Metallurgy is the study of metal. Welding Metallurgy is the study of how welding affects the microstructure of metal.

Did you know that there are metallurgists who devote their lives to only studying carbon steels? So what about all the other metals like Stainless steel, nickel alloys, aluminum, magnesium, titanium, cobalt, and copper alloys?

Metallurgy is such a deep and mysterious subject that it takes a lifetime to completely understand carbon steels much less all the rest.

So if is such a deep subject, what chance does a welder have in understanding enough about metallurgy in order to be a better welder.

There is good news. And its not that I saved a bunch of money on my car insurance by switching to GEICO.

The good news is that you dont have to understand everything about metallurgy. You just need to understand some basic principles.

The absolute fundamental thing to understand is that heat from welding affects metal. That sounds really simple but it is profound. Why? Because heat affects different metals in different ways.

When you heat a piece of metal to red hot, and then quench it by dunking it in a bucket of cold water, what do you think happens? If you answer «it hardens» you are only partially right. Only a few metals harden by heating and quick cooling. Most other metals react totally differently.

Carbon and low alloy Steels like 4130, tool steel, cast iron, and some 400 series stainless steels harden by quick cooling from a red hot temperature.

But most other stainless steels, nickel alloys, aluminum, magnesium, titanium, cobalt, and copper alloys will actually soften and lose properties by heating up red hot and quick cooling.

So what does this mean to you the welder?

If you are doing a weld on 4130 chromoly, you need to know not to speed cool the weld or it will harden.
If you are welding 6061 t6 aluminum, you need to know that the weld area will soften if it gets too hot for too long, and strength will be lost and never regained unless a full heat treatment can be done.

Welding 301 full hard stainless steel is easy to do, but heat from welding recrystallizes the work hardened microstructure and the strength and hardness goes right out the window.

Welding 304 stainless can cause carbon and chromium to bind up and form chromium carbides if the weld area stays too hot for too long.

So do you get the picture. Heat affects different metals in different ways.

Welding Metallurgy studies exactly how the heat from welding affects metal and if you the welder take the time to study metallurgy, the knowledge gained will make you better.

Powder metallurgy was formerly known as lost art. Not like clay or other stoneware materials, the skills in molding and firing useful and ornamental metallic objects were seldom applied in the early phases of history.

Metal powders like gold, copper and also bronze and many other powdered oxides specifically iron oxide which are used as colors, were utilized for ornamental uses in ceramic objects, used as base in paints and inks and also in cosmetics since the start of history. Powdered gold has been used in illustrating several manuscripts in the early times. The procedure in producing the powdered gold was not known, but it was possible that lots of powder were taken through granulation after the melting of the metal. Low dissolving points as well as resistance to corrosion favored the procedures, particularly in production of gold powder.

The utilization of these fine particles for pigments or decorative purposes is not a real powder metallurgy, since the important features of the current art are the creation of powder and consolidation into the hard form by means of putting force and heat at the warmth below the liquefying point of the main element.

The two principal techniques utilized to shape and consolidate the ceramics or powder metallurgy are sintering and injection of metal molding. Current improvements have possibly done to make use of speedy manufacturing techniques that use metal powder. Due to this method the powder is not sintered but melted so better mechanical power can be attained.

A much broader assortment of products might be attained from powder processing rather than straight alloying of merged materials. In dissolving procedure the «phase rule» can be applied to all untainted and merged elements and firmly dictates the sharing of solid and liquid stages which may exist for particular compositions. Furthermore, the entire body liquefying of starting substances is needed for alloying, hence, commanding annoying element, thermal and suppression limitation on manufacturing. Unluckily, the management of aluminum/iron tiny particles poses principal problems. Other materials that are principally reactive by means of atmospheric oxygen like tin is sintered in unique atmosphere or by means of temporary coatings.

In ceramics or powder metallurgy, it is probable to produce components which would disintegrate or decay. All concerns of solid–liquid stage changes may be overlooked, so powder procedures are more supple than forging, casting or extrusion techniques. Controllable character of products set by the use of several powder technologies including automatic, magnetic and some unconventional characteristics of such substances as spongy solids, aggregates and inter–metallic compounds. Competitive distinctiveness of production procedures can also be regulated strictly.

Products of powder metallurgy at present are used in the broad range of business, from automotive as well as aerospace applications into power apparatus and household appliances. Every year the international awards for powder metallurgy highlight the increasing capabilities of the expertise.

Today's Ford's powertrain cost operations is slashed by the discovery of its revolutionary software called VAC. Virtual Aluminum Castings or VAC software was developed by Ford to aid in designing cast components. Said software is capable of pointing out potential stress points in parts for cylinder heads and engine blocks while they are still on the drawing board. Hence, the process is made simplified and more effective.

VAC cuts down the expenses allotted for Ford car parts design purposes. Aside from that, the trial and error stage is spared. Hence, the automaker can save so much time which can be used for other vehicle manufacturing needs and demands.

The VAC software has helped Ford create the new 3.5–liter V–6 engine's cylinder head. It is used to power the new Ford Edge. With VAC software, the process for casting engine parts is made easier and uncomplicated. The traditional and complex process which includes designing a mold, filling it with hot liquid metal, cooling and more is made undemanding. VAC uses advanced thermodynamics, metallurgy and design to make the previously complex and expensive undertaking, simple and easy.

According to Steve Matera, Ford's systems supervisor for the engine, «The use of VAC enabled a flawless launch, and reduced our development time by four months.»

John Allison, senior technical leader at Ford Research and Advanced Engineering also noted, «VAC is revolutionizing the way Ford develops cast aluminum components. We now have the capability to ensure the feasibility of a given design without actually casting a part. The result is increased quality and significantly lowered costs.»

VAC technology was used in developing more than 10 engine programs and it was reported that the total amount of savings amounted to more than $90 million.

Dr. Charles Wu, director of Manufacturing and Vehicle Design Research and Advanced Engineering "VAC is a major accomplishment which demonstrates how Research and Development can work collaboratively within the Ford technical community. It is user friendly software that has been transferred to computer–aided engineering groups worldwide."