Handbook of Metallurgical Process Design PDF
Preview Handbook of Metallurgical Process Design
Handbook of Metallurgical Process Design Copyright © 2004 by Marcel Dekker, Inc. MATERIALS ENGINEERING 1. Modern Ceramic Engineering: Properties, Processing, and Use in Design. Second Edition, Revised and Ex- panded, David W.Richerson 2. Introduction to Engineering Materials: Behavior, Properties, and Selection, G.T.Murray 3. Rapidly Solidified Alloys: Processes • Structures • Applications, edited by Howard H.Liebermann 4. Fiber and Whisker Reinforced Ceramics for Structural Applications, David Belitskus 5. Thermal Analysis of Ceramics, Robert F.Speyer 6. Friction and Wear of Ceramics, edited by Said Jahanmir 7. Mechanical Properties of Metallic Composites, edited by Shojiro Ochiai 8. Chemical Processing of Ceramics, edited by Burtrand I.Lee and Edward J.A.Pope 9. Handbook of Advanced Materials Testing, edited by Nicholas P.Cheremisinoff and Paul N.Cheremisinoff 10. Ceramic Processing and Sintering, M.N.Rahaman 11. Composites Engineering Handbook, edited by P.K.Mallick 12. Porosity of Ceramics, Roy W.Rice 13. Intermetallic and Ceramic Coatings, edited by Narendra B.Dahotre and T.S.Sudarshan 14. Adhesion Promotion Techniques: Technological Applications, edited by K.L.Mittal and A.Pizzi 15. Impurities in Engineering Materials: Impact, Reliability, and Control, edited by Clyde L.Briant 16. Ferroelectric Devices, Kenji Uchino 17. Mechanical Properties of Ceramics and Composites: Grain and Particle Effects, Roy W.Rice 18. Solid Lubrication Fundamentals and Applications, Kazuhisa Miyoshi 19. Modeling for Casting and Solidification Processing, edited by Kuang-O (Oscar) Yu 20. Ceramic Fabrication Technology, Roy W.Rice 21. Coatings of Polymers and Plastics, edited by Rose A.Ryntz and Philip V.Yaneff 22. Micromechatronics, Kenji Uchino and Jayne R.Giniewicz 23. Ceramic Processing and Sintering: Second Edition, M.N.Rahaman 24. Handbook of Metallurgical Process Design, edited by George E.Totten, Kiyoshi Funatani, and Lin Xie Additional Volumes in Preparation Copyright © 2004 by Marcel Dekker, Inc. Handbook of Metallurgical Process Design edited by George E.Totten G.E.Totten & Associates, LLC Seattle, Washington, U.S.A. Kiyoshi Funatani IMST Institute Nagoya, Japan Lin Xie SolidWorks Corporation Concord, Massachusetts, U.S.A. MARCEL DEKKER, INC. NEW YORK • BASEL Copyright © 2004 by Marcel Dekker, Inc. Transferred to Digital Printing 2005 Although great care has been taken to provide accurate and current information, neither the author(s) nor the publisher, nor anyone else associated with this publication, shall be liable for any loss, damage, or liability directly or indirectly caused or alleged to be caused by this book. The material contained herein is not intended to provide specific advice or recommendations for any specific situation. Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress. ISBN: 0-8247-4106-4 Headquarters Marcel Dekker, Inc., 270 Madison Avenue, New York, NY 10016, U.S.A. tel: 212–696–9000; fax: 212–685–4540 Distribution and Customer Service Marcel Dekker, Inc., Cimarron Road, Monticello, New York 12701, U.S.A. tel: 800–228–1160; fax: 845–796–1772 Eastern Hemisphere Distribution Marcel Dekker AG, Hutgasse 4, Postfach 812, CH-4001 Basel, Switzerland tel: 41–61–260–6300; fax: 41–61–260–6333 World Wide Web http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/ Professional Marketing at the headquarters address above. Copyright © 2004 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. Copyright © 2004 by Marcel Dekker, Inc. Preface In addition to material selection and component design, there are other equally important considerations that must be addressed in the overall process of design selection. One of these is process design, which not only affects cost and ease of production, but may also impact the final microstructure and mechanical properties of the component being produced. While there are various texts which address a particular process design such as forging, casting, and rolling, there is a need for a single text that will provide an overview of these processes as they relate to metallurgical component design. The objective of this text is to provide