3 Strengthening Mechanisms for Single Phase Metals:

1: Deformation Processing - Cold Work (Strain Hardening)

Activity - Deformation at room temperature
Forming reduces cross-sectional area:

Metal Forming I

-Forging

force

die
Ao blank

-Rolling
Ad

roll

Ao

-Drawing

die

Ad

roll

force

Ao

A A
d x 100
%CW o
A
o

1. pipes
Ad

2. I beam

tensile
force

die

-Extrusion

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Ao

Dr. Lynn C. Erickson, Ph.D., P.Eng.

force

School of Energy

container

ram

billet

container

die holder
extrusion

die

Ad

3. bike gear

4. window screen
frames

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Metal Fabrication

Hot Rolling and Recrystallization

deformation above the
Recrystallization Temp.
> 0.4 TM.P. pure
metals
>0.6 TM.P. - alloys
recrystallization occurs
at the same time as
deformation
material is easy to form

How do we fabricate metals?

Blacksmith - hammer (____________)
Molding - __________
Forming Operations
Rough stock formed to _________ shape
Hot working

vs.

Temp. high enough for

recrystallization
________deformations

Cold working
well below Tm
work hardening
________ deformations

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Similar to Cold working

followed by Annealing

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Hot Rolling of Low Carbon Steel

Defects in Worked (Wrought) Metal

ROLL

Shrinkage cavity
in ingot
If open to air,
it becomes __________.
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Defects in Worked (Wrought) Metal

Defects in Worked (Wrought) Metal

_____________ in plate

ROLL

Slag particles in an ingot

(silicates, sulphides,)
Seam in bar

Pipe in bar

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Slag and impurity

particles in the ingot
become __________ in
the direction of working.

______________

(open to surface)

(___________)

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Defects in Worked (Wrought) Metal

Defects in Worked (Wrought) Metal

Structure of
___________ article

Weaker when loaded ______________ to the stringers

F
F

Structure of
___________ article
VS.

Normal
Strength

________________ (fibers)
- in plate or bar

A rolled bar
with ____________

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FORMING TEMPERATURE

- May have
_________________

______________

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Thread Rolling of Low Carbon Steel

Cold worked microstructures

--generally are very ____________! _______________
--Forged
--Swaged
--Fracture resistant!
(a)
(b)

(c)
Reprinted w/ permission from R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering
Materials", (4th ed.), John Wiley and Sons, Inc., 1996. (a) Fig. 10.5, p. 410 (micrograph courtesy of G.
Vander Voort, Car Tech Corp.); (b) Fig. 10.6(b), p. 411 (Orig. source: J.F. Peck and D.A. Thomas,
Trans. Metall. Soc. AIME, 1961, p. 1240); (c) Fig. 10.10, p. 415 (Orig. source: A.J. McEvily, Jr.
and R.H. Bush, Trans. ASM 55, 1962, p. 654.)
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Metal Fabrication Methods - I

Metal Fabrication Methods - I

FORMING

CASTING

FORMING

JOINING

CASTING

JOINING

Heavy Forging
(Hot Working Process)
A Large cast ingot is squeezed in multiple steps.

Rolling (Hot or Cold Rolling)

Hot metal is squeezed between rotating metal rolls.
Typical products: ___________________________________

Products ________________________________________.
force

roll

Typical Properties

Ad

Ao
roll

UTS
% Elong
Izod

Adapted from Fig. 11.8,

Callister 7e.

Cast Ingot

Hot Rolled
Steel

50,000 psi
15%
5 ft lb

60,000 psi
____%
_____ ft lb

die
A o blank

A d

force

Adapted from
Fig. 11.8,
Callister 7e.

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Metal Fabrication Methods - I

Metal Fabrication Methods - I

Hot Working Process

Hot Working Process

Drop Forging (Hammering; Stamping)

A small cast ingot is hammered between 2 dies.

Extrusion

Typical Products _______________________, machine components

subjected to high stress.

Starting material is a cast billet

______ M.P. metals are extruded.
Products _______________________.
Ao

force
force

die
A o blank

A d

container

ram

billet

die holder
extrusion

container

Ad

die

ductile metals, e.g. Cu, Al, Mg (hot)

force

Typical Extruded Shape

Adapted from
Fig. 11.8,
Callister 7e.

Adapted from
Fig. 11.8,
Callister 7e.

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Metal Fabrication Methods - I

Metal Fabrication Methods - I

Cold Working Process

Cold Working Process

Impact Extrusion

Impact Extrusion

Small slug of soft metal (Al, Pb) is hit by a punch

The metal flows over the punch to form a sleeve.
Typical products: _________________________________

- Combination of operations, such as _____________

____________________.
Advantages :

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Improved mechanical properties

Good control of dimensional tolerances
______________________________
Elimination of the need for billet heating

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Metal Fabrication Methods - I

Metal Fabrication Methods - I

Cold Working Process

Deep Drawing
Starting material is rolled sheet
A punch stretches it into a deep cup-like shape
Typical products: _________________________________________

FORMING
CASTING
Cold Working Process

Drawing
The starting material is rolled rod
The rod is pulled through a series of smaller dies to make wire
Typical products: ________________________________
die
Ao

Ad

tensile
force

die

Adapted from
Fig. 11.8,
Callister 7e.

die must be well lubricated & clean

Deep Drawing
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JOINING

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Metal Fabrication Methods - I

Metal Fabrication Methods - I

Cold Working Process
Drawing

Cold Working Process

Spinning
The starting material is rolled sheet
The rod is rotated and gradually forced over a wooden form

Thin walled tube can also be made

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Metal Fabrication Methods - I

22

ANNOUNCEMENTS

Cold Working Process

Spinning
Typical products: _____________________________________

Reading: Chapter 11, Section 11.4

- Check out WileyPlus tutorials/animations

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