- Introduction and Metal Processes Overview. The structure of metals. Deformation and strength considerations. The S-N curve and repetitive stress cycling. Mechanical properties testing. Typical material and process selection criteria.
- Casting and Molding. Die casting. Investment and sand casting. Permanent molds. Injection molding. Near net shape considerations. Advantages and disadvantages of each process. Process capabilities. Defects and defect prevention. Casting and molding design considerations. Producibility considerations. Economics of casting and molding.
Case studies.
- Sheet Metal Forming and Stamping. Sheet metal characteristics. Shearing, cutting, and common bending operations. Stamping operations. Stretch forming. Deep drawing. Rolling. Hydroforming. Other sheet metal forming processes. Sheet metal design considerations. Spot welding, conventional welding, rivets, adhesives, and other fastening methods. Process capabilities. Producibility considerations. Economics of forming and stamping operations.
Case studies.
- Extrusion and Drawing. Hot and cold extrusion. Impact extrusion. Extrusion equipment. The extrusion process. Residual stress considerations. Process capabilities. Producibility considerations. Common extruded parts. Economics of extrusion and drawing.
Case studies.
- Machining and Abrasion-Based Processes. Basic cutting considerations. Machining versus other metal working operations. Turning processes. Milling processes. Broaching processes. Sawing. Grinding processes. Ultrasonic, electrical discharge, laser, and other non-conventional machining processes. Process capabilities. Producibility considerations. Common machined and ground parts. Economics of machining and grinding.
Case studies.
- Powder Metallurgy and Metal Injection Molding. Production of powdered metal parts. Sintering. Secondary and finishing operations. Design considerations. Binders. Selective laser sintering. Economics of powdered metallurgy parts. Powder metallurgy process capabilities. Powdered metal producibility considerations. Common powdered metal parts. Powdered metal parts economic considerations.
Case studies.
- Surface Treatment, Coating, and Cleaning. Surface hardening. Vapor deposition. Electrochemical and electroless plating. Anodizing. Painting and powder coating. Cleaning technologies. Environmental considerations.
Case studies.
- Other Metal Parts Comparisons and Considerations. Process capability and yield comparisons. Reliability and strength comparisons. Lead time considerations. Cost estimation approaches. Make versus buy approaches. Supplier evaluation approaches. Other supplier management considerations.
Case studies.
- Course Wrap-Up. Course review. Questions and answers. Plans for future actions. Course critique.