This reference guide or undergraduate text shows how to determine, by analyzing metallurgical failures, the validity of a product design. This revision of a successful work features new techniques in electron microscopy, testing fracture toughness, and fracture mechanics. It describes destructive and nondestructive techniques regarding their advantages, limitations, applications, and meaning. Written to be understood by all engineers concerned about component failure, this edition approaches typical problem areas from a physical and mechanical viewpoint. Also described is the relationship between the practical and the theoretical, so that failure analyses can best be resolved and failure recurrence prevented. The book maintains English and SI units throughout.

Metal Cutting Mechanics outlines the fundamentals of metal cutting analysis, reducing the extent of empirical approaches to the problems as well as bridging the gap between design and manufacture. The author distinguishes his work from other works through these aspects: considering the system engineering of the cutting process identifying the singularity of the cutting process among other closely related manufacturing processes by chip formation, caused by bending and shear stresses in the deformation zone suggesting a distinctive way toward predictability of the metal cutting process devoting special attention to experimental methodology Metal Cutting Mechanics provides an exceptional balance between general reading and research analysis, presenting industrial and academic requirements in terms of basic scientific factors as well as application potential.

The title presents an up-to-date account of the research, development, and applications of metallic alloys, recent research into the structure of charge materials, melt treatment, and casting technologies, and their influence on the properties of melts and ingots. This research has confirmed theoretical concepts about the microheterogenous constitution of metallic melts and has made it possible to manage the quality of castings and ingots of various alloys by their special treatment in the liquid state. The four chapters of the book give theoretical and experimental evidence of the effect of the melt constitution on the structure and properties of the solid metal. Liquid Metal Processing: Applications to Aluminium Alloy Production considers common features of structure formation in aluminium alloys for a wide range of solidification conditions, including ultrasonic and thermal melt treatments and discusses the technological problems of these treatments.

A teaching tool intended to complement existing books on the theory of materials science, metallurgy, and electron microscopy, this text focuses on metals and alloys. It visualizes key structural elements common to crystalline materials, including crystal lattice imperfections, along with the principles and steps involved in the microstructure development in metallic materials under external influences. Designed as an atlas, Microstructure of Metals and Alloys contains a collection of carefully selected original transmission electron microscope (TEM) micrographs taken by the authors. These images demonstrate typical crystal lattice defects, elements of the microstructure of metals and alloys, and the basic processes occurring to the crystal structure during plastic deformation, polygonization, recrystallization, and rapid solidification. The book is organized into six chapters. Each deals with a particular problem in the field of physical metallurgy, and begins with a description of the basic concept and terms. These descriptions enable readers to achieve a better understanding of the essential issues relevant to specific challenges. Providing comprehensive, illustrative coverage of the basic topics in materials science, this important work emphasizes fundamental principles over specific materials, in a manner that is fully consistent with the contemporary tendency in materials science teaching.

This book surveys the broad field of mechanical alloying from a scientific and technological perspective to form a timely and comprehensive resource valuable to both students and researchers. The treatment progresses from the historical background through a description of the process, the different metastable effects produced, and the mechanisms of phase formation to applications of mechanically alloyed products. The presentation is straightforward and easy to understand but does not compromise the scientific accuracy. It includes an unusually extensive listing of the results of different metastable effects obtained in various alloy systems along with thorough references in each chapter.

This practical reference/text provides a thorough overview of cost estimating as applied to various manufacturing industries, with special emphasis on metal manufacturing concerns. It presents examples and study problems illustrating potential applications and the techniques involved in estimating costs.;Containing both US and metric units for easy conversion of world-wide manufacturing data, Estimating and Costing for the Metal Manufacturing Industries: outlines professional societies and publications dealing with cost estimating and cost analysis; details the four basic metalworking processes - machining, casting, forming, and joining; reveals five techniques for capital cost estimating, including the new AACE International's Recommended Practice 16R-90 and the new knowledge and experience method; discusses the effect of scrap rates and operation costs upon unit costs; offers four formula methods for conceptual cost estimating and examines material-design-cost relationships; describes cost indexes, cost capacity factors, multiple-improvement curves, and facility cost estimation techniques; offers a generalized metal cutting economics model for comparison with traditional economic models; and more.;Estimating and Costing for the Metal Manufacturing Industries serves as an on-the-job, single-source reference for cost, manufacturing, and industrial engineers and as a text for upper-level undergraduate, graduate, and postgraduate students in cost estimating, engineering economics, and production operations courses.;A Solutions manual to the end-of-chapter problems is available free of charge to instructors only. Requests for the manual must be made on official school stationery.

