meltprocessing

Melt processing is a set of manufacturing methods in which a material is heated to a molten state and shaped while liquid, followed by solidification. It encompasses metal alloys and polymer resins, which are melted, refined, and formed into shapes through pouring, molding, or other forming steps. The approach emphasizes control of temperature, melt cleanliness, and solidification to achieve desired microstructure and properties.

In metals, common melt-processing techniques include casting (such as sand casting, investment casting, and permanent-mold casting), and continuous casting for billets and slabs. Die casting uses high-pressure injection of molten metal into precision molds for high-volume parts. Some processes also involve remelting and refining (for example vacuum arc remelting or electroslag remelting) to improve purity and microstructure, or melt infiltration for metal matrix composites.

In polymers, melt processing uses the molten resin to form final shapes by extrusion, injection molding, blow molding, thermoforming, or compression molding. Key considerations include thermal stability, viscosity, and shear sensitivity of the polymer, as well as fillers or reinforcements. Processing temperatures are chosen to avoid degradation while achieving adequate flow and filling.

Advantages of melt processing include the ability to produce complex geometries at high production rates and good material uniformity. Limitations include sensitivity to solidification defects (porosity, segregation), residual stresses, and energy intensity. For metals, oxidation and inclusion control are important; for polymers, thermal degradation and shelf life affect process windows.

Applications span automotive, aerospace, consumer electronics, and packaging, where cast components, extruded profiles, and molded parts are common.