PRODUCT PROCESSES:
- Investment Casting - using designed mold as an expendable pattern with a refractory slurry coating that sets at room temperature, after which the wax or plastic pattern is removed through the use of heat furnace prior to filling the mold with liquid metal.
- Extrusion - using long straight metal parts can be produced. It is done by squeezing metal in a closed cavity through aa tool, known as a die using either a mechanical or hydraulic press and produces compressive and shear forces in the stock.
- Forging - we process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press.
- Machining - we have the Turning is performed on a machine LATHE which the tool is stationary and the part is rotated. Also Milling is as important process as drilling, it sets up so many degrees of freedom, milling is usually less accurate than turning or grinding unless especially rigid fixing is implemented.
- Powder Metal - The metal powder is compacted by placing in a closed metal cavity (the die) under pressure. This compacted material is placed in an oven and sintered in a controlled atmosphere at high temperatures and the metal powders coalesce and form a solid. A second pressing operation, repressing, can be done prior to sintering to improve the compaction and the material properties. Useful in making parts that have irregular curves, or recesses that are hard to machine. It is suitable for high volume production with very little wastage of material.
- Metal Injection Molding - (MIM) is a technology that combines the strengths of conventional metallurgy and plastic injection molding. Its cost-effective process in making small parts with complicated shapes. The process starts with kneaded feedstock is then granulated and fed into injection molding machines. Under pressure and heat, the feedstock flows into the mold cavity forming the desired shapes. After being removed from the mold, the molded parts go through a debinding process to remove the binders. The debound parts are then to a density greater the 95%.
- Die-casting - is being process where metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) psi . This results in a more uniform part, generally good surface finish and good dimensional accuracy, as good as 0.2 % of casting dimension. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size. Aluminum, Zinc and Copper alloys are the predominantly used as materials.
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