Manufacturing

Manufacturing

1. Solidification

   • Metal casting
   • Glass working
   • Injection moudling
   • Rubber shaping
   • Benefits
     • Net Shape
     • Complex geometries
     • Facilitates Recycling
   • Environmental Concerns
     • Energy Intensive
     • Furnace Emissions
     • Material Emissions
     • Mould Emissions

2. Particulate

   • Powder Metallurgy
   • Additive Manufacture
   • Ceramics/Cermets
   • Benefits
     • Net shape
     • Use hard to machine materials
     • Can create alloys and cermets
   • Environmental Concerns
     • Particle storage - explosion risk
     • Health issues
     • Powder production - energy intensive
     • Binder Burn off
     • Sintering energy / heat for firing

3. Deformation

   • Rolling
   • Forging
   • Extrusion
   • Benefits
     • Near net shape
     • Efficient volume manufacturing
     • Cheaper than material removal
     • Low material waste
   • Environmental Concerns
     • Use of lubricants
     • Cleaning fluids
     • Sheet metal cutting - waste
     • Large Tooling

4. Removal

   • Milling
   • Drilling
   • Turning
   • Grinding
   • Laser/Water jet
   • Benefits
     • FLexible
   • Environmental Concerns
     • Cutting fluid for metal - health and waste issues
     • Scrap - swarf/chips
     • Energy Intensive
     • Large virgin material required

5. Heat Treatment

   • Surface hardening
   • Annealing
   • Quenching
   • Tempering
   • Benefits
     • Improve material performance - ductility, fatigue life, hardness
     • Longer service life
   • Environmental Concerns
     • Intensive energy usage
     • Furnace Emissions
     • Chemicals - nitriding, carbonising

6. Sand Binder By Products

   • Heating of sand during casting- produce harmful air pollutants