Materials are typically mined from their ores and refined before being used in a variety of applications. The stages from mining to purification are often tedious and expensive, such that the finished products in their pure state become expensive as well.
Many technologies are emerging that require materials with very specific properties. Hence, the use of pure materials becomes inherently limited because of their intrinsic properties—they are generally softer, can be easily corroded, and above all are not cost-effective for a wide range of applications.
An alternative solution to these challenges is the development of alloys.
Why are Alloys Used?
During the process of synthesizing alloys, all components are initially melted and mixed. As mixing proceeds, contaminants are removed while the product is also protected from oxidation. Industrial manufacturing of alloys uses arc melting and induction to facilitate the melting and mixing process.
AerMet100 alloy is one of such alloys made from steel, cobalt, and nickel. Often added are also chromium and molybdenum. The combination of these materials confers fracture toughness and ductility, superior hardness, resistance to corrosion cracking, and high tensile strength.
AerMet100 Steel and Processing
This alloy is produced by the Carpenter technology corporation and is well known for its ultra-high-strength,
According to a Service Steel Aerospace Corp. fact sheet, tensile strength and ductility make this alloy a candidate for applications such as landing gear, armor, fasteners, actuators, ordnance, jet engine shafts, driveshafts, structural tubing, etc. It can function properly in temperatures as high as 800° F (427° C).
The need for materials is increasing and the shapes of parts are becoming very complex such that traditional forging methods are no longer suitable for their production. Many preforming operations are required before finishing forging (Forging involves heating, deforming, and finishing a piece of metal) when the desired final shape of the item is complicated. This ensures a better functional cross-section and final shape. Therefore, the process is longer as the complexity of the parts increases.