The volume contains more than 70 papers covering the important topics and issues in metallurgy today including papers as follows: keynote papers covering a tribute to David Robertson, workforce skills needed in the profession going forward, copper smelting, ladle metallurgy, process metallurgy and resource efficiency, new flash iron making technology, ferro-alloy electric furnace smelting and on the role of bubbles in metallurgical processing operations. Topics covered in detail in this volume include ferro-alloys, non-ferrous metallurgy, iron and steel, modeling, education, and fundamentals.

This book presents guidelines on quantitative and qualitative measures of the geometric features and imperfections of welds to ensure that it meets the fatigue strength requirements laid out in the recommendations of the IIW (International Institute of Welding). Welds that satisfy these quality criteria can be assessed in accordance with existing IIW recommendations based on nominal stress, structural stress, notch stress or linear fracture mechanics. Further, the book defines more restrictive acceptance criteria based on weld geometry features and imperfections with increased fatigue strength. Fatigue strength for these welds is defined as S-N curves expressed in terms of nominal applied stress or hot spot stress. Where appropriate, reference is made to existing quality systems for welds.In addition to the acceptance criteria and fatigue assessment curves, the book also provides guidance on their inspection and quality control. The successful implementation of these methods depends on adequate training for operators and inspectors alike. As such, the publication of the present IIW Recommendations is intended to encourage the production of appropriate training aids and guidelines for educating, training and certifying operators and inspectors.

This book provides a comprehensive introduction to numerical modeling of size effects in metal plasticity. The main classes of strain gradient plasticity formulations are described and efficiently implemented in the context of the finite element method. A robust numerical framework is presented and employed to investigate the role of strain gradients on structural integrity assessment. The results obtained reveal the need of incorporating the influence on geometrically necessary dislocations in the modeling of various damage mechanisms. Large gradients of plastic strain increase dislocation density, promoting strain hardening and elevating crack tip stresses. This stress elevation is quantified under both infinitesimal and finite deformation theories, rationalizing the experimental observation of cleavage fracture in the presence of significant plastic flow. Gradient-enhanced modeling of crack growth resistance, hydrogen diffusion and environmentally assisted cracking highlighted the relevance of an appropriate characterization of the mechanical response at the small scales involved in crack tip deformation. Particularly promising predictions are attained in the field of hydrogen embrittlement. The research has been conducted at the Universities of Cambridge, Oviedo, Luxembourg, and the Technical University of Denmark, in a collaborative effort to understand, model and optimize the mechanical response of engineering materials.

This book describes and systemizes analytical and numerical solutions for a broad range of instantaneous and continuous, stationary and moving, concentrated and distributed, 1D, 2D and 3D heat sources in semi-infinite bodies, thick plane layers, thin plates and cylinders under various boundary conditions. The analytical solutions were mainly obtained by the superimposing principle for various parts of the proposed 1D, 2D and 3D heat sources and based on the assumption that only heat conduction plays a major role in the thermal analysis of welds. Other complex effects of heat transfer in weld phenomena are incorporated in the solutions by means of various geometrical and energetic parameters of the heat source. The book is divided into 13 chapters. Chapter 1 briefly reviews various welding processes and the energy characteristics of welding heat sources, while Chapter 2 covers the main thermophysical properties of the most commonly used alloys. Chapter 3 describes the physical fundamentals of heat conduction during welding, and Chapter 4 introduces several useful methods for solving the problem of heat conduction in welding. Chapters 5 and 6 focus on the derivation of analytical solutions for many types of heat sources in semi-infinite bodies, thick plane layers, thin plates and cylinders under various boundary conditions. The heat sources can be instantaneous or continuous, stationary or moving, concentrated or distributed (1D, 2D or 3D). In Chapter 7 the temperature field under programmed heat input (pulsed power sources and weaving sources) is analyzed. In turn, Chapters 8 and 9 cover the thermal cycle, melting and solidification of the base metal. Heating and melting of filler metal are considered in Chapter 10. Chapter 11 addresses the formulation and solution of inverse heat conduction problems using zero-, first- and second-order algorithms, while Chapter 12 focuses on applying the solutions developed here to the optimization of welding conditions. In addition, case studies confirm the usefulness and feasibility of the respective solutions. Lastly, Chapter 13 demonstrates the prediction of local microstructure and mechanical properties of welded joint metals, while taking into account their thermal cycle. The book is intended for all researches, welding engineers, mechanical design engineers, research engineers and postgraduate students who deal with problems such as microstructure modeling of welds, analysis of the mechanical properties of welded metals, weldability, residual stresses and distortions, optimization of welding and allied processes (prewelding heating, cladding, thermal cutting, additive technologies, etc.). It also offers a useful reference guide for software engineers who are interested in writing application software for simulating welding processes, microstructure modeling, residual stress analysis of welds, and for robotic-welding control systems.

