# Process effects

Troubleshooting machining chatter, tool wear, distortion, springback and weld defects.

[Manufacturing Wiki](https://planar.so/wiki/index.md)

- [Built-up edge](https://planar.so/wiki/production/process-effects/built-up-edge.md): Workpiece adhesion at a cutting edge: changing geometry, surface damage, diagnosis and bounded choices for a machining trial.
- [Burr formation](https://planar.so/wiki/production/process-effects/burr-formation.md): Residual edge material from manufacturing: process-dependent formation, inspection boundaries, prevention and controlled removal.
- [Cutting dross](https://planar.so/wiki/production/process-effects/cutting-dross.md): Adherent thermal-cutting residue: plasma dross types, laser and oxyfuel distinctions, diagnosis, removal, dimensional protection and acceptance.
- [Decarburization](https://planar.so/wiki/production/process-effects/decarburization.md): Surface carbon loss in steel: complete and partial layers, measurement endpoints, process control and finished-part acceptance.
- [Distortion after machining](https://planar.so/wiki/production/process-effects/distortion-after-machining.md): Shape changes after material removal: bulk and machining-induced stress, clamping, temperature and a controlled measurement handoff.
- [Galling](https://planar.so/wiki/production/process-effects/galling.md): Severe adhesive wear in loaded sliding contacts: material pairs, lubrication, fastener assembly and bounded test interpretation.
- [Galvanic corrosion](https://planar.so/wiki/production/process-effects/galvanic-corrosion.md): Dissimilar conductive materials in wet service: electrical and electrolyte paths, galvanic-series limits, wetted areas, isolation, coatings and investigation.
- [Heat-affected zones](https://planar.so/wiki/production/process-effects/heat-affected-zones.md): Unmelted material changed by thermal processing: alloy-dependent hardening, softening, corrosion effects and qualified inspection.
- [Hydrogen embrittlement](https://planar.so/wiki/production/process-effects/hydrogen-embrittlement.md): Hydrogen-related loss of mechanical performance: susceptibility, exposure, stress, delayed failure and the limits of process and material tests.
- [Intergranular corrosion](https://planar.so/wiki/production/process-effects/intergranular-corrosion.md): Grain-boundary attack, stainless-steel sensitization, alloy-specific tests and the limits of mass-loss and delivery-test results.
- [Lack of fusion](https://planar.so/wiki/production/process-effects/lack-of-fusion.md): Unfused weld interfaces: sidewall, inter-run and root distinctions, process causes, inspection limits, acceptance scope and controlled repair.
- [Machining chatter](https://planar.so/wiki/production/process-effects/machining-chatter.md): Diagnosing unstable cutting without confusing chatter, forced vibration, tool marks or a universal speed correction.
- [Porosity in welds](https://planar.so/wiki/production/process-effects/porosity-in-welds.md): Gas cavities in fusion welds: morphology, material-specific sources, shielding checks, inspection limits and acceptance decisions.
- [Recast layers](https://planar.so/wiki/production/process-effects/recast-layers.md): Resolidified surface material after thermal machining: EDM layer structure, process-dependent evidence, removal allowance and measurement limits.
- [Residual stress](https://planar.so/wiki/production/process-effects/residual-stress.md): Self-equilibrated internal stress: manufacturing origins, distortion and service effects, measurement depth and reference-state limits, redistribution and stress relief.
- [Sensitization of stainless steel](https://planar.so/wiki/production/process-effects/sensitization-of-stainless-steel.md): Chromium-depleted microstructures, time–temperature dependence and why susceptibility is different from observed corrosion.
- [Springback](https://planar.so/wiki/production/process-effects/springback.md): Shape change after unloading a formed part: angular recovery, sidewall curl, twist, compensation and the limits of bend estimates.
- [Tool wear](https://planar.so/wiki/production/process-effects/tool-wear.md): Progressive cutting-edge deterioration, competing failure modes, tool-life criteria and the limits of wear-based production estimates.
- [Weld shrinkage](https://planar.so/wiki/production/process-effects/weld-shrinkage.md): Cooling contraction in weldments: longitudinal and transverse shrinkage, angular movement, restraint, sequence and dimensional-prediction limits.
- [Work hardening](https://planar.so/wiki/production/process-effects/work-hardening.md): Strengthening during plastic deformation, alloy-dependent mechanisms, temper boundaries and the distinction between reduction and material properties.