What is the Difference between ingot and billet?
An ingot is a piece of metal that has been formed by casting a
generic shape from molten liquefied metal, allowing it to freeze
and crystallize back into a solid form.
Billet is formed by taking an ingot and applying uniform
pressure on the surface to compact and redirect the microscopic
crystalline structure of the metal. This process provides a much
denser alloy as it can remove tiny imperfections due to the nature
of casting. Also when done using the proper heating and quenching
methods, this process can be used to control the ductility,
hardness, and other properties, of the final raw billet.
Billet is compressed to, or cut to size for machining the final
product. This process can be understood simply by looking at wood,
when looking at a raw board one will notice the grain running along
the surface. If you take a board that is long thin and wide say;
12"X1/2" and 8 feet long, and try and snap it in half, it is
difficult if not impossible. If that board is cut shorter lets say
12"X1/2" by 1 foot long and turned sideways, you are now able to
strike it between the grain and it will break easily. This is what
we have all seen before with little kids in Karate classes punching
through wood.
Metal acts the same way, when it is liquid being cast it acts
like river rapids swirling and moving around many different
directions in the mold, until suddenly small molecules start to
seed into a crystal structure. This can be likened to when you
place a water filled ice tray in the freezer and come back too soon
for ice. You now find in each little pocket of the tray there are
different shapes of ice that are similar but not all the same none
are entirely frozen but all have both water and ice.
When molten metal is poured it is just like that water only it
is going to reach its freezing point much more quickly. Suddenly a
small section inside the mold freezes and forms a small crystal and
it very rapidly grows on that crystal in very uniform structure,
like when a big building is being built and covered in scaffolding
every piece joins the one above beside and below it. every one is
the same size and shape but collectivly the make a larger grid or
structure. only this structure does not sit up and down it forms
according to the orientation of the first crystal. And that crystal
is not alone millions of these crystals form close to the same time
and every one has its own orientation or direction. When that
swirling liquid was poured in the mold, it moved in all kinds of
shapes and directions, now suddenly those shapes and directions
freeze causing the metal to be trapped in a random swirling
pattern.
While someone might say who cares metal is metal. This factor is
just as important as the board mentioned earlier. If your house was
made with boards like the short one that broke easily because it
was broken with the grain, it would not be standing, it would fall
to pieces. Similarly, the structure of the grain of the metal
affects its long term durability and its performance under
stress.
As part of the process of making billet a metal is heated to
just under it's melting point. The same crystals that had been
frozen now start to move or loose some of their bonds to each
other, at this point if extreme pressure is applied most of those
crystal structures can be aligned together. This takes away one of
the factors that will cause metal to fail because in a casting
there is a big likelihood that somewhere in the cast metal there is
a place that the structure just doesn't quite line up and that spot
just so happens to cross a part of the piece that sees a lot of
wear or pressure, and that causes a failure. By using billet you
all but remove that likelihood, and are left with a much more
reliable part in the end.
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