The process of producing components to final net-shapes is fast becoming a desirable goal for metal working industries. This is due to a combination of factors such as the development of new materials and escalating energy costs. Computer Applications in Near Net-Shape Operations addresses the design, analysis and simulation of near net-shape operations using some of the most advanced computer techniques and tools available. Topics covered include: Sheet metal forming operations: progressive stamping, fine blanking, nesting, flat pattering, bending and nibbling; Die design, construction and NC programming of wire EDM; Bulk metal forming processes such as cold upsetting and close-die forging; Injection mould design, analysis and simulation; Computer-aided design of CNC machines for near net-shape operations; Intelligent progressive die design system IPD. This collection of the latest developments from leading experts in the field will be of interest to practising engineers, graduate students and researchers of metal forming, stamping, mould and die design.

Providing a comprehensive overview of hot stamping (also known as 'press hardening'), this book examines all essential aspects of this innovative metal forming method, and explores its various uses. It investigates hot stamping from both technological and business perspectives, and outlines potential future developments. Individual chapters explore topics such as the history of hot stamping, the state of the art, materials and processes employed, and how hot stamping is currently being used in the automotive industry to create ultra-high-strength steel components. Drawing on experience and expertise gathered from academia and industry worldwide, the book offers an accessible resource for a broad readership including students, researchers, vehicle manufacturers and metal forming companies.

This collection presents papers from a symposium on extraction of rare metals as well as rare extraction processing techniques used in metal production. Topics include the extraction and processing of elements like antimony, arsenic, gold, indium, palladium, platinum, rare earth metals including yttrium and neodymium, titanium, tungsten, and vanadium. Rare processing techniques are covered, including direct extraction processes for rare-earth recovery, biosorption of precious metals, fluorination behavior of uranium and zirconium mixture of fuel debris treatment, and recovery of valuable components of commodity metals such as zinc, nickel, and metals from slag.

The "Metal Forming Handbook" presents the fundamentals of metal forming processes and press design. As a textbook and reference work in one, it provides an in-depth study of the major metal forming technologies: sheet metal forming, cutting, hydroforming and solid forming.Written by qualified, practically-oriented experts for practical implementation, supplemented by sample calculations and illustrated throughout by clearly presented color figures and diagrams, this book provides fundamental information on the state-of-the-art in the field of metal forming technology.

This book provides a comprehensive overview of the main nuclear characterization techniques used to study hydrogen absorption and desorption in materials. The various techniques (neutron scattering, nuclear magnetic resonance, ion-beams, positron annihilation spectroscopy) are explained in detail, and a variety of examples of recent research projects are given to show the unique advantage of these techniques to study hydrogen in materials. Most of these nuclear techniques require very specialized instrumentation, and there are only a handful of these instruments available worldwide. Therefore, the aim of this book is to reach out to a readership with a very diverse background in the physical sciences and engineering and a broad range of hydrogen-related research interests. The same technique can be used by researchers interested in the improvement of the performance of hydrogen storage materials and by those focused on hydrogen ingress causing embrittlement of metals. The emphasis of this book is to provide tutorial material on how to use nuclear characterization techniques for the investigation of hydrogen in materials - information that cannot readily be found in conference and regular research papers. Provides a comprehensive overview of nuclear techniques used for hydrogen-related research Explains all nuclear techniques in detail for the non-expert Covers the whole range of hydrogen-related research Features chapters written by world-renowned experts in nuclear technique and hydrogen-related research

This collection provides researchers and industry professionals with complete guidance on the synthesis, analysis, design, monitoring, and control of metals, materials, and metallurgical processes and phenomena. Along with the fundamentals, it covers modeling of diverse phenomena in processes involving iron, steel, non-ferrous metals, and composites. It also goes on to examine second phase particles in metals, novel sensors for hostile-environment materials processes, online sampling and analysis techniques, and models for real-time process control and quality monitoring systems.

