In the sintering vs. melting discussion, the definition of melting is straightforward: applying enough heat to transform material from a solid state to a liquid. On a molecular level, as the temperature increases, the ions in the metal vibrate more and more, eventually breaking their bonds and moving freely. Once the bonds are loosened, and the material’s internal structure shifts, it becomes a liquid. Different melting temperatures are often required when combining two or more metals since each material has its own melting point. Some metals, like iron and nickel, melt relatively easily, while refractory metals, as mentioned before, don’t melt under normal conditions.
Melting is sometimes used to change a metal’s physical characteristics, but its most frequent use is to prepare metal for casting. In casting, the manufacturer pours molten metal into a die or mold to create a part. Patterns for casting can be made of molding sand, wax or other metals. Casting is particularly useful in manufacturing intricate or large components, such as an engine block. Disadvantages of casting include:
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