a thorough overview of the more important processes from the standpoint of the effect of design. There are an extensive array of process designs discussed in this book. In Part One, Chapters 1 and 2 provide an overview of hot and cold forming process design, which includes forging process design. Chapter 3 details the effect of steel rolling process on microstructure and properties. Chapter 4 provides the most thorough and current over- view on aluminum rolling process design available anywhere. Chapter 5 discusses semisolid metal-forming design. Chapter 6 provides a rigorous overview of the principles of aluminum extrusion process design and Chapter 7 is a comprehensive review of superplastic forming design. Part Two focuses on casting process design for steel and aluminum, including continuous process designs in addition to a summary of various foundry casting process designs. Extensive guidelines for die casting process design are also included. Various heat treatment practices are conducted to achieve the desired microstructural and mechanical properties of a particular material. Proper design is vital to the end-use properties of the component being produced. Part Three deals with various heat-treatment topics including: an overview of the effect of heat-treatment process design on hardening, tempering, annealing and other properties, carburizing and carbonitriding, nitriding, induction heating, and laser hardening. Chapter 17 discusses the use of quench factor analysis for selection of appropriate quench media for aluminum processing. Chapter 18 covers the use of intensive quenching methodology to provide superior compressive stresses and fatigue properties and/or the replacement of more expensive steel alloys with less expensive plain-carbon steels. Part Four deals with a topic of ever-increasing importance—surface engineering. This section includes topics on ion implantation, physical vapor deposition (PVD), chemical vapor deposition (CVD), and thermal spray process design. Coating process design for surface endurance is also discussed. In Part Five, Chapter 22 provides information on designing for machining processes, which is a key topic in metallurgical process design. This book is an invaluable reference for persons involved in any aspect of product design including metallurgists, material scientists, product and process engineers, and component designers. It is also appropriate for use in an advanced undergraduate or graduate class on material design. iii Copyright © 2004 by Marcel Dekker, Inc. iv Preface We are indebted to the persistence and thorough work of the contributors to this book. We are also especially grateful for the patience and invaluable assistance provided by the staff at Marcel Dekker, Inc. throughout the preparation of this text. George E.Totten Kiyoshi Funatani Lin Xie Copyright © 2004 by Marcel Dekker, Inc. Contents Preface iii Contributors vii Part One Hot and Cold Forming 1. Design of Forming Processes: Bulk Forming 1 Chester J.Van Tyne 2. Design of Forming Processes: Sheet Metal Forming 23 T.Wanheim 3. Design of Microstructures and Properties of Steel by Hot and Cold Rolling 47 Rafael Colás, Roumen Petrov, and Yvan Houbaert 4. Design of Aluminum Rolling Processes for Foil, Sheet, and Plate 69 Julian H.Driver and Olaf Engler 5. Design of Semisolid Metal-Forming Processes 115 Manabu Kiuchi 6. Extrusion 137 Sigurd Støren and Per Thomas Moe 7. Superplastic Materials and Superplastic Metal Forming 205 Namas Chandra Part Two Casting 8. The Design of Continuous Casting Processes for Steel 251 Roderick I.L.Guthrie and Mihaiela Isac v Copyright © 2004 by Marcel Dekker, Inc. vi Contents 9. Continuous Casting Design by the Stepanov Method 295 Stanislav Prochorovich Nikanorov and Vsevolod Vladimirovich Peller 10. Production and Inspection of Quality Aluminum and Iron Sand Castings 349 William D.Scott, Hanjun Li, John Griffin, and Charles E.Bates 11. Die Casting Process Design 401 Frank E.Goodwin Part Three Heat Treatment 12. Heat-Treating Process Design 453 Lauralice Campos Franeschini Canale, George E.Totten, and David Pye 13. Design of Carburizing and Carbonitriding Processes 507 Malgorzata Przylecka, Wojciech Gestwa, Kiyoshi Funatani, George