particles with electric charge via electromagnetic fields. The electromagnetic force is one of the four fundamental forces of nature. It is the dominant force in the interactions of atoms and molecules. Electromagnetism can be thought of as a combination of electrostatics and magnetism, two distinct but closely intertwined phenomena.
Electromagnetic fieldAn electromagnetic field (also EM field or EMF) is a classical (i.e. non-quantum) field produced by moving electric charges. It is the field described by classical electrodynamics (a classical field theory) and is the classical counterpart to the quantized electromagnetic field tensor in quantum electrodynamics (a quantum field theory). The electromagnetic field propagates at the speed of light (in fact, this field can be identified as light) and interacts with charges and currents.
SteelSteel is an alloy of iron and carbon with improved strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels, which are resistant to corrosion and oxidation, typically need an additional 11% chromium. Because of its high tensile strength and low cost, steel is used in buildings, infrastructure, tools, ships, trains, cars, bicycles, machines, electrical appliances, furniture, and weapons. Iron is the base metal of steel.
Non-ferrous metalIn metallurgy, non-ferrous metals are metals or alloys that do not contain iron (allotropes of iron, ferrite, and so on) in appreciable amounts. Generally more costly than ferrous metals, non-ferrous metals are used because of desirable properties such as low weight (e.g. aluminium), higher conductivity (e.g. copper), non-magnetic properties or resistance to corrosion (e.g. zinc). Some non-ferrous materials are also used in the iron and steel industries.
ViscoplasticityViscoplasticity is a theory in continuum mechanics that describes the rate-dependent inelastic behavior of solids. Rate-dependence in this context means that the deformation of the material depends on the rate at which loads are applied. The inelastic behavior that is the subject of viscoplasticity is plastic deformation which means that the material undergoes unrecoverable deformations when a load level is reached. Rate-dependent plasticity is important for transient plasticity calculations.
Electromagnetic radiationIn physics, electromagnetic radiation (EMR) consists of waves of the electromagnetic (EM) field, which propagate through space and carry momentum and electromagnetic radiant energy. Types of EMR include radio waves, microwaves, infrared, (visible) light, ultraviolet, X-rays, and gamma rays, all of which are part of the electromagnetic spectrum. Classically, electromagnetic radiation consists of electromagnetic waves, which are synchronized oscillations of electric and magnetic fields.
Electromagnetic pulseAn electromagnetic pulse (EMP), also referred to as a transient electromagnetic disturbance (TED), is a brief burst of electromagnetic energy. The origin of an EMP can be natural or artificial, and can occur as an electromagnetic field, as an electric field, as a magnetic field, or as a conducted electric current. The electromagnetic interference caused by an EMP can disrupt communications and damage electronic equipment. An EMP such as a lightning strike can physically damage objects such as buildings and aircraft.
Computer simulationComputer simulation is the process of mathematical modelling, performed on a computer, which is designed to predict the behaviour of, or the outcome of, a real-world or physical system. The reliability of some mathematical models can be determined by comparing their results to the real-world outcomes they aim to predict. Computer simulations have become a useful tool for the mathematical modeling of many natural systems in physics (computational physics), astrophysics, climatology, chemistry, biology and manufacturing, as well as human systems in economics, psychology, social science, health care and engineering.
Electromagnetic tensorIn electromagnetism, the electromagnetic tensor or electromagnetic field tensor (sometimes called the field strength tensor, Faraday tensor or Maxwell bivector) is a mathematical object that describes the electromagnetic field in spacetime. The field tensor was first used after the four-dimensional tensor formulation of special relativity was introduced by Hermann Minkowski. The tensor allows related physical laws to be written very concisely, and allows for the quantization of the electromagnetic field by Lagrangian formulation described below.
Semi-finished casting productsSemi-finished casting products are intermediate castings produced in a steel mill that need further processing before being finished goods. There are four types: ingots, blooms, billets, and slabs. Ingot Ingots are large rough castings designed for storage and transportation. The shape usually resembles a rectangle or square with generous fillets. They are tapered, usually with the big-end-down. In the era of commercial wrought iron, blooms were slag-riddled iron castings poured in a bloomery before being worked into wrought iron.
Solid mechanicsSolid mechanics (also known as mechanics of solids) is the branch of continuum mechanics that studies the behavior of solid materials, especially their motion and deformation under the action of forces, temperature changes, phase changes, and other external or internal agents. Solid mechanics is fundamental for civil, aerospace, nuclear, biomedical and mechanical engineering, for geology, and for many branches of physics and chemistry such as materials science.
