Casting

Centrifugal casting is a metallurgical manufacturing process by casting that

may refer to either:
Continuous casting, also called strand casting, is the process
whereby molten metal is solidified into a "semifinished" billet, bloom, or slab for
subsequent rolling in the finishing mills. Prior to the introduction of continuous
casting in the 1950s, steel was poured into stationary molds to form ingots. Since
then, "continuous casting" has evolved to achieve improved yield, quality,
productivity and cost efficiency. It allows lower-cost production of metal sections
with better quality, due to the inherently lower costs of continuous, standardised
production of a product, as well as providing increased control over the process
through automation. This process is used most frequently to cast steel (in terms
of tonnage cast). Aluminium and copper are also continuously cast.
Die 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 tinbased
alloys. Depending on the type of metal being cast, a hot- or cold-chamber
machine is used.
Resin casting is a method of plastic casting where a mold is filled with a
liquid synthetic resin, which then hardens. It is primarily used for small-scale
production like industrial prototypes and dentistry. It can be done by
amateur hobbyists with little initial investment, and is used in the production of
collectible toys, models and figures, as well as small-scale jewelry production.
Sand casting, also known as sand molded casting, is a metal casting process
characterized by using 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. Over 70% of all metal castings
are produced via a sand casting process.

Molding
Powder metallurgy (PM) is a term covering a wide range of ways in which
materials or components are made from metal powders. One of the older such
methods, and still one used to make around 1Mt/yr of structural components of
iron-based alloys, is the process of blending fine (<180microns) metal (normally
iron) powders with additives such as a lubricant wax, C, Cu and/or Ni, pressing
them, normally uniaxially and in precision dies, into a desired shape or form
(compacting), and then heating the compressed material ("green part") in a
controlled (normally reducing) atmosphere to bond the material (sintering).

Forming
Forging is a manufacturing process involving the shaping of metal using
localized compressive forces. The blows are delivered with a hammer (often
a power hammer) or a die. Forging is often classified according to the
temperature at which it is performed: cold forging (a type of cold working), warm
forging, or hot forging (a type of hot working). For the latter two, the metal
is heated, usually in a forge. Forged parts can range in weight from less than a
kilogram to hundreds of metric tons.
Rolling is a metal forming process in which metal stock is passed through one or
more pairs of rolls to reduce the thickness and to make the thickness uniform.
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 ashot rolling. If the
temperature of the metal is below its recrystallization temperature, the process is
known as cold rolling. In terms of usage, hot rolling processes more tonnage
than any other manufacturing process, and cold rolling processes the most
tonnage out of allcold working processes.
Extrusion is a process used to create objects of a fixed cross-sectional profile. A
material is pushed or pulled through a die of the desired cross-section. The two
main advantages of this process over other manufacturing processes are its
ability to create very complex cross-sections, and to work materials that are
brittle, because the material only encounters compressive and shear stresses. It
also forms parts with an excellent surface finish.
Bending is a manufacturing process that produces a V-shape, U-shape, or
channel shape along a straight axis in ductilematerials, most commonly sheet
metal.

Shearing, also known as die cutting,[1] is a process which cuts stock without the
formation of chips or the use of burning or melting. In strict technical terms, the
process of "shearing" involves the use of straight cutting blades; and, if the
cutting blades are curved then the process is considered a "shearing-type
operation."[2] The most commonly sheared materials are in the form of sheet
metal or plates, however rods can also be sheared. Shearing-type operations
include: blanking, piercing, roll slitting, and trimming. It is used in metalworking
and also with paper and plastics.