METALS

Types, Properties and Production

FFD 301 Furniture Design By Ertan Demirkan 2012

Manufacturing Processes

All manufacturing processes can be classified into seven types:

1. Casting and Molding 2. Forming and Shearing 3. Machining (material removal) Chip-making Chipless Heat cutting 4. Heat treating 5. Finishing 6. Assembly 7. Inspection

Manufacturing Methods

Types of Metals

Metals

Ferrous Nonferrous Powdered Metallurgy

Cast Iron Teapot

Forged Iron Table Forged Iron Chair

Steel Coffe Table Tool Steel (hi-alloy) Swords

Steel Armchair

Aluminium Table (sheet top, cast foot)

Aluminium Folding Chair (tube structure) Aluminium accessories (cast)

Gold cabinet(sheet top, cast foot)

Gold Plated Mirror

Silver Urns

Silver Embossed Chest

Silver Ring

Chrome plated water tap Chrome plated furniture parts

Chrome plated car

Nickel plated gun

Platinum diamond ring

Titanium plated watches Tin boxes

How to Form Metal

Liquid State Forming - Casting and Molding

Casting: -A mold is prepared with the pattern (model of the object) - Melted metal is poured into the mold. - When it gets cold, object is taken off and finishings are made. Molding: -A mold is prepared (usually from a harder and temperature resistant metal -steel-) - Metal granules or heated metal (not melted-fluid) is injected and pressured into the mold. - Heat treatment under pressure is applied to the mold. - When it gets cold, object is taken off and finishings are made.

Liquid State Forming - Casting and Molding

Liquid State Forming - Casting and Molding

Liquid State Forming - Casting and Molding

Furniture accessories (legs, handles, knobs, etc.)

Furniture parts

Liquid State Forming - Casting and Molding

Furniture produced by Casting

Plastic State Forming

Plastic State Forming is a forming operation on a solid bar of metal, at elevated temperature, but below critical or melting temperature. The aim of this operation is not only to shape the material, but also to control the grain structure, so the strength of the formed part is enhanced.

Plastic State Forming - Rolling

Plastic State Forming – Forging (Drop forging)

Plastic State Forming – Forging

Plastic State Forming – Drawn Wire

Plastic State Forming – Direct Extrusion

Plastic State Forming – Direct Extrusion

Plastic State Forming – Direct Extrusion

Extruded (aluminium) profiles

Plastic State Forming – Direct Extrusion

Extruded (aluminium) parts in furniture

Plastic State Forming – Extrusion

Extruded (aluminium) parts in furniture

Plastic State Forming – Impact Extrusion

Solid State Forming

Solid State Forming – Wire and Tube Bending

Solid State Forming – Wire and Tube Bending

Eames, Eiffel Chair Harry Bertoia, Wire Chair

Solid State Forming – Wire and Tube Bending

Solid State Forming – Wire and Tube Bending

Solid State Forming – Roll Bending (sheet metal)

Solid State Forming – Roll Bending (sheet metal)

Solid State Forming – Die Bending (Press Brake - sheet metal)

Solid State Forming – Die Bending (Press Brake - sheet metal)

Solid State Forming – Die Bending (Press Brake - sheet metal)

Solid State Forming – Spinning (sheet metal)

Solid State Forming – Spinning (sheet metal)

Solid State Forming – Drawing and Deep Drawing (sheet metal)

Solid State Forming – Punching (sheet metal)

Solid State Forming – Shearing (sheet metal)

Chip Forming Cutting - Machining

Chip Forming Cutting - Machining

Chip Forming Cutting – Flame and Lazer cutting

Chip Forming Cutting – Flame and Lazer cutting

Metal Joining

Metal Joining - Soldering

Metal Joining – Gas Welding

Metal Joining – Arc Welding

Metal Joining – Arc Welding

Metal Joining – Gas Tungsten Arc Welding

Metal Joining – Resistance Welding

Metal Joining – Adhesive Joining

Metal Joining – Mechanical

Metal Joining – Mechanical

Metal Joining – Mechanical

Metal Joining – Mechanical (Pop Riveting)

Metal Joining – Mechanical

Appearance Finishing and Coating

RESOURCES:

1. Industrial Design, Materials and Manufacturing Guide, Jim Lesco, 2008, 2nd ed.,John Wiley & Sons, New Jersey

2. Materials and Processes in Manufacturing, E. Paul DeGarmo, 1969, 3rd ed., The Macmillan Company, Canada

3. Internet resources; Youtube, Wikipedia, Design Websites. (by keyword research)

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