# S1E59 How Oxidation Weakens Aluminum, and Why Engineers Make the World Better | Ogun Unal

- Show: [Being an Engineer](https://hardwarepodcasts.com/podcast/being-an-engineer)
- Published: 2020-12-31
- Length: 48m
- Episode: 59
- Page: https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu
- Listen: https://teampipeline.us/why-engineers-make-the-world-better/

## Summary

Ogun Unal, a metallurgical and industrial engineer at SMP USA, explains how aluminum oxide films formed during casting can be pushed sub-surface into molten metal, creating weak points that lead to component failure. He discusses the technical challenges of Tesla's Giga Casting process, specifically managing oxidation in large aluminum castings, and shares best practices for designing sheet metal parts, emphasizing the importance of understanding manufacturing tolerances and processes. Unal also highlights the value of lean manufacturing principles, such as reducing non-value-added steps like unnecessary walking, to significantly improve efficiency and reduce costs in production environments.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=0) Introduction: Ogun Unal and Engineering Mindset
- [9:05](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=545) Tesla Giga Casting and Aluminum Oxidation Challenges
- [12:38](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=758) Designing for Sheet Metal and Tolerances
- [16:50](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=1010) Lean Manufacturing and Reducing Waste
- [23:19](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=1399) Aluminum Alloy Quality and Casting Defects
- [30:37](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=1837) Engineering Education and Adaptability
- [35:29](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=2129) Additive Manufacturing and Operator Training
- [40:37](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu#t=2437) Personal Projects and Company Culture

## Topics

- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Factory operations & automation](https://hardwarepodcasts.com/topic/factory-operations)
- [Careers & education](https://hardwarepodcasts.com/topic/engineering-careers-and-education)

## Most relevant to

early-stage companies

## Mentioned

- SMP USA (company)
- Tesla (company)
- SolidWorks (tool)

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- [A New Era of Automotive Manufacturing: The Synergy of Die-Casting and AM with Wes Byleveld of Exco Engineering](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes) (Additive Snack)
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- [Chocolate Castings, Apprenticeships and the Future of Manufacturing Careers w/ Mike Kubacki](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2025-11-04-chocolate-castings-apprenticeships-and-the-future-of-manufacturing-careers-w-mik) (The Manufacturing Executive)
- [384: Finally! A use for Spencers!](https://hardwarepodcasts.com/podcast/making-it/2023-01-13-384-finally-a-use-for-spencers) (Making It)

## Citing this page

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