Definition
A metalworking process in which sheet metal or other workable metal is shaped into its final form at room temperature, without the application of heat. The metal is bent, drawn, pressed, or rolled using mechanical force, and the working itself increases the strength and hardness of the finished part through a phenomenon called work hardening.
Plain English
Shaping metal by bending or pressing it while it is cold, instead of heating it first. Working the metal this way also makes it stronger and stiffer.
Context Anchor
Seen in aircraft sheet-metal work, structural repair discussions, and manufacturing descriptions for parts that are bent or shaped before installation.
Derivation
Cold simply means the metal is at normal shop temperature, not heated. Forming comes from the Latin formare, meaning to shape. Together they distinguish this process from hot forming, where metal is heated until soft before being shaped.
Why Pilots Care
Preserves the original strength and fatigue resistance of metals used in airframes and engine parts.
Analogy
It is like bending a paper clip with your fingers instead of heating it with a flame first. The shape changes, but the material was not softened by heat before you bent it.
Intuition Check
Cold does not mean the metal is chilled or frozen. Here, cold means the metal is shaped without being heated first.
Example Sentence 1
The wing ribs were cold formed from aluminum sheet on a press brake at the factory.
Example Sentence 2
Cold forming avoids weakening the metal structure that can occur when heat is applied.