Aluminum-Lithium Alloys: Process Metallurgy, Physical Metallurgy, and Welding provides theoretical foundations of the technological processes for melting, casting, forming, heat treatment, and welding of Al-Li alloys. It contains a critical survey of the research in the field and presents data on commercial Al-Li alloys, their phase composition, microstructure, and heat treatment of the ingots, sheets, forgings, and welds of Al-Li alloys. It details oxidation kinetics, protective alloying, hydrogen in Al-Li alloys, and crack susceptibility. It also discusses grain structure and solidification, as well as structural and mechanical properties. The book is illustrated with examples of Al-Li alloy applications in aircraft structures. Based on the vast experience of the coauthors, the book presents recommendations on solving practical problems involved with melting and casting ingots, welding of Al-Li alloys, and producing massive stampings for welded products. Provides comprehensive coverage of Al-Li alloys, not available in any single source. Presents research that is at the basis of the production technology for of ingots and products made of Al-Li alloys. Combines basic science with applied research, including upscaling and industrial implementation. Covers welding of Al-Li alloys in detail. Discusses gas and alkali-earth impurities in Al-Li alloys. Describes technological recommendations on casting and deformation of Al-Li alloys.

This book provides information on the generation and the effects of hazardous substances that are produced during welding and allied processes. These processes are thermal cutting, thermal spraying, soldering and brazing. The book offers guidance on the determination of hazardous substances and it simplifies assessment of the hazard due to hazardous substances. In addition, the book explains tests in order to understand the concentration and intensity of key hazardous substances. Last but not least, the book suggests several possibilities of avoiding the risk to worker's health as a result of exposing them to these substances.

Biomass and Carbon Fuels in Metallurgy presents contemporary and new insights into the use of carbonaceous (Biomass) fuels in the metallurgical sector. The authors describe application of these fuels in different technological processes to produce pig iron, steel and ferroalloys. Emphasis is placed on biomass and its metallurgical utilization. Coverage includes the specification of fuels, their classification and the characteristics of their basic properties. The use of carbonaceous fuels in the production of various kinds of agglomerates (ferriferous, manganese and metalized) is also covered. Key Features: Provides a comprehensive view of carbonaceous fuels in various metallurgy processes Details experiments conducted on the use of traditional and alternative (biomass) carbonaceous fuels for the production of agglomerates. Demonstrates that the energy potential of biomass can also be successfully used in pyrometallurgical processes Describes applications of biomass-based fuels in different technological processes for the production of pig iron, steel and ferroalloys. Coverage includes the specification of fuels, their classification and the characteristics of their basic properties.

Spray forming combines the metallurgical processes of metal casting and powder metallurgy to fabricate metal products with enhanced properties. This introduction to the various modelling and simulation techniques employed demonstrates how they are applied in process analysis and development. Udo Fritsching derives and describes the main models and then presents their application in the simulation of the key features of spray forming. Fritsching documents theoretical results by referencing them to experimental data wherever possible.

A Complete Reference Covering the Latest Technology in Metal Cutting Tools, Processes, and Equipment Metal Cutting Theory and Practice, Third Edition shapes the future of material removal in new and lasting ways. Centered on metallic work materials and traditional chip-forming cutting methods, the book provides a physical understanding of conventional and high-speed machining processes applied to metallic work pieces, and serves as a basis for effective process design and troubleshooting. This latest edition of a well-known reference highlights recent developments, covers the latest research results, and reflects current areas of emphasis in industrial practice. Based on the authors' extensive automotive production experience, it covers several structural changes, and includes an extensive review of computer aided engineering (CAE) methods for process analysis and design. Providing updated material throughout, it offers insight and understanding to engineers looking to design, operate, troubleshoot, and improve high quality, cost effective metal cutting operations. The book contains extensive up-to-date references to both scientific and trade literature, and provides a description of error mapping and compensation strategies for CNC machines based on recently issued international standards, and includes chapters on cutting fluids and gear machining. The authors also offer updated information on tooling grades and practices for machining compacted graphite iron, nickel alloys, and other hard-to-machine materials, as well as a full description of minimum quantity lubrication systems, tooling, and processing practices. In addition, updated topics include machine tool types and structures, cutting tool materials and coatings, cutting mechanics and temperatures, process simulation and analysis, and tool wear from both chemical and mechanical viewpoints. Comprised of 17 chapt

This book represents the first ever scientific monograph including an in-depth analysis of all major field-assisted sintering techniques. Until now, the electromagnetic field-assisted technologies of materials processing were lacking a systematic and generalized description in one fundamental publication; this work promotes the development of generalized concepts and of comparative analyses in this emerging area of materials fabrication. This book describes modern technologies for the powder processing-based fabrication of advanced materials. New approaches for the development of well-tailored and stable structures are thoroughly discussed. Since the potential of traditional thermo-mechanical methods of material treatment is limited due to inadequate control during processing, the book addresses ways to more accurately control the resultant material's structure and properties by an assisting application of electro-magnetic fields. The book describes resistance sintering, high-voltage consolidation, sintering by low-voltage electric pulses (including spark plasma sintering), flash sintering, microwave sintering, induction heating sintering, magnetic pulse compaction and other field-assisted sintering techniques. Includes an in-depth analysis of all major field-assisted sintering techniques; Explains new techniques and approaches for material treatment; Provides detailed descriptions of spark plasma sintering, microwave sintering, high-voltage consolidation, magnetic pulse compaction, and various other approaches when field-assisted treatment is applied.

Using a mold for centrifugal casting as an example, discusses the types of apparatus and tools that are commonly affected by thermal fatigue during industrial processes, and examines the various factors that lead to such failure. Focuses on the performance of particular industrial components under d

Thin films of conducting materials, such as metals, alloys and semiconductors are currently in use in many areas of science and technology, particularly in modern integrated circuit microelectronics that require high quality thin films for the manufacture of connection layers, resistors and ohmic contacts. These conducting films are also important for fundamental investigations in physics, radio-physics and physical chemistry. Physical Properties of Thin Metal Films provides a clear presentation of the complex physical properties particular to thin conducting films and includes the necessary theory, confirming experiments and applications. The volume will be an invaluable reference for graduates, engineers and scientists working in the electronics industry and fields of pure and applied science.

Written by a tribological expert with more than thirty years of experience in the field, Mechanical Wear Fundamentals and Testing, Second Edition compiles an extensive range of graphs, tables, micrographs, and drawings to illustrate wear, friction, and lubrication behavior in modern engineering applications. The author promotes a clear understanding of wear testing methodologies for avoidance and resolution of deterioration and weakening in specific engineering designs. Comprehensively describes more than 20 different phenomenological wear tests and over 10 operational wear tests

One of two self-contained volumes belonging to the newly revised Steel Heat Treatment Handbook, Second Edition, this book focuses on process design, equipment, and testing used in steel heat treatment. Steel Heat Treatment: Equipment and Process Design presents the classical perspectives that form the basis of heat treatment processes while incorporating detailed descriptions of the latest advances since the 1997 publication of the first edition. This book covers the basic principles of heat treatment and the equipment used in modern industrial settings. It also offers detailed coverage of induction heat treatment as well as important types of furnaces, heat transfer, cooling processes, computation, power supplies, laser treatments, residual stress and loading, microstructural analysis, and quality control. The book features thoroughly updated and new information, most notably in the chapters on vacuum heat processing, designing quench processes, laser hardening, and metallurgical property testing. Steel Heat Treatment: Equipment and Process Design provides a focused resource for everyday use by advanced students and practitioners in metallurgy, process design, heat treatment, and mechanical and materials engineering.

