Polymer

Processing
Blow Molding
Compression
Molding
Injection
Molding
Gas Assist IM
Insert/ Over
molding
Low volume IM
Multi-shot IM
Rapid IM
Reaction IM
Structural
Foam Molding
Thermoformin
g
Transfer
Molding
Vacuum
Forming
Rotational
Molding
Contact
Molding
Metal Injection
Molding
Boring
Broaching
Drilling
Non
Conventional
EDM
Ram EDM
Wire EDM
ECM
Mfg. Process
Machining
ECM
Grinding
Laser beam
M/c
Milling
Reaming
Sawing
Tapping
Turning
Metal Forming
Extrusion
Forging
S/M
Fabrication
Cutting
Shearing
Blanking
Punching
Stamping
Forming
Bending
Roll Forming
Spinning
Deep Drawing
Stretch
forming
Powder
Metallurgy
Swaging
Casting
Casting
Expendable Mold
Sand Casting
Shell Casting
Investment Casting
Lost Foam
Casting/Expanded
Polystyrene
Vacuum Molding
Ceramic Mold
Casting
Die Casting
High
Pressure DC
Low
pressure DC
Gravity DC
Casting
Plaster Mold
Multiple Use Mold
Permanent Mold
Casting
Die Casting
Hot Chamber
Cold Chamber
Centrifugal Casting
True C.C
Semi C.C
Centrifuge Casting
Die Casting Gravity DC
Vacuum DC
Squeeze DC
Furnace
Cupolas Cast Iron
Direct fuel fired
furnaces
Cu based alloys
& Al
Lift out type
Typical Pouring Temp
CI : 1400C
Steel : 1650C
Aluminum : 660C
Zinc : 419C
Furnace
Crucible
furnaces
Bronze, Brass ,
Alloys of Zn & Al
Stationary
Tilting
Electric arc
furnaces
Steel
Induction
furnaces
Steel, CI & Al
alloys
Ferrous
Cast Iron
SG
Iron/Ductile
Gray CI
Nodular CI
White CI
Casting
Metal
Ferrous White CI
Malleable
Iron
Alloy CI
Steel
Non Ferrous
Aluminum
Cu Alloys
Form/Shape/Size
Ingots
More than 2' thick
(~ 6'wide X 20' long)
Pencil Ingots
Semis
(Semi finished steel
products)
Blooms
Square or Rectangular;
size more than 5x5
Billets
Square or Rectangular;
size less than 5x5
Slabs
width 150-250mm
width at least 3t
Plate
> 6mm ( .25"),
width +500mm
Sheet
0.15-6.0mm (.006" -
.25"), +500mm
Strip
Foil
< 0.15mm (0.006" )
Thin Slabs
Usually 35-50mm thick
Bars & Rods
Hot rolling/forging
of billets/blooms
Steel
Finished Steel
Long Products
CTD/TMT
Wire Rod
Angles, Shapes &
Section
Rails
Wires
Bright Bars
Flat Products
D/DD/IF Steel
Composition
Alloy Steel
Non alloy
/pencil ingots
G90 >> 90 oz/ft2 (both sides)
The coating on one square
foot of sheet (total coating,
both sides of the sheet)
weighs a minimum of 0.90
ounces. If equally applied to
both sides of the sheet, there
would be a minimum of 0.45
ounces on each surface.
welding
Material name Composition Properties Applications
Low Carbon Steels
Up to 0.30%
Carbon
Good formability, good
weld-ability, low cost
0.1%-0.2% carbon: Chains, stampings, rivets, nails, wire, pipe,
and where very soft, plastic steel is needed.
0.2%-0.3% carbon: Machine and structural parts
Medium Carbon
Steels
0.30% to 0.80%
Carbon
A good balance of
properties, fair
formability
0.3%-0.4% carbon: Lead screws, gears, worms, spindles, shafts,
and machine parts.
0.4%-0.5% carbon: Crankshafts, gears, axles, mandrels, tool
shanks, and heat-treated machine parts
0.6%-0.8% carbon: "Low carbon tool steel" and is used where
shock strength is wanted. Drop hammer dies, set screws,
screwdrivers, and arbors.
0.7%-0.8% carbon: Tough and hard steel. Anvil faces, band 0.7%-0.8% carbon: Tough and hard steel. Anvil faces, band
saws, hammers, wrenches, and cable wire.
High Carbon Steels
0.80% to ~2.0%
Carbon
Low toughness,
formability, and weld-
ability, high hardness and
wear resistance, fair
formability
0.8%-0.9% carbon: Punches for metal, rock drills, shear blades,
cold chisels, rivet sets, and many hand tools.
0.9%-1.0% carbon: Used for hardness and high tensile
strength, springs, cutting tools
1.0%-1.2% carbon: Drills, taps, milling cutters, knives, cold
cutting dies, wood working tools.
1.2%-1.3% carbon: Files, reamers, knives, tools for cutting
wood and brass.
