1- SAND CASTING

Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand.

2- INVESTMENT CASTING

Castings allow the production of components with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys. Lostfoam casting is a modern form of investment casting that eliminates certain steps in the process.The process is generally used for small castings, but has been used to produce complete aircraft door frames, steel castings of up to 300 kg (660 lbs) and aluminium castings of up to 30 kg (66 lbs). It is generally more expensive per unit than die casting or sand casting, but has lower equipment costs. It can produce complicated shapes that would be difficult or impossible with die casting, yet like that process, it requires little surface finishing and only minor machining.

3- POWDER METALLURGY
Powder metallurgy is the process of blending fine powdered materials, pressing them into a desired shape or form (compacting), and then heating the compressed material in a controlled atmosphere to bond the material (sintering). The powder metallurgy process generally consists of four basic steps: powder manufacture, powder blending, compacting, and sintering. Compacting is generally performed at room temperature, and the elevated-temperature process of sintering is usually conducted at atmospheric pressure. Optional secondary processing often follows to obtain special properties or enhanced precision.[1]

4- FUSION WELDING
Fusion welding is a generic term for welding processes that rely upon melting to join materials of similar compositions and melting points.[1]:755 Due to the high-temperature phase transitions inherent to these processes, a heat-affected zone is created in the material[1]:755 (although some techniques, like beam welding, often minimize this effect by introducing comparatively little heat into the workpiece[1]:778).

5- SOLDERED/BRAZED
Brazing is a metal-joining process whereby a filler metal is heated above melting point and distributed between two or more close-fitting parts by capillary action. The filler metal is brought slightly above its melting (liquidus) temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then cooled to join the workpieces together.[1] It is similar tosoldering, except the temperatures used to melt the filler metal are higher.

6- SPOT WELD

Spot welding (RSW)[1] is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time (approximately ten milliseconds).[2] That permits the welding to occur without excessive heating to the remainder of the sheet.

*7- FIBER REIN. PLASTIC/COMPOSITES

Fibre-reinforced plastic (FRP) (also fibre-reinforced polymer) is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass, carbon, basalt oraramid, although other fibres such as paper or wood or asbestos have been sometimes used. The polymer is usually an epoxy, vinylester or polyester thermosetting plastic, and phenol formaldehyde resins are still in use. FRPs are commonly used in the aerospace, automotive, marine, and construction industries.

8- ANODIZED ALUM

Anodizing (also spelled "anodising", particularly in the UK) is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts. The process is called "anodizing" because the part to be treated forms the anode electrode of an electrical circuit. Anodizing increasescorrosion resistance and wear resistance, and provides better adhesion for paint primers and glues than does bare metal. Anodic films can also be used for a number of cosmetic effects, either with thick porous coatings that can absorb dyes or with thin transparent coatings that add interference effects to reflected light.

*9- RAM EDM

Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks).[1]Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by adielectric liquid and subject to an electric voltage. THICK CUTS vs WIRE EDM

10- ALUM-ZINC DIE CASTING

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from nonferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter an d tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

11- TRANSFER MOLDING

Transfer molding, ( BrE moulding ) like compression molding, is a process where the amount of molding material (usually a thermoset plastic) is measured and inserted before the molding takes place. The molding material is preheated and loaded into a chamber known as the pot. A plunger is then used to force the material from the pot through channels known as a sprue and runner system into the mold cavities. The mold remains closed as the material is inserted and is opened to release the part from the sprue and runner. The mold walls are heated to a temperature above the melting point of the mold material; this allows a faster flow of material through the cavities.

12- WIRE EDM

In wire electrical discharge machining (WEDM), also known as wire-cut EDM and wire cutting,[25] a thin single-strand metal wire, usuallybrass, is fed through the workpiece, submerged in a tank of dielectric fluid, typically deionized water.[23] Wire-cut EDM is typically used to cut plates as thick as 300mm and to make punches, tools, and dies from hard metals that are difficult to machine with other methods.

13- BLOW MOLDING

Blow molding ( BrE moulding ) is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tubelike piece of plastic with a hole in one end in which compressed air can pass through.

14- IMPACT EXTRUSION

Impact extrusion is a manufacturing process similar to extrusion and drawing by which products are made with a metal slug. The slug is pressed at a high velocity with extreme force into a die/mold by a punch.

15- UPSET FORGING OR COLD HEADING

Upset forging increases the diameter of the workpiece by compressing its length.[12] Based on number of pieces produced, this is the most widely used forging process.[12] A few examples of common parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other fasteners.

16- METAL MACHINING

Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The many processes that have this common theme, controlled material removal, are today collectively known assubtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing.

17- IMPRESSION DIE FORGING

Impression-die forging is also called closed-die forging. In impression-die forging, 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. The hammer is generally in contact with the workpiece on the scale of milliseconds. Depending on the size and complexity of the part, the hammer may be dropped multiple times in quick succession. Excess metal is squeezed out of the die cavities, forming what is referred to as flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger than the metal in the die, so it helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. After forging, the flash is removed.[6][10]

18- HYDROFORM
Hydroforming is a specialized type of die forming that uses a high pressure hydraulic fluid to press room temperature working material into a die. To hydroform aluminum into a vehicle's frame rail, a hollow tube of aluminum is placed inside a negative mold that has the shape of the desired result. High pressure hydraulic pumps then inject fluid at very high pressure inside the aluminum which causes it to expand until it matches the mold.

*19- PLASTIC and ALUMINUM EXTRUSION

Extrusion is a process used to create objects of a fixed, cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex crosssections and work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms finished parts with an excellent surface finish.[1]

20- PLASTIC INJECTION

Injection molding (British English: moulding) is a manufacturing process for producing parts by injecting material into a mold. Injection molding can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplasticand thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity.[1]:240 After a product is designed, usually by an industrial designer or an engineer, molds are made by amoldmaker (or toolmaker) from metal, usually either steel or aluminum, and precisionmachined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars.