Fundamentals of Metallurgy

589 Pages·2005·5.34 MB·English

by  Seetharaman, Seshadri.

Fundamentals of metallurgy
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Fundamentals of
metallurgy
Edited by
Seshadri Seetharaman
Woodhead Publishing and Maney Publishing
on behalf of
The Institute of Materials, Minerals & Mining
CRC Press
Boca Raton Boston New York Washington, DC
Woodhead Publishing Limitedand Maney PublishingLimited onbehalfof
The Instituteof Materials, Minerals &Mining
Published byWoodhead PublishingLimited, AbingtonHall, Abington,
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Contents
Contributor contact details xi
Preface xiii
PartI Understandingtheeffectsofprocessingonthe
propertiesofmetals
1 Descriptionsofhigh-temperaturemetallurgical
processes 3
H Y SOHN,University ofUtah andS SRIDHAR,Carnegie Mellon
University, USA
1.1 Introduction 3
1.2 Reactions involving gases and solids 4
1.3 Reactions involving liquid phases 17
1.4 Casting processes 27
1.5 Thermomechanical processes 31
1.6 References 34
1.7 Appendix: notation 37
2 Thermodynamicaspectsofmetalsprocessing 38
R E AUNE and S SEETHARAMAN, RoyalInstituteof
Technology,Sweden
2.1 Introduction 38
2.2 Basic concepts in thermodynamics 39
2.3 Chemical equilibrium 44
2.4 Unary and multicomponent equilibria 49
2.5 Thermodynamics of solutions 57
2.6 Thermodynamics of multicomponent dilute solutions 66
2.7 Modelling of metallic systems 70
vi Contents
2.8 Thermodynamics of ionic melts 72
2.9 Basics of electrochemical thermodynamics 79
2.10 Conclusions 79
2.11 Further reading 80
2.12 References 80
3 Phasediagrams,phasetransformations,andthe
predictionofmetalproperties 82
K MORITA,The Universityof Tokyoand N SANO,NipponSteel
Corporation,Japan
3.1 Introduction 82
3.2 Phase diagrams and potential diagrams 83
3.3 Ternary phase diagrams 87
3.4 Solidification in ternary systems and four-phase equilibria 95
3.5 Examples of solidification behaviour from a phase diagram
perspective 102
3.6 Conclusions 107
3.7 References 108
4 Measurementandestimationofphysical
propertiesofmetalsathightemperatures 109
K C MILLS, ImperialCollege London,UK
4.1 Introduction 109
4.2 Factors affecting physical properties and their measurement 113
4.3 Measurements and problems 120
4.4 Fluid flow properties 122
4.5 Properties related to heat transfer 136
4.6 Properties related to mass transfer 146
4.7 Estimating metal properties 148
4.8 Acknowledgements 169
4.9 References 169
4.10 Appendix A: calculation of structural parameters NBO/T and
optical basicity 175
4.11 Appendix B: notation 176
5 Transportphenomenaandmetalsproperties 178
A K LAHIRI,Indian Institute ofScience,India
5.1 Introduction 178
5.2 Mass transfer 178
5.3 Heat transfer 200
Contents vii
5.4 Fluid flow 217
5.5 Further reading 235
5.6 References 236
6 Interfacialphenomena,metalsprocessingand
properties 237
K MUKAI,KyushuInstituteof Technology, Japan
6.1 Introduction 237
6.2 Fundamentals of the interface 238
6.3 Interfacial properties of a metallurgical melts system 257
6.4 Interfacial phenomena in relation to metallurgical processing 260
6.5 Further reading 267
6.6 References 267
7 Thekineticsofmetallurgicalreactions 270
S SRIDHAR,Carnegie Mellon University, USAand
H Y SOHN,University ofUtah
7.1 Introduction 270
7.2 Fundamentals of heterogeneous kinetics 270
7.3 Solid-state reactions 278
7.4 Gas–solid reactions 290
7.5 Liquid–liquid reactions 311
7.6 Solid–liquid reactions 313
7.7 Gas–liquid reactions 318
7.8 Comprehensive process modeling 321
7.9 References 341
7.10 Appendix: notation 346
8 Thermoanalyticalmethodsinmetalsprocessing 350
O N MOHANTY, TheTata Iron andSteel Company,India
8.1 Introduction 350
8.2 Thermogravimetry (TG) 356
8.3 Differential thermal analysis (DTA) and differential scanning
calorimetry (DSC) 358
8.4 Evolved gas analysis (EGA) and detection (EGD) 363
8.5 References 365
viii Contents
PartII Improvingprocessandproductquality
9 Improvingprocessdesigninsteelmaking 369
D SICHEN, RoyalInstituteof Technology, Sweden
9.1 Introduction 369
9.2 Overview of process design 369
9.3 Thermodynamics and mass balance 375
9.4 Kinetics – mass transfer and heat transfer 385
9.5 Optimization of interfacial reactions 387
9.6 Micro-modelling 393
9.7 Conclusions 396
9.8 References 396
10 Solidificationandsteelcasting 399
A W CRAMB,Carnegie MellonUniversity, USA
10.1 Introduction 399
10.2 Solidification fundamentals 400
10.3 The growth of solids 413
10.4 The casting of steels 428
10.5 Conclusions 449
10.6 Acknowledgements 450
10.7 References 450
11 Analysingmetalworkingprocesses 453
G ENGBERG,SSAB Tunnpla˚tABand MIKResearch AB
(MIKRAB) and L KARLSSON,Dalarna University, Sweden
11.1 Introduction 453
11.2 Work hardening 454
11.3 Rate effects 457
11.4 Interaction with phase transformations 462
11.5 Examples of material behaviour during processing 463
11.6 Development trends 468
11.7 References 469
12 Understandingandimprovingpowder
metallurgicalprocesses 471
F LEMOISSON and L FROYEN,KatholiekeUniversiteit Leuven,
Belgium
12.1 Introduction 471
12.2 Production processes for powders 471
12.3 Forming processes towards near-net shape 486
Contents ix
12.4 Conclusions 500
12.5 References 500
13 Improvingsteelmakingandsteelproperties 503
T EMI,RoyalInstitute ofTechnology, Sweden
13.1 Introduction 503
13.2 Developing processes and properties with reference to market,
energy, and environment 506
13.3 Optimization of processes to meet properties and productivity 523
13.4 Economic optimization 537
13.5 Environmental optimization 546
13.6 Future trends 550
13.7 Further reading 553
13.8 References 553
Index 555