Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are known as alloys.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as brazing and soldering, which do not melt the base metal.
A printed circuit board (PCB), also called printed wiring board (PWB), is a medium used to connect or "wire" components to one another in a circuit. It takes the form of a laminated sandwich structure of conductive and insulating layers: each of the conductive layers is designed with an artwork pattern of traces, planes and other features etched from one or more sheet layers of copper laminated onto and/or between sheet layers of a non-conductive substrate. Electrical components may be fixed to conductive pads on the outer layers in the shape designed to accept the component's terminals, generally by means of soldering, to both electrically connect and mechanically fasten them to it. Another manufacturing process adds vias, plated-through holes that allow interconnections between layers.
Powder metallurgy (PM) is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can reduce or eliminate the need for subtractive processes in manufacturing, lowering material losses and reducing the cost of the final product.
Since the mid-20th century, electron-beam technology has provided the basis for a variety of novel and specialized applications in semiconductor manufacturing, microelectromechanical systems, nanoelectromechanical systems, and microscopy.
Electric resistance welding (ERW) is a welding process where metal parts in contact are permanently joined by heating them with an electric current, melting the metal at the joint. Electric resistance welding is widely used, for example, in manufacture of steel pipe and in assembly of bodies for automobiles. The electric current can be supplied to electrodes that also apply clamping pressure, or may be induced by an external magnetic field. The electric resistance welding process can be further classified by the geometry of the weld and the method of applying pressure to the joint: spot welding, seam welding, flash welding, projection welding, for example. Some factors influencing heat or welding temperatures are the proportions of the workpieces, the metal coating or the lack of coating, the electrode materials, electrode geometry, electrode pressing force, electric current and length of welding time. Small pools of molten metal are formed at the point of most electrical resistance as an electric current is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are limited to relatively thin materials.
A superalloy, or high-performance alloy, is an alloy with the ability to operate at a high fraction of its melting point. Key characteristics of a superalloy include mechanical strength, thermal creep deformation resistance, surface stability, and corrosion and oxidation resistance.
Laser powder forming, also known by the proprietary name is an additive manufacturing technology developed for fabricating metal parts directly from a computer-aided design (CAD) solid model by using a metal powder injected into a molten pool created by a focused, high-powered laser beam. This technique is also equivalent to several trademarked techniques that have the monikers direct metal deposition (DMD), and laser consolidation (LC). Compared to processes that use powder beds, such as selective laser melting (SLM) objects created with this technology can be substantially larger, even up to several feet long.
Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike conventional liquid paint which is delivered via an evaporating solvent, powder coating is typically applied electrostatically and then cured under heat or with ultraviolet light. The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as household appliances, aluminium extrusions, drum hardware, automobiles, and bicycle frames. Advancements in powder coating technology like UV-curable powder coatings allow for other materials such as plastics, composites, carbon fiber, and MDF to be powder coated due to the minimum heat and oven dwell time required to process these components.
Fusion bonded epoxy coating, also known as fusion-bond epoxy powder coating and commonly referred to as FBE coating, is an epoxy-based powder coating that is widely used to protect steel pipe used in pipeline construction from corrosion. It is also commonly used to protect reinforcing bars and on a wide variety of piping connections, valves etc. FBE coatings are thermoset polymer coatings. They come under the category of protective coatings in paints and coating nomenclature. The name fusion-bond epoxy is due to resigning cross-link and the application method, which is different from a conventional paint. In 2020 the market size was quoted at 12 billion dollars.
Titanium powder metallurgy (P/M) offers the possibility of creating net shape or near net shape parts without the material loss and cost associated with having to machine intricate components from wrought billet. Powders can be produced by the blended elemental technique or by pre-alloying and then consolidated by metal injection moulding, hot isostatic pressing, direct powder rolling or laser engineered net shaping.
Thermal spraying techniques are coating processes in which melted materials are sprayed onto a surface. The "feedstock" is heated by electrical or chemical means.
Gas dynamic cold spraying or cold spraying (CS) is a coating deposition method. Solid powders are accelerated in a supersonic gas jet to velocities up to ca. 1200 m/s. During impact with the substrate, particles undergo plastic deformation and adhere to the surface. To achieve a uniform thickness the spraying nozzle is scanned along the substrate. Metals, polymers, ceramics, composite materials and nanocrystalline powders can be deposited using cold spraying. The kinetic energy of the particles, supplied by the expansion of the gas, is converted to plastic deformation energy during bonding. Unlike thermal spraying techniques, e.g., plasma spraying, arc spraying, flame spraying, or high velocity oxygen fuel (HVOF), the powders are not melted during the spraying process.
Electron-beam additive manufacturing, or electron-beam melting (EBM) is a type of additive manufacturing, or 3D printing, for metal parts. The raw material is placed under a vacuum and fused together from heating by an electron beam. This technique is distinct from selective laser sintering as the raw material fuses having completely melted.
Ultrasonic Consolidation (UC) or Ultrasonic Additive Manufacturing (UAM) is a low temperature additive manufacturing or 3D printing technique for metals.
Selective laser melting (SLM) is one of many proprietary names for a metal additive manufacturing (AM) technology that uses a bed of powder with a source of heat to create metal parts. Also known as direct metal laser sintering (DMLS), the ASTM standard term is powder bed fusion (PBF). PBF is a rapid prototyping, 3D printing, or additive manufacturing technique designed to use a high power-density laser to melt and fuse metallic powders together.
Roll bonding is a solid state, cold welding process, obtained through flat rolling of sheet metals. In roll bonding, two or more layers of different metals are passed through a pair of flat rollers under sufficient pressure to bond the layers. The pressure is high enough to deform the metals and reduce the combined thickness of the clad material. The mating surfaces must be previously prepared in order to increase their friction coefficient and remove any oxide layers. The process can be performed at room temperature or at warm conditions. In warm roll bonding, heat is applied to pre-heat the sheets just before rolling, in order to increase their ductility and improve the strength of the weld. The strength of the rolled bonds depends on the main process parameters, including the rolling conditions, the pre-rolling treatment conditions and the post-rolling heat treatments.
A variety of processes, equipment, and materials are used in the production of a three-dimensional object via additive manufacturing. 3D printing is also known as additive manufacturing, because the numerous available 3D printing process tend to be additive in nature, with a few key differences in the technologies and the materials used in this process.
Cold spray additive manufacturing (CSAM) is a particular application of cold spraying, able to fabricate freestanding parts or to build features on existing components. During the process, fine powder particles are accelerated in a high-velocity compressed gas stream, and upon the impact on a substrate or backing plate, deform and bond together creating a layer. Moving the nozzle over a substrate repeatedly, a deposit is building up layer-by-layer, to form a part or component. If an industrial robot or computer controlled manipulator controls the spray gun movements, complex shapes can be created. To achieve 3D shape, there are two different approaches. First to fix the substrate and move the cold spray gun/nozzle using a robotic arm, the second one is to move the substrate with a robotic arm, and keep the spray-gun nozzle fixed. There is also a possibility to combine these two approaches either using two robotic arms or other manipulators. The process always requires a substrate and uses only powder as raw material.
Laser metal deposition (LMD) is an additive manufacturing process in which a feedstock material is melted with a laser and then deposited onto a substrate. A variety of pure metals and alloys can be used as the feedstock, as well as composite materials such as metal matrix composites. Laser sources with a wide variety of intensities, wavelengths, and optical configurations can be used. While LMD is typically a melt-based process, this is not a requirement, as discussed below. Melt-based processes typically have a strength advantage, due to achieving a full metallurgical fusion.
