Process Encyclopaedia

Overview

Bulk metal shaping is generally done near-net-shape by forging or casting although further finishing work is usually required. However, it does reduce the material wasted by machining and is usually much faster. For many components, casting and forging are in direct competition and there is often no easy way to decide which is the better choice; both are usually undertaken by specialist companies (foundries and forges respectively).

There are a variety of sheet forming processes suitable for metals less than 6mm thick, and in general all products based on sheet will be made using one of these processes. Sheet is made by rolling, which is also used to produce most large stock items held by material suppliers and a few final products such as I-beams.

Extrusion is also used to produce some stock items with constant cross-section, such as tubes, and some finished items, such as window frames.

Process details

Materials and shapes

Economics

Typical products

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