Ingot A material, usually metal, that is cast into a shape suitable for further processing.

. Billet - A length of metal that has a round or square cross-section, with an area less than 36 sq in (230 cm2). Billets are created directly via continuous casting or extrusion or indirectly via hot rolling an ingot. Bloom - Similar to billets except the cross-sectional area is greater than 36 sq in (230 cm2). Slab - A slab is a length of metal that is rectangular in cross-section, created directly from continuous casting or indirectly by rolling an ingot. Cast Structure - Large, columnar grains; dendrites; coring; microporosity. Wrought Structure Recrystallized grain structure; less compositional segregation (compared to cast structure), porosity welded shut, brittle inclusions broken, ductile inclusions deform Stringers - Filaments of slag left in wrought iron after the production process. In their correct proportions their presence is beneficial, as they help to control the ductility of the finished product, but when the proportion of slag is too high, or when the filaments run at right angles to the direction of tension, they can cause weakness. Pickling - a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from ferrous metals, copper, and aluminum alloys. A solution called pickle liquor, which contains strong acids, is used to remove the surface impurities. It is commonly used to descale or clean steel in various steelmaking processes. Scale (Mill Scale) - the flaky surface of hot rolled steel, iron oxides consisting of iron(II,III) oxide, hematite, and magnetite. Open-Die Forging - In open-die forging, a hammer strikes and deforms the workpiece, which is placed on a stationary anvil. Blocking (no definition) The stage in forging where the part shape is made from the bar stock. Upset [Forging] - Upset forging increases the diameter of the workpiece by compressing its length. Closed-Die Forging Here, the metal is placed in a die resembling a mold, which is attached to the anvil. Usually, the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the metal to flow and fill the die cavities. No flash is formed. Impression-Die Forging Workpiece acquires the shape of the die cavity. Generally the same as closeddie forging with the addition of flash being formed. Isothermal Forging - Isothermal forging is a hot working process that attempts to maintain the work piece at its maximum elevated temperature throughout the entire operation. This is achieved by heating the die to the temperature of, or slightly below the temperature of the starting work piece.

Drop-Hammer Forging - Drop forging is a forging process where a hammer is raised and then "dropped" onto the workpiece to deform it according to the shape of the die. Counter-blow vs Conventional Hammer Forging The main difference between the two types is that counterblow hammers have two rams that simultaneously approach each other to forge the part, transmitting less vibration to the foundation than traditional hammers. Press Forging - Works by slowly applying a continuous pressure or force, which differs from the nearinstantaneous impact of drop-hammer forging. The amount of time the dies are in contact with the workpiece is measured in seconds (as compared to the milliseconds of drop-hammer forges). The press forging operation can be done either cold or hot. The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the complete workpiece. Drop-hammer forging usually only deforms the surfaces of the work piece in contact with the hammer and anvil; the interior of the workpiece will stay relatively undeformed. Flash Material that flows radially outward past the die cavity. Rolling Process of reducing thickness or changing (cross-sectional) shape using a set of rolls. Plates Thickenss > 6mm, structural applications Sheets Thickness < 6mm, automobile bodies, appliances, food containers, etc. Foil Thickness < 200m Ring Rolling - a specialized type of hot rolling that increases the diameter of a ring. The starting material is a thick-walled ring. This workpiece is placed between two rolls: an idler roll, while another roll, called the driven roll, presses the ring from the outside. Thread Rolling A cold-forming process in which treads are formed on round rods or workpieces by passing them between reciprocating/rotating dies (makes screws, bolts, etc.) Extrusion Pushing material through a die; produces long lengths of solid/hollow products with constant cross-section; usually done by hot-working and non-ferrous. Spider-mandrel Die - An extrusion die for producing hollow shapes, whose mandrel is supported by multiple legs attached to the cap. Metal flows between the spider's legs and reunites before emerging through the die aperture. CCD Circumscribing Circle Diameter; diameter of smallest circle the part shape will fit into. Shape Factor Ratio of the perimeter to the cross-sectional area. Extrusion Ratio - the starting cross-sectional area divided by the cross-sectional area of the final extrusion

Drawing Pulling material through a die; usually simple shapes (wire); usually cold working; thickness not reduced. Stamping (Pressing) - includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. Bending - a manufacturing process that produces a V-shape, U-shape, or channel shape along a straight axis in ductile materials, most commonly sheet metal. Forming - the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged Shearing - a process which cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are shearing-type operations. Blanking [& Piercing] - shearing processes in which a punch and die are used to modify webs. The tooling and processes are the same between the two, only the terminology is different: in blanking the punched out piece is used and called a blank; in piercing the punched out piece is scrap. Punching - a metal forming process that uses a punch press to force a tool, called a punch, through the workpiece to create a hole via shearing. The punch often passes through the work into a die. Deep Drawing - a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. Fine blanking - Fine blanking is a specialized form of blanking where there is no fracture zone when shearing. This is achieved by compressing the whole part and then an upper and lower punch extract the blank. Flanging - A bending operation that bends the edge of a part to add stiffness. Flanging most often creates a 90 degree bend in the metal. Beading [Curling] - A forming operation that creates a curved rim around the top of a hollow part. Hemming - A bending operation that bends and folds an edge of sheet metal back upon itself. Hemming conceals the sharp edge of sheet metal. Lancing - A shearing operation that cuts an interior section of the metal without removing the section. A lancing operation leaves an opened metal tab.

Notching A shearing operation that removes a section from the outer edge of the metal strip or part. Perforating Punching a number of holes in a sheet. Press Brake - a machine tool for bending sheet and plate material, most commonly sheet metal. It forms predetermined bends by clamping the workpiece between a matching punch and die. Seaming - A bending operation that joins the interlocking edges of two separate metal sheets together by folding them over one another. Springback - The tendency for sheet metal to return to its original shape after a bending or forming operation.