FusionForged® Technology

FusionForged® Technology
was originally developed specifically for precious metals, but is also applicable to many other alloys. The process produces superior quality, symmetrically formed parts with a fine-grain, defect free microstructure.

What is Fusion Forging? The key feature of Fusion Forging is the simultaneous application of high temperature, high hydrostatic pressure and high-shear plastic deformation to form metals into a useful shape.

Temperatures as high as 1200C (2200F), together with hydrostatic pressures up to 3,500 Mpa (500+ksi) and substantial plastic deformation (up to 100:1), applied simultaneously, combine to produce metals that are fully dense, free of flaws, and exhibit optimum mechanical properties.

Material Benefits of FusionForged® Materials
• Maximum Theoretical Density
• Porosity Free
• Symmetrical Deformation Textures ( Flow Lines)
• Uniform Fine Grain Structure / Fully Wrought Microstructure
• Uniform Temper or Hardness
• Optimal Mechanical Properties
• Economies of Near Net Shapes

Our Precious Metals expertise acts as a fresh set of educated eyes to engineers and manufacturers who may be familiar with traditional metal forming techniques but are not at all familiar with the benefits of FusionForged® technology.

FusionForged® Multi-Metals
Our proprietary Fusion Forging process provides a unique method for producing clads or multi-metals with desirable combinations of properties. By using the benefits of direct forward lubricated extrusion and high temperatures we in effect, provide an incubator to create fully bonded, multiple-layered materials, such as: noble or platinum group metals combined with base or refractory metals. This results in products with multiple material characteristics and benefits.

Benefits of FusionForged® Multi-Metals are identical to single metal materials with the addition of the following:

  • Thicker layers of metallurgically bonded materials provide longer product life than products made using plating or coatings with substantially thinner and less durable layers.

  • Eliminates assembly and plating costs

  • NOBILIS METALS Engineered Precious Metals works directly with product and material engineers to develop improvements in our customer’s products by:

    • Increasing your products “In Service Life”. Reducing or eliminating material failure within the prescribed life of the product or process being engineered is one of an engineer’s primary concerns. NOBILIS METALS addresses that critical concern.
    • Creating multi-metal solutions that improve performance and decrease material costs.
    • Providing practical precious metals manufacturing experience. This experience provides insight into the practical limits of the today’s manufacturing technology as compared with textbook theory.

    Q and A
    • Porosity 
      A primary enemy of a metal’s useful life is porosity. By combining super-heated materials with a force equaling 450,000 tons of pressure, NOBILIS METALS can virtually eliminate porosity by attaining maximum theoretical density.
    • Fully Wrought Microstructure
      NOBILIS METAL’S ability to produce a fully wrought microstructure to these high temperature materials provides metals with ideal grain size and orientation.
    • Uniform Temper or Hardness
      The entire tube, rod or component formed through the FusionForged® process creates consistent temper levels throughout the product.
    • Symmetrical Deformation Textures
      Flow lines provide added strength.
    • Optimal Mechanical Properties
      NOBILIS METALS materials provide improved response to applied stresses by creating materials with ideal tensile strength, yield strength and hardness.
    FusionForged® metal forming process allows 2 or more materials to be co-extruded, forming multi-ply metals of up to 7 layers of materials. The process creates the necessary combination of heat and pressure that allows metals with certain similar characteristics to permanently bond together. Atoms migrate from one metal to the other at sufficiently similar rates to produce fully bonded material which under ideal conditions cannot be separated one from the other. Titanium and Gold or Titanium and Silver can be FusionForged® to create optimum thicknesses of either material in order to:
    • Provide only enough precious metal to accommodate the function of the designed product, thus reducing cost.
    • Provide other metals that address other design needs such as strength.
    • Creating sandwiched materials again provides engineers with improved thicknesses of inside and outside precious metal surfaces while providing strength or other material attributes between the precious metal layers at reduced costs.

    Titanium clads are just one of hundreds of metal combinations that can be formed using the FusionForged® Process.

    Precious Metals and their partner elements are simply the colors on a material palette that allow you to create your own High Performance FusionForged® Precious Metals. You, the engineer, become the artist that applies your knowledge of what material properties and characteristics are needed. At NOBILIS METALS we will help you select the materials that will in a practical way accomplish your product vision.

    We invite you, the engineers, to create your own FusionForged® metals to accommodate your companies precious metal product needs.

    Feed Stock Dimensions

    Depending on the materials selected and the product form NOBILIS METALS Clad Products will fall within the dimensional ranges shown below.

    The dimensional range of tubing depend to a degree on the outside diameter to wall ratio as well as the material or alloy selected. NOBILIS METALS makes both seamless and seamed tubing and can accommodate:

    Outside Diameters from .060" (1.52 mm) to 1.280" (32.5 mm)

    Wall thicknesses from 0027" (.069 mm) to .150" (3.81 mm)

    Tube Length: Maximum tube lengths are of course determined by the OD and wall dimensions of the tube. Tube can be cut to length as required.

    Rod & Wire

    Minimum Diameter: .003" (076 mm)

    Maximum Diameter: 1.90" (48.26mm)

    Straight Lengths for diameters from .025" (.635 mm) to .377" (9.58 mm) / 1 to 12' length.

    Coils / Spools for diameters from .022" (.559 mm) to .350" (8.89 mm)
    Weight per spool 50 to 300 troy ounces depending on coil, spool or reel size.
    NOBILIS METALS will customize wire packaging as required

    Flat Stock
    Sheet, Strip, Foil, Ribbon

    Thickness: .001" (.0254 mm) to .100" (2.54 mm)

    Note: Thicker material can be produced if a high grade finish is not required.

    Widths: Maximum Width is 12" (304.8 mm) Minimum width is determined by thickness and material selected.

    Call for details.

    Straight Lengths: Maximum of 8'

    Coiled lengths: 300 Toz Maximum

    Tolerance: Dimensional tolerances will vary depending on the thickness and width required.


    Clads for Electrical Applications

    • Test Probes - Circuit Boards
    • Electrical Contacts
    • Electrodes

    Clads as Contact Alloys
    A simple example of an electrical contact would be a switch which has two pieces of metal called contacts that touch to make a circuit, and separate to break the circuit. The contact material is chosen for its resistance to corrosion, because most metals form insulating oxides that would prevent the switch from working.

    Electrical Contacts are often clad with precious metals or manufactured from solid precious metal alloys. Contact materials are also chosen on the basis of electrical conductivity, hardness (resistance to abrasive wear), mechanical strength, low cost and low toxicity.

    Clads as Electrodes
    An electrode is an electrical conductor used to make contact with a nonmetallic part of a circuit (e.g. a semiconductor, an electrolyte or a vacuum). Electrodes can be made from Gold, Silver, Platinum and combination alloys, depending on the application and required characteristics appropriate to the application


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