PROSES

MANUFAKTUR
MATERIAL
 PROSES MANUFAKTUR LOGAM
Logam Mentah
(hasil ekstraksi bijih)

Pembentukan mekanis Penuangan Metalurgi

(deformasi plastis) (cor) serbuk

Perlakuan
panas
Pengelasan/ Pemotongan
penyambungan (machining)
produk 1/2 jadi
Perlakuan panas

Finishing
produk jadi
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The Refining of Metals
The Electric Arc Furnace
Ingots
How Metal are formed : Casting
How Metal are formed : Rolling
◦ 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 as hot
rolling. If the temperature of the metal is below its recrystallization temperature, the
process is known as cold rolling.
◦ Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly
process metal, typically steel, into products such as structural steel (I-beams, angle
stock, channel stock, and so on), bar stock, and rails. Most steel mills have rolling mill
divisions that convert the semi-finished casting products into finished products.
◦ There are many types of rolling processes, including ring rolling, roll bending, roll
forming, profile rolling, and controlled rolling.
How Metal are formed : Forging
◦ 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).
◦ Forging has been done by smiths for millennia; the traditional products
were kitchenware, hardware, hand tools, edged weapons, cymbals, and jewellery.
Since the Industrial Revolution, forged parts are widely used
in mechanisms and machines wherever a component requires high strength;
such forgings usually require further processing (such as machining) to achieve a
finished part.
Metalurgi Serbuk
◦ Metalurgi serbuk adalah metode yang terus dikembangkan dari proses manufaktur
yang dapat mencapai bentuk komponen akhir dengan mencampurkan serbuk secara
bersamaan dan dikompaksi dalam cetakan, dan selanjutnya disinter di dalam furnace
(tungku pemanas).
◦ Langkah-langkah yang harus dilalui dalam metalurgi serbuk, antara lain:
1. Preparasi material
2. Pencampuran (mixing)
3. Penekanan (kompaksi)
4. Pemanasan (sintering)
Proses pemanasan yang dilakukan harus berada di bawah titik leleh serbuk material
yang digunakan
Welding
◦ Welding is a fabrication or sculptural process that joins materials,
usually metalsor thermoplastics, by causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering, which do not melt the base metal.
In addition to melting the base metal, a filler material is typically added to the joint to form a
pool of molten material (the weld pool) that cools to form a joint that is usually stronger than
the base material. Pressure may also be used in conjunction with heat, or by itself, to
produce a weld. Welding also requires a form of shield to protect the filler metals or melted
metals from being contaminated or oxidized.
◦ Until the end of the 19th century, the only welding process was forge welding,
which blacksmiths had used for millennia to join iron and steel by heating and
hammering. Arc welding and oxyfuel welding were among the first processes to develop
late in the century, and electric resistance welding followed soon after. Welding technology
advanced quickly during the early 20th century as the world wars drove the demand for
reliable and inexpensive joining methods. Following the wars, several modern welding
techniques were developed, including manual methods like SMAW, now one of the most
popular welding methods, as well as semi-automatic and automatic processes such as
GMAW, SAW, FCAW and ESW. Developments continued with the invention of laser beam
welding, electron beam welding, magnetic pulse welding (MPW), and friction stir welding in
the latter half of the century. Today, the science continues to advance. Robot welding is
commonplace in industrial settings, and researchers continue to develop new welding
methods and gain greater understanding of weld quality.
Some of the best known welding methods include:
◦ Oxy-fuel welding – also known as oxyacetylene welding or oxy welding, uses fuel gases and oxygen to weld and cut metals.
◦ Shielded metal arc welding (SMAW) – also known as "stick welding" or "electric welding", uses an electrode that has flux around it to protect the
weld puddle. The electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle from atmospheric contamination.
◦ Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert gas), uses a non-consumable tungstenelectrode to produce the weld.
The weld area is protected from atmospheric contamination by an inert shielding gas such as argon or helium.
◦ Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert gas), uses a wire feeding gun that feeds wire at an adjustable speed
and flows an argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from atmospheric
contamination.
◦ Flux-cored arc welding (FCAW) – almost identical to MIG welding except it uses a special tubular wire filled with flux; it can be used with or
without shielding gas, depending on the filler.
◦ Submerged arc welding (SAW) – uses an automatically fed consumable electrode and a blanket of granular fusible flux. The molten weld and
the arc zone are protected from atmospheric contamination by being "submerged" under the flux blanket.
◦ Electroslag welding (ESW) – a highly productive, single pass welding process for thicker materials between 1 inch (25 mm) and 12 inches
(300 mm) in a vertical or close to vertical position.
◦ Electric resistance welding (ERW) – a welding process that produces coalescence of laying surfaces where heat to form the weld is generated
by the electrical resistance of the material. In general, an efficient method, but limited to relatively thin material.
◦ Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction,
and ultrasound. While often an industrial process, welding may be performed in many different environments, including in open air, under
water, and in outer space. Welding is a hazardous undertaking and precautions are required to avoid burns, electric shock, vision damage,
inhalation of poisonous gases and fumes, and exposure to intense ultraviolet radiation.
Machining
◦ Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The processes
that have this common theme, controlled material removal, are today collectively
known as subtractive manufacturing,[1] in distinction from processes of controlled
material addition, which are known as additive manufacturing. Exactly what the
"controlled" part of the definition implies can vary, but it almost always implies the use
of machine tools (in addition to just power tools and hand tools).
◦ Machining is a part of the manufacture of many metal products, but it can also be
used on materials such as wood, plastic, ceramic, and composites.[2] A person who
specializes in machining is called a machinist. A room, building, or company where
machining is done is called a machine shop. Much of modern-day machining is carried
out by computer numerical control (CNC), in which computers are used to control the
movement and operation of the mills, lathes, and other cutting machines.
The three principal machining processes are classified as turning, drilling and milling
•Turning operations are operations that rotate the workpiece as the primary method of moving
metal against the cutting tool. Lathes are the principal machine tool used in turning.
•Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear
against the workpiece. Milling machines are the principal machine tool used in milling.
•Drilling operations are operations in which holes are produced or refined by bringing a rotating
cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations
are done primarily in drill presses but sometimes on lathes or mills.
•Miscellaneous operations are operations that strictly speaking may not be machining operations
in that they may not be swarf producing operations but these operations are performed at a
typical machine tool. Burnishing is an example of a miscella.neous operation. Burnishing
produces no swarf but can be performed at a lathe, mill, or drill press. Other operations falling into
miscellaneous categories include shaping, planing, boring, broaching and sawing
Heat treatment
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 The major objectives are …..
to increase strength, hardness and wear resistance
(bulk hardening, surface hardening)
It’s a material heat and cooling process
to get structure change for increasing to increase ductility and softness (tempering,
material ability, so increasing material recrystallization annealing
efficiency
Its for minimizing potential damage that
to increase toughness (tempering,
will happen on a material, its need a
heat treatment process for increasing
recrystallization annealing)
material resource
to obtain fine grain size (recrystallization
annealing, full annealing, normalising)

