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| Materials processing | |
|---|---|
| Name | Materials processing |
| Discipline | Materials science |
| Related | Metallurgy; Ceramics; Polymers; Composites |
Materials processing is the set of industrial and laboratory operations that transform raw materials and feedstocks into engineered products through thermal, mechanical, chemical, electrical, and additive procedures. It links foundational innovations from the Industrial Revolution and the Bessemer process to modern developments at institutions such as Massachusetts Institute of Technology, Fraunhofer Society, and Lawrence Livermore National Laboratory. Practitioners draw on practices developed by figures like Henry Bessemer, Harry Brearley, and organizations including ASM International and American Society for Metals to tailor microstructure, composition, and properties for sectors served by companies like General Electric, Siemens, and Boeing.
Materials processing integrates inputs from suppliers such as Rio Tinto Group and ArcelorMittal with design guidance from standards bodies like ASTM International and ISO. The discipline encompasses the lifecycle from extraction at sites like Chuquicamata and Carajás Mine through conversion at facilities operated by Tata Steel and Nippon Steel into components used by Lockheed Martin, Toyota, and Apple Inc.. Key historical milestones include the rise of the Iron Age, the introduction of the Bessemer process, and advances in the Semiconductor revolution led by firms such as Intel and research centers like Bell Labs.
Common processing routes include casting practices refined by firms like P&O, forging methods used by Rolls-Royce Holdings, and welding techniques developed in research at Imperial College London. Techniques such as powder metallurgy applied by GKN and additive manufacturing advanced at MIT Media Lab coexist with chemical vapor deposition pioneered at Bell Labs and physical vapor deposition used by Applied Materials. Thermal treatments trace lineage to work at Oak Ridge National Laboratory and Los Alamos National Laboratory, while surface engineering methods from Daimler AG and BMW incorporate coatings from suppliers like DuPont.
Processed materials range from ferrous alloys produced by ArcelorMittal and Nucor to nonferrous metals obtained by Alcoa and Rio Tinto Group; ceramics developed at Corning Incorporated and polymers formulated by BASF and Dow Chemical Company; as well as composites engineered by Hexcel and Toray Industries. Properties targeted include strength standards used in ASME codes, fatigue protocols from SAE International, and corrosion criteria referenced by NACE International. High-performance classes such as superalloys associated with GE Aviation and semiconductor wafers from TSMC illustrate the linkage to organizations and facilities like Semiconductor Research Corporation.
Processing equipment spans blast furnaces once typified by Carnegie Steel Company installations, electric arc furnaces utilized by Paul Héroult-inspired firms, and rolling mills instituted by Stephenson family-era rail producers. Instrumentation for characterization includes X-ray diffractometers from Rigaku and Bruker, scanning electron microscopes supplied by JEOL and FEI Company, and thermal analyzers developed at TA Instruments. Automation and robotics incorporate systems from ABB and Fanuc, while control platforms often cite implementations from Siemens and Rockwell Automation.
Statistical process control originates from teachings associated with Shewhart and was popularized through programs at Bell Laboratories and Western Electric Company. Metrology practices reference calibrations maintained by bodies such as National Institute of Standards and Technology and Physikalisch-Technische Bundesanstalt. Certification regimes involve auditors from ISO and accreditation by International Accreditation Forum, while reliability modeling uses methods influenced by Weibull analysis and standards from MIL-STD specifications used by United States Department of Defense contractors.
Materials processing underpins aerospace programs at NASA and Boeing, automotive manufacture at Ford Motor Company and Toyota, energy infrastructure for Siemens Energy and Schneider Electric, medical devices produced by Medtronic and Johnson & Johnson, and electronics supply chains led by Samsung Electronics and Intel. Construction projects such as those by Bechtel and Vinci rely on processed concretes and steels, while consumer goods from Procter & Gamble and Unilever incorporate polymers and coatings derived from processing lines.
Environmental controls reference emission limits set by agencies like the Environmental Protection Agency and European Environment Agency and remediation methods developed at Argonne National Laboratory. Occupational safety protocols follow guidance from Occupational Safety and Health Administration and International Labour Organization, and lifecycle assessments draw on frameworks from UNEP and IPCC reports. Emerging initiatives include circular economy strategies promoted by Ellen MacArthur Foundation and decarbonization roadmaps advocated by International Energy Agency.