This book details aluminum alloys with special focus on the aluminum silicon (Al-Si) systems - that are the most abundant alloys second only to steel. The authors include a description of the manufacturing principles, thermodynamics, and other main characteristics of Al-Si alloys. Principles of processing, testing, and in particular applications in the Automotive, Aeronautical and Aerospace fields are addressed.

In this thesis, the author investigates experimentally and numericallythe fracture behavior of an electron beam welded joint made fromtwo butt S355 plates. The 2D Rousselier model, the Gurson-Tvergaard-Needleman (GTN) model and the cohesive zone model (CZM) wereadopted to predict the crack propagation of thick compact tension (CT)specimens. Advantages and disadvantages of the three mentioned modelsare discussed. The cohesive zone model is suggested as it is easy to usefor scientists & engineers because the CZM has less model parametersand can be used to simulate arbitrary crack propagation. The resultsshown in this thesis help to evaluate the fracture behavior of a metallicmaterial. A 3D optical deformation measurement system (ARAMIS) andthe synchrotron radiation-computed laminography (SRCL) techniquereveal for the first time the damage evolution on the surface of the sampleand inside a thin sheet specimen obtained from steel S355. Damageevolution by void initiation, growth and coalescence are visualized in2D and 3D laminographic images. Two fracture types, i.e., a flat crackpropagation originated from void initiation, growth and coalescenceand a shear coalescence mechanism are visualized in 2D and 3D imagesof laminographic data, showing the complexity of real fracture. Inthe dissertation, the 3D Rousselier model is applied for the first timesuccessfully to predict different microcrack shapes before shear cracksarise by defining the finite elements in front of the initial notch withinhomogeneous f0-values. The influence of the distribution of inclusionson the fracture shape is also discussed. For the analyzed material, ahomogeneous distribution of particles in the material provides thehighest resistance to fracture.

This books presents a current look at friction stir welding technology from application to characterization and from modeling to R&D. It is a compilation of the recent progress relating to friction stir technologies including derivative technologies, high-temperature applications, industrial applications, dissimilar alloy/materials, lightweight alloys, simulation, and characterization. With contributions from leaders and experts in industry and academia, this will be a comprehensive source for the field of Friction Stir Welding and Processing.

This collection gives broad and up-to-date results in the research and development of materials characterization and processing. Coverage is well-rounded from minerals, metals, and materials characterization and developments in extraction to the fabrication and performance of materials. In addition, topics as varied as structural steels to electronic materials to plant-based composites are explored. The latest research presented in this wide area make this book both timely and relevant to the materials science field as a whole. The book explores scientific processes to characterize materials using modern technologies, and focuses on the interrelationships and interdependence among processing, structure, properties, and performance of materials. Topics covered include ferrous materials, non-ferrous materials, minerals, ceramics, clays, soft materials, method development, processing, corrosion, welding, solidification, composites, extraction, powders, nanomaterials, advanced materials, and several others.

The papers in this collection cover a diverse range of topics on the topic of fatigue of materials. The editors have grouped the papers into five sections. Sections 1 and 2 contain papers that (i) review the current state of knowledge both related and relevant to the subject of fatigue behavior of materials, and (ii) present new, innovative, and emerging techniques for experimental evaluation of the fatigue behavior. Sections 3 and 4 focus on advanced materials that are used in performance-critical applications in the aerospace and automotive industries, such as the alloys of titanium, nickel, aluminum, and magnesium. Section 5 presents papers relating to other materials of engineering interest, such as iron and steel, polymer, rubber, and composites.

