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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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Q: What is the Difference between ingot and billet?
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