E.Totten, David Pye 14. Design of Nitrided and Nitocarburized Materials 545 Michel J.Korwin, Witold K.Liliental, Christopher D.Morawski, and George J.Tymowski 15. Design Principles for Induction Heating and Hardening 591 Valentin S.Nemkov and Robert C.Goldstein 16. Laser Surface Hardening 641 Janez Grum 17. Design of Steel-Intensive Quench Processes 733 Nikolai I.Kobasko, Boris K.Ushakov, and Wytal S.Morhuniuk 18. Design of Quench Systems for Aluminum Heat Treating 765 D.Scott MacKenzie Part Four Surface Engineering 19. Surface Engineering Methods 791 Paul K.Chu, Xiubo Tian, and Liuhe Li 20. Design of Thermal Spray Processes 833 Bernhard Wielage, Johannes Wilden, and Andreas Wank 21. Designing a Surface for Endurance: Coating Deposition Technologies 857 Joaquin Lira-Olivares Part Five Machining 22. Designing for Machining: Machinability and Machining Performance Considerations 919 I.S.Jawahir Copyright © 2004 by Marcel Dekker, Inc. Contributors Charles E.Bates, Ph.D. University of Alabama at Birmingham, Birmingham, Alabama, U.S.A. Lauralice Campos Franeschini Canale, Ph.D. University of Sao Paulo, Sao Carlos, Brazil Namas Chandra, Ph.D. Florida State University, Tallahassee, Florida, U.S.A. Paul K.Chu, Ph.D. City University of Hong Kong, Kowloon, Hong Kong Rafael Colás, B.Eng. (Met.), M. Met. Ph.D. Universidad Autónoma de Nuevo León, San Nicolás de los Garza, N.L., Mexico Julian H.Driver, B.Sc., Ph.D. Ecole des Mines de Saint Etienne, St. Etienne, France Olaf Engler, Ph.D. Hydro Aluminium Deutschland, Bonn, Germany Kiyoshi Funatani, Ph.D. IMST Institute, Nagoya, Japan Wojciech Gestwa, Ph.D. Poznan University of Technology, Poznan, Poland Robert C.Goldstein, B.S.Ch.E. Centre for Induction Technology, Inc., Auburn Hills, Michigan, U.S.A. Frank E.Goodwin, Sc.D. International Lead Zinc Research Organization, Inc., Research Triangle Park, North Carolina, U.S.A. John Griffin University of Alabama at Birmingham, Birmingham, Alabama, U.S.A. Janez Grum, Ph.D. University of Ljubljana, Ljubljana, Slovenia Roderick I.L.Guthrie, A.R.S.M., Ph.D. D.I.C. F.R.S.C., F.A.E., F.C.I.M.Eng. McGill University, Montreal, Quebec, Canada Yvan Houbaert, Dr.Ir. Ghent University, Ghent, Belgium vii Copyright © 2004 by Marcel Dekker, Inc. viii Contributors Mihaiela Isac, B.Sc.Eng., M.Eng., Ph.D. McGill University, Montreal, Quebec, Canada I.S.Jawahir University of Kentucky, Lexington, Kentucky, U.S.A. Manabu Kiuchi, Ph.D. Kiuchi Laboratory, Tokyo, Japan Nikolai I.Kobasko, Ph.D. Intensive Technologies Ltd., Kiev, Ukraine Michel J.Korwin Nitrex Metal, Inc., St. Laurent, Quebec, Canada Hanjun Li, Ph.D. City University of Hong Kong, Kowloon, Hong Kong Liuhe Li, Ph.D. City University of Hong Kong, Kowloon, Hong Kong Wiltold K.Liliental Nitrex Metal Technologies, Inc., Burlington, Ontario, Canada Joaquin Lira-Olivares, Ph.D. Simon Bolívar University, Caracas, Venezuela D.Scott MacKenzie, Ph.D. Houghton International Inc., Valley Forge, Pennsylvania, U.S.A. Per Thomas Moe, M.Sc.-Eng. Norwegian University of Science and Technology, Trondheim, Norway Christopher D.Morawski Nitrex Metal, Inc., St. Laurent, Quebec, Canada Wytal S.Morhuniuk, Ph.D. Intensive Technologies Ltd., Kiev, Ukraine Valentin S.Nemkov, Ph.D. Centre for Induction Technology, Inc., Auburn Hills, Michigan, U.S.A. Stanislav Prochorovich Nikanorov, Dr.Sc. A.F. loffe Physical Technical Institute of Russian Academy of Sciences, Saint Petersburg, Russia Vsevolod Vladimirovich Peller, M.D. A.F. loffe Physical Technical Institute of Russian Academy of Sciences, Saint Petersburg, Russia Roumen Petrov, Ph.D. Ghent University, Ghent, Belgium Malgorzata Przylecka, D.Sc. Poznan University of Technology, Poznan, Poland David Pye Pye Metallurgical Consulting, Inc., Meadville, Pennsylvania, U.S.A. William D.Scott, P.E. AAA Alchemy, Birmingham, Alabama, U.S.A. Sigurd Støren, Ph.D. Norwegian University of Science and Technology, Trondheim, Norway Xiubo Tian, Ph.D. City University of Hong Kong, Kowloon, Hong Kong George E.Totten, Ph.D., F.A.S.M. G.E. Totten & Associates, LLC, Seattle, Washington, U.S.A. George J.Tymowski Nitrex Metal, Inc., St. Laurent, Quebec, Canada Copyright © 2004 by Marcel Dekker, Inc.
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