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Metallurgy

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.

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Etymology and pronunciation[edit]

Metallurgy derives from the Ancient Greek μεταλλουργός, metallourgós, "worker in metal", from μέταλλον, métallon, "mine, metal" + ἔργον, érgon, "work" The word was originally an alchemist's term for the extraction of metals from minerals, the ending -urgy signifying a process, especially manufacturing: it was discussed in this sense in the 1797 Encyclopædia Britannica.[6]


In the late 19th century, metallurgy's definition was extended to the more general scientific study of metals, alloys, and related processes. In English, the /mɛˈtæləri/ pronunciation is the more common one in the United Kingdom. The /ˈmɛtəlɜːri/ pronunciation is the more common one in the United States US and is the first-listed variant in various American dictionaries, including Merriam-Webster Collegiate and American Heritage.

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Metallurgy encompasses both the science and the technology of metals, including the production of metals and the engineering of metal components used in products for both consumers and manufacturers. Metallurgy is distinct from the craft of metalworking. Metalworking relies on metallurgy in a similar manner to how medicine relies on medical science for technical advancement. A specialist practitioner of metallurgy is known as a metallurgist.


The science of metallurgy is further subdivided into two broad categories: chemical metallurgy and physical metallurgy. Chemical metallurgy is chiefly concerned with the reduction and oxidation of metals, and the chemical performance of metals. Subjects of study in chemical metallurgy include mineral processing, the extraction of metals, thermodynamics, electrochemistry, and chemical degradation (corrosion).[1] In contrast, physical metallurgy focuses on the mechanical properties of metals, the physical properties of metals, and the physical performance of metals. Topics studied in physical metallurgy include crystallography, material characterization, mechanical metallurgy, phase transformations, and failure mechanisms.[2]


Historically, metallurgy has predominately focused on the production of metals. Metal production begins with the processing of ores to extract the metal, and includes the mixture of metals to make alloys. Metal alloys are often a blend of at least two different metallic elements. However, non-metallic elements are often added to alloys in order to achieve properties suitable for an application. The study of metal production is subdivided into ferrous metallurgy (also known as black metallurgy) and non-ferrous metallurgy, also known as colored metallurgy.


Ferrous metallurgy involves processes and alloys based on iron, while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95% of world metal production.[3]


Modern metallurgists work in both emerging and traditional areas as part of an interdisciplinary team alongside material scientists and other engineers. Some traditional areas include mineral processing, metal production, heat treatment, failure analysis, and the joining of metals (including welding, brazing, and soldering). Emerging areas for metallurgists include nanotechnology, superconductors, composites, biomedical materials, electronic materials (semiconductors) and surface engineering. Many applications, practices, and devices associated or involved in metallurgy were established in ancient India and China, such as the innovation of the wootz steel , bronze, blast furnace, cast iron, hydraulic-powered trip hammers, and double acting piston bellows.[4][5]

Much effort has been placed on understanding iron–carbon alloy system, which includes steels and cast irons. Plain carbon steels (those that contain essentially only carbon as an alloying element) are used in low-cost, high-strength applications, where neither weight nor corrosion are a major concern. Cast irons, including ductile iron, are also part of the iron-carbon system. Iron-Manganese-Chromium alloys (Hadfield-type steels) are also used in non-magnetic applications such as directional drilling.


Other engineering metals include aluminium, chromium, copper, magnesium, nickel, titanium, zinc, and silicon. These metals are most often used as alloys with the noted exception of silicon, which is not a metal. Other forms include:

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particularly Austenitic stainless steels, galvanized steel, nickel alloys, titanium alloys, or occasionally copper alloys are used, where resistance to corrosion is important.

Stainless steel

Aluminium alloys and magnesium alloys are commonly used, when a lightweight strong part is required such as in automotive and aerospace applications.

Copper-nickel alloys (such as ) are used in highly corrosive environments and for non-magnetic applications.

Monel

Nickel-based like Inconel are used in high-temperature applications such as gas turbines, turbochargers, pressure vessels, and heat exchangers.

superalloys

For extremely high temperatures, alloys are used to minimize creep. In modern electronics, high purity single crystal silicon is essential for metal-oxide-silicon transistors (MOS) and integrated circuits.

single crystal

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– molten metal is poured into a shaped mold. Variants of casting include sand casting, investment casting, also called the lost wax process, die casting, and continuous castings. Each of these forms has advantages for certain metals and applications considering factors like magnetism and corrosion.[30]

Casting

– a red-hot billet is hammered into shape.

Forging

– a billet is passed through successively narrower rollers to create a sheet.

Rolling

– a hot and malleable metal is forced under pressure through a die, which shapes it before it cools.

Extrusion

lathes, milling machines and drills cut the cold metal to shape.

Machining

– a powdered metal is heated in a non-oxidizing environment after being compressed into a die.

Sintering

– sheets of metal are cut with guillotines or gas cutters and bent and welded into structural shape.

Fabrication

– metallic powder is blown through a movable laser beam (e.g. mounted on a NC 5-axis machine). The resulting melted metal reaches a substrate to form a melt pool. By moving the laser head, it is possible to stack the tracks and build up a three-dimensional piece.

Laser cladding

– Sintering or melting amorphous powder metal in a 3D space to make any object to shape.

3D printing