METALS

Dato, Dominic M.
Esquillo, Mark Ryan L.
Fabia, Bernardo M.
Sison, Elijah G.
Tan, Nicolas T.
 WHAT IS A METAL?

• a solid material that is typically hard, shiny, malleable, fusible, and ductile, with
good electrical and thermal conductivity.
• Most metals are malleable and ductile and are, in general, denser than the other
elemental substances.
 Where do metals come from?
- Most pure metals, like aluminium, silver and copper, come from the Earths crust. They
are found in ores solid materials called minerals, usually occurring in rock, from which the
pure metal has to be extracted. The properties of pure metals can be improved by mixing them
with other metals to make alloys.

- People first began making things from metal over 6000 years ago, when they discovered
how to get copper from its ore. They then learned how to make a harder alloy, bronze, by
adding tin to the copper. About 3000 years ago, they discovered iron. By adding small
amounts of carbon to iron, they found that they could make a particularly useful alloy steel.
METAL MANUFACTURING
PROCESS
Types of Metal Manufacturing Processes
 PRODUCTION
• CASTING
 Depending on the metal and its purpose, the metal may simply be melted down and
molded to shape. This process is known as casting
• POWDER PROCESSING
 Powder processing treats powdered metals with pressure (pressing) and heat
(sintering) to form different shapes.
• FORMING
 Metal forming takes a raw metal (usually in sheet metal form) and mechanically
manipulates it into a desired shape.
 FABRICATION
• DEFORMATION
 Deformation includes bending, rolling, forging, and drawing. 
• MACHINING
 Machining refers to any fabrication method that removes a section of the metal.
• JOINING
 Joining or assembly is one of the last steps of the metal manufacturing process.
• FINISHING
 Finishing includes everything from galvanization to powder coating, and can take
place throughout the manufacturing process.
PHYSICAL PROPERTIES OF
METAL
 DUCTILE
• able to be deformed without
losing toughness; pliable, not
brittle.
• Example: gold, silver, copper.
 MALLEABLE
• able to be hammered or pressed
permanently out of shape without
breaking or
cracking.
• Example: Stainless
 METALLIC LUSTER
• Metallic luster is for minerals that
are opaque and reflective and have
the look of polished metal.
• Example: Galena, Cesium
 CONDUCTORS
• Metals are generally
good conductors of heat for the
same reason they are
good conductors of electricity.
• Example: silver, aluminum,
copper
 CORROSION
• The process of corroding metal,
stone, or other materials.
• Example: rust
 Mechanical Properties of Metals
• Often materials are subject to an external force when they are used.
Mechanical Engineers calculate those forces and material scientists how
materials deform or break as a function of force, time, temperature, and
other conditions.
• Some of the important mechanical properties of the metals are:
Brittleness, Creep, Ductility, Elasticity, Fatigue, Hardness,
Malleability, Plasticity, Resilience, Stiffness, Toughness, Yield
strength. 
 ALLOYS
• Alloy Steels - Alloy steel is steel that is alloyed with a variety of elements
in total amounts between 1.0% and 50% by weight to improve its
mechanical properties. Alloy steels are made by combining carbon steel
with one or several alloying elements, such as manganese, silicon, nickel,
titanium, copper, chromium and aluminum.
 TOOL STEEL
• Type of carbon alloy steel that is well-matched for tool manufacturing,
such as hand tools or machine dies.
• Tool steel is typically used in heat treated condition which provides
increased hardness. Several grades have additional resistance to corrosion
due to added chemical properties such as vanadium. Also, with certain
grades the manganese content is restricted in order to minimize the
potential of cracking while water quenching.
TOOL STEEL GRADES
 Water Hardening (W-Grades)
• This is basically a high carbon steel. This steel can achieve a high
hardness, but it is rather brittle when compared to other tool steels.
• Typical applications of W-Grade tool steel include Cold Heading,Cutting
tools and knives, Embossing, Reamers and Cutlery.
 Air Hardening (A-Grades)
• This is a very versatile, all-purpose tool steel that is characterized by low
distortion factor during heat treatment, due to the increased chromium
content. This tool steel has good machinability and a balance of wear
resistance and toughness.
• Typical applications of A-Grade tool steel include Arbors, Cams, Die
Bending, Blanking, Coining, Embossing, Cold Forming, Lamination, Cold
Swaging, Cold Trimming, Gages, Chipper Knives, Cold Shear knives,
Woodworking Knives, Lathe Center Knives.
 D Type (D-Grades)
• This is a high carbon, high chromium (air hardening) tool steel. It was
formulated to combine both the abrasion resistance and air-hardening
characteristics.
• Typical Applications of D-Grade tool steel include Burnishing Tools, File
Cutting, Paper Cutters, Die Bending, Blanking, Coining, Cold Heading
Die Inserts, Embossing, Cold Extrusion, Cold Forming, Lamination, Cold
Swaging, Thread Roll, Cold Trimming, Wire Drawing, Gages, Paper
Knives, Rotary Slitters, Cold Shear Knives, Woodworking Knives,
Knurling tools and Lathe Center Knives.
 Oil Hardening (O-Grades)
• This is a general purpose oil hardening tool steel. It has good abrasion
resistance and toughness for a wide range of applications.
• Typical applications of O-Grade tool steel include Arbors, Bushing,
Chasers (Thread Cutting), Collets, Die Blanking, Cold Forming, Cold
Trimming, Drill Bushing, Gages, Knurling Tools.
 Shock resisting types (S-Grades)
• This type of tool steel has been designed to resist shock at low or high
temperatures (E.g. Jackhammer bits). Its low carbon content is required to
achieve the necessary toughness.
• Typical applications of S-Grade tool steel include Battering Tools, Boiler-
Shop Tools, Chisel Blacksmiths, Chisel Cold Working, Chisel Hot
Working, Chuck Jaws, Clutch Parts, Collets, Cold Gripper, Hot Gripper,
Cold Swaging, Hot Swaging, Hot Trimming, Chipper Knives, Cold Shear
and Hot Shear.
 Hot-Working (H-Grades)
• This tool steel group is used to cut material at high temperatures. The H-
Group has added strength and hardness for prolonged exposure to elevated
temperatures. They are low in carbon and moderately high in additional
alloys.
• Typical applications of H-Grade tool steel include Cold Heading Die
Casings, Die Casting Dies and Cores for Zinc and Aluminum, Hot
Extrusion for Aluminum and Magnesium, Hot Forging, Hot Gripper, Hot
Swaging, Hot Trimming, Dummy Blocks (Hot Extrusion), and Hot Shear
Knives.
ALLOY CAST STEEL AND
IRON
 CAST STEEL
• ferrous (iron-based) alloy with a
maximum carbon content of
approximately 0.75 percent.
• Mechanical properties for cast
steel are generally lower than
wrought steels with the same
chemical composition.
 CAST IRON
• is a group of iron-carbon alloys with a carbon
content greater than 2%. Its usefulness derives
from its relatively low melting temperature.
• The alloy constituents affect its color when
fractured: white cast iron has carbide impurities
which allow cracks to pass straight through,
grey cast iron has graphite flakes which
deflect a passing crack and initiate countless
new cracks as the material breaks, and ductile
cast iron has spherical graphite "nodules"
which stop the crack from further progressing.
 COPPER ALLOY
• are metal alloys that
have copper as their principal
component. They have high
resistance against corrosion.
 ALUMINUM ALLOY
• are alloys in which aluminum (Al)
is the predominant metal. The
typical alloying elements
are copper, magnesium, manganes
e, silicon, tin and zinc.
 MAGNESIUM ALLOYS
• are mixtures of magnesium with
other metals (called an alloy).
• Magnesium is the lightest
structural metal. 
 REFERENCES
• https://me-mechanicalengineering.com/mechanical-properties-of-metals/
• https://www.nature.com/subjects/metals-and-alloys
• http://www.funscience.in/study-zone/Chemistry/Metals/PhysicalPropertiesOfMetals.php
• https://www.slideshare.net/KunalGupta146/physical-properties-of-metals-and-non-
metals
• https://schoolworkhelper.net/metals-chemical-physical-properties/
• http://www.historyworld.net/wrldhis/PlainTextHistories.asp?ParagraphID=bax
• https://blog.mchoneind.com/blog/metal-manufacturing-processes
• https://sites.esm.psu.edu/courses/emch13d/design/design-
tech/manufacturing/manuf_2.html