to remove internal stresses induced by

differential deformation by cold working,
non-uniform cooling from high temperature
during casting and welding (stress relief
annealing)
 KLASIFIKASI PERLAKUAN PANAS BAJA

 Perlakuan panas termal : Annealing, Homogenising, Hardening, dst.

(thermal treatment)

 Perlakuan panas termokimia : Carburising, Carbonitriding, Nitriding,

(thermochemical treatment) Nitrocarburising, dst.

 Perlakuan panas termomekanik : Ausforming, Isoforming, dst.

(themomechanical treatment)

 Perlakuan inovatif permukaan : Enhanced plasma diffusional treatment,

(innovative surface treatment) Laser/electron beam surface alloying,
Laser surface hardening, dst.

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Annealing
It is a heat treatment wherein a material is altered, causing
changes in its properties such as strength and hardness

1. Stress-Relief Annealing (or Stress-relieving)

2. Normalizing
3. Isothermal Annealing
4. Spheroidizing Annealing (or Spheroidizing )
 QUENCHING
In quench hardening, fast cooling rates, depending on the
chemical composition of the steel and its section size, are applied
to prevent diffusion-controlled trans formations in the pearlite
range and to obtain a structure consisting mainly of martensite
and bainite

TEMPERING
Tempering is done to toughen the metal by transforming brittle
martensite or bainite into a combination of ferrite and cementite or
sometimes Tempered martensite
 Austenit

Bainit
Austenitizing
Temperature

Pre-heating 1st Tempering 2nd Tempering

Ferrite Martensite
Time
Udahan….