Material processing techniques that employ severe plastic deformation have evolved over the past decade, producing metals, alloys and composites having extraordinary properties. Variants of SPD methods are now capable of creating monolithic materials with submicron and nanocrystalline grain sizes. The resulting novel properties of these materials has led to a growing scientific and commercial interest in them. They offer the promise of bulk nanocrystalline materials for structural applications, including nanocomposites of lightweight alloys with unprecedented strength. These materials may also enable the use of alternative metal shaping processes, such as high strain rate superplastic forming. Prospective applications for medical, automotive, aerospace and other industries are already under development.

This book offers a unique approach to integrated high-temperature process modelling, intended to serve as a design aid for new metal processing technologies. The second edition has been substantially expanded to include new content such as: a new algorithm and test results of 3D stereoscopic visualization; new programming procedures for modelling; the validation of computer simulation using experimental results; a multiscale model of grain growth; a conceptual methodology developing "high-temperature" CCT (continuous cooling transformation) diagrams, and many more examples validating the numerical simulations. The models presented are applied in comprehensive tests in order to solve problems related to the high-temperature deformation of steel. The testing methods include both physical tests using specialist laboratory instruments, and advanced mathematical modelling: the Finite Element method (FE), Smoothed Particle Hydrodynamics method (SPH) and Mo nte Carlo method (MC).This approach, which integrates the fields of physical and computer-based simulations, forms the basis for the described concept of integrated high-temperature process modelling, presented in detail in this book.

This book describes the fundamentals of residual stresses in friction stir welding and reviews the data reported for various materials. Residual stresses produced during manufacturing processes lead to distortion of structures. It is critical to understand and mitigate residual stresses. From the onset of friction stir welding, claims have been made about the lower magnitude of residual stresses. The lower residual stresses are partly due to lower peak temperature and shorter time at temperature during friction stir welding. A review of residual stresses that result from the friction stir process and strategies to mitigate it have been presented. Friction stir welding can be combined with additional in-situ and ex-situ manufacturing steps to lower the final residual stresses. Modeling of residual stresses highlights the relationship between clamping constraint and development of distortion. For many applications, management of residual stresses can be critical for qualification of component/structure.
Reviews magnitude of residual stresses in various metals and alloysDiscusses mitigation strategies for residual stresses during friction stir weldingCovers fundamental origin of residual stresses and distortion

This conference proceedings presents the research papers in the field of mine planning and mining equipment including themes such as mine automation, rock mechanics, drilling, blasting, tunnelling and excavation engineering. The papers presents the recent advancement and the application of a range of technologies in the field of mining industry. It is of interest to the professionals who practice in mineral industry including but not limited to engineers, consultants, managers, academics, scientist, and government staff.

Covering the physical and numerical modeling of materials processing, this book includes contributions across the range of metals and minerals. This collection offers a unique opportunity to present models and results for key processes involved in extraction, joining, separation, and casting of materials. The corresponding fundamentals of mass and heat transport as well as physical and thermodynamics properties are addressed, allowing for a cross-disciplinary vision of the field.

The 3rd edition of this popular textbook covers current topics in all areas of casting solidification. Partial differential equations and numerical analysis are used extensively throughout the text, with numerous calculation examples, to help the reader in achieving a working knowledge of computational solidification modeling. The features of this new edition include: * new chapters on semi-solid and metal matrix composites solidification * a significantly extended treatment of multiscale modeling of solidification and its applications to commercial alloys * a survey of new topics such as solidification of multicomponent alloys and molecular dynamic modeling * new theories, including a theory on oxide bi-films in the treatment of shrinkage problems * an in-depth treatment of the theoretical aspects of the solidification of the most important commercial alloys including steel, cast iron, aluminum-silicon eutectics, and superalloys * updated tables of material constants.

This book focuses on the new direction of magnetic pulsed metal working by attraction of sheet metals. In the first part, the authors focus on the magnetic pulsed pressure for forming of inner angles in the sheet metals. Part 2 of the book presents the magnetic pulsed attraction of thin-walled metals. In the third and last part, the authors present the practical realization of external restoring the dents on the car bodies by electromagnetic metal forming attraction.