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How are alloys usually made from commercially pure metals?

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Diagram of a zinc-lead blast furnace system showing ore and coke entering through charge hoppers, with labeled furnace, air preheater, blower, taphole for slag and lead bullion, and a connected lead-splash condenser using rotors to separate and cool lead and zinc, with pathways for molten metals and off-gas. — metallurgy A zinc-lead blast furnace and lead-splash condenser. This technology is utilized mainly for producing zinc while managing both lead and zinc from raw materials, a technique that was highly influential in 20th-century smelting.

Most alloys are created by mixing commercially pure elements while in a liquid state, as this process is significantly easier than attempting to mix them in a solid state.1

The general procedure involves melting a base metal—such as iron, aluminum, or copper—and subsequently adding the desired alloying agents. During this stage, purification is often performed simultaneously to ensure the quality of the final material. To protect the molten metal from oxidation, the process is frequently conducted in air using slag as a protective layer, or alternatively, it is performed entirely within a vacuum chamber to allow for precise control over the composition.1

Melting is typically achieved using electricity through induction heating or arc melting. In specific cases where an inhomogeneous or composite structure is required, such as with certain cutting tools, manufacturers may bypass melting entirely in favor of powder metallurgical techniques.1