1.3%-1.4% carbon: Used where a keen cutting edge is
necessary (razors, saws, etc.) and where wear resistance is
important.
Material name Composition Properties Applications
Stainless Steel
Stainless steel is a family of corrosion
resistant steels. They contain at least 10.5%
chromium, with or without other elements.
The Chromium in the alloy forms a self-
healing protective clear oxide layer. This
oxide layer gives stainless steels their
corrosion resistance.
Good corrosion resistance,
appearance, and mechanical
properties
Austenitic Steels: Contains chromium and
nickel. The typical chromium content is in
the range of 16% to 26%; nickel content is
commonly less than 35%.
Good mechanical and
corrosion resisting properties,
high hardness and yield
strength as well as excellent
ductility and are usually non-
magnetic
Kitchen sinks, architectural
applications such as roofing,
cladding, gutters, doors and
windows; Food processing
equipment; Heat exchangers;
Ovens; Chemical tanks
Good ductility, weld-ability,
Automotive trim, catalytic
Ferritic Steels: Magnetic with a high
chromium and low nickel content usually
alloyed with other elements such as
aluminum or titanium.
Good ductility, weld-ability,
and formability; reasonable
thermal conductivity, and
corrosion resistance with a
good bright surface
appearance
Automotive trim, catalytic
converters, radiator caps, fuel
lines, cooking utensils,
architectural and domestic
appliance trim applications
Martensitic Steels: Typically contains 11.0%
to 17.0% chromium, no nickel, and 0.10% to
0.65% carbon levels. The high carbon
enables the material to be hardened by
heating to a high temperature, followed by
rapid cooling (quenching).
Good combination of corrosion
resistance and excellent
mechanical properties,
produced by heat treatment,
to develop maximum hardness,
strength, and resistance to
abrasion and erosion.
Cutlery, scissors, surgical
instruments, wear plates,
garbage disposal shredder lugs,
industrial knives, vanes for
steam turbines, fasteners,
shafts, and springs
Material name Composition Properties Applications
Aluminum /
Aluminum alloys
Pure metal / Easily alloyed with small
amounts of copper, manganese,
silicone, magnesium, and other
elements
Low density, good electrical
conductivity (approx. 60% of
copper), nonmagnetic,
noncombustible, ductile,
malleable, corrosion resistance;
easily formed, machined, or cast
Window frames, aircraft parts,
automotive parts, kitchenware
Brass
Alloy of copper and zinc, 65% to 35%
is the common ratio
Reasonable hardness; casts,
forms, and machines well; good
electrical conductivity and
acoustic properties
Parts for electrical fittings, valves,
forgings, ornaments, musical
instruments
Copper Pure metal
Excellent ductility, thermal and
electrical conductivity
Electrical wiring, tubing, kettles,
bowls, pipes, printed circuit boards
Lead Pure metal
Heaviest common metal,
ductile, and malleable, good
corrosion resistance
Pipes, batteries, roofing, protection
against X-Rays
corrosion resistance
against X-Rays
Magnesium /
Magnesium Alloys
Pure metal / Used as an alloy
element for aluminum, lead, zinc,
and other nonferrous alloys; alloyed
with aluminum to improve the
mechanical, fabrication, and welding
characteristics
Lightest metallic material
(density of about 2/3 of that of
aluminum), strong and tough,
most machinable metal, good
corrosion resistance, easily cast
Automobile, portable electronics,
appliances, power tools, sporting
goods parts, and aerospace
equipment
Nickel / Nickel
Alloys
Pure metal / Alloys very well with
large amounts of other elements,
chiefly chromium, molybdenum, and
tungsten
Very good corrosion resistance
(can be alloyed to extend
beyond stainless steels), good
high temperature and
mechanical performance, fairly
good conductor of heat and
electricity
The major use of nickel is in the
preparation of alloys or plating -
frequently used as an undercoat in
decorative chromium plating and
to improve corrosion resistance;
applications include electronic lead
wires, battery components, heat
exchangers in corrosive
environments
Material name Composition Properties Applications
Titanium / Titanium
Alloys
Pure metal / Easily alloys with
aluminum, nickel, chromium, and
other elements
Low density, low coefficient of
thermal expansion, high
melting point, excellent
corrosion resistance, nontoxic
and generally biologically
compatible with human tissues
and bones, high strength,
stiffness, good toughness
Aerospace structures and
other high-performance
applications, chemical and
petrochemical applications,
marine environments, and
biomaterial applications
Zinc / Zinc Alloys
Pure metal/ Metal is employed to
form numerous alloys with other
metals. Alloys of primarily zinc with
small amounts of copper, aluminum,
and magnesium are useful in die-
casting. The most widely used alloy
of zinc is brass
Excellent corrosion resistance,
light weight, reasonable
conductor of electricity
Used principally for galvanizing
iron (more than 50% of
metallic zinc goes into
galvanizing steel), numerous
automotive applications
because of its light weight
of zinc is brass
because of its light weight