With a history that reaches back some 90 years, the Hume-Rothery rules were developed to provide guiding principles in the search for new alloys. Ultimately, the rules bridged metallurgy, crystallography, and physics in a way that led to the emergence of a physics of the solid state in 1930s, although the physical implications of the rules were never fully resolved. Even today, despite a revived interest brought about by the 1984 discovery of quasicrystals, much about the rules remains an enigma. Now almost a century after the rules were put forward, Hume-Rothery Rules for Structurally Complex Alloy Phases provides researchers with an insightful and applicable interpretation of the Hume-Rothery electron concentration rule. Invoking first-principle band calculations, the book emphasizes the stability of structurally complex metallic alloys (CMAs).Written by Uichiro Mizutani, long considered the most knowledgeable expert on both the history and science of Hume-Rothery, this seminal work - Offers a unified interpretation of phase stabilization mechanism of CMAs in different classes Explains how to determine the effective valency of transition metal elements Details establishment of d-states-mediated-FsBz interactions in strongly orbital-hybridizing systems Covers the contrast between e/a and VEC, two notions of electron concentration parameters and includes a way to differentiate between them in designing new alloys Explores strengths and shortcomings for the theory on alloy phase stability Discusses the latest take on electron concentration for gamma-brass This work summarizes the ongoing history of Hume-Rothery and reflects the theoretical studies that Professor Mizutani embarked upon to gain deeper understanding of the basic physics behind stabilizing effects related to electron concentration. It describes how metallic and coval

This book covers the latest advances in processing techniques for producing metallic biomaterial implants. It also discusses recent developments in surface modifications using bioactive ceramics and blood-compatible polymers, as well as the adhesive strength of bioactive surface layers, before introducing the practical applications of metallic biomaterials in the fields of surgery and dentistry. As such, the book provides an essential reference guide for researchers, graduate students and clinicians working in the fields of materials, surgery, dentistry, and mechanics. Mitsuo Niinomi, PhD, D.D.Sc., is a Professor at the Institute for Materials Research, Tohoku University, Japan Takayuki Narushima, PhD, is a Professor at the Department of Materials Processing, Tohoku University, Japan Masaaki Nakai, PhD, is an Associate Professor at the Institute for Materials Research, Tohoku University, Japan

This volume reveals the behaviour and design of cold-formed steel structures, connections and systems. It describes the AISI Specification for the Design of Cold-Formed Steel Structural Members published in July 2000, which governs the design of all cold-formed steel frames, including roof, wall and racking systems, and cold-formed steel residential construction in the USA. The text offers worked examples which can be programmed using MATHCAD or EXCEL.

In this valuable work, all aspects of the reactive magnetron sputtering process, from the discharge up to the resulting thin film growth, are described in detail, allowing the reader to understand the complete process. Hence, this book gives necessary information for those who want to start with reactive magnetron sputtering, understand and investigate the technique, control their sputtering process and tune their existing process, obtaining the desired thin films.

The book briefly describes the structure, properties and applications of various grades of steel, primarily aimed at non-metallurgical students from other engineering streams. The book consists of nine chapters covering most of the important types of steels and their physical metallurgy, microstructure and engineering applications including iron-carbon diagram, heat treatment, surface hardening methods, effect of alloying, specific applications, selection of materials, case studies and so forth. The book also contains subjective and objective questions aimed at exam preparation. Key Features Exclusive title aimed at introduction to steels for non-metallurgy audience Includes microstructure, composition, and properties of all the most commonly used steels Describes the heat treatments and the required alloying additions to process steel for the intended applications Discusses effects of alloying elements on steel Explores development of steels for specialized areas such as the automobile, aerospace, and nuclear industries

This book describes systematically the theory and technology of the precision forming of large, complex and thin-walled superalloy castings for aircraft engines, covering all the