Process Metallurgy & Manufacturing

From ore to finished part. Casting, extraction, steelmaking and solidification, forging, welding and additive manufacturing.

• Casting — Casting pours molten metal into a mould shaped like the part. Learn sand, die and investment casting, patterns and allowances, gating and risers, solidification time (Chvorinov's rule), and common defects.
• Extractive & Process Metallurgy: From Ore to Product — How metals are made and shaped. Learn mineral processing and extraction routes (pyro-, hydro- and electrometallurgy), Ellingham diagrams and reduction thermodynamics, ironmaking in the blast furnace and DRI, steelmaking (BOF, EAF, secondary refining, degassing), continuous casting, aluminium (Bayer + Hall–Héroult) and copper extraction, solidification and casting (nucleation, dendrites, segregation, Chvorinov's rule, risers, defects), metal forming (rolling, forging, extrusion, drawing, recrystallisation), powder metallurgy and green steel — with Python for Ellingham comparisons, aluminium electrolysis energy and solidification times.
• Forging — Forging shapes hot or cold metal by compressive force. Learn open- and closed-die forging, hot vs cold working, grain flow, true strain and flow stress, forging-force estimation and design rules.
• Welding — Welding joins metals by melting and fusing them. Learn arc processes (SMAW, MIG/MAG, TIG, SAW), heat input, joint types and symbols, weld strength calculations, heat-affected zone, distortion and defects.
• Additive Manufacturing — Additive manufacturing builds parts layer by layer from digital models. Learn the seven ISO/ASTM process families, metal powder-bed fusion, DED and binder jetting, energy density, supports, post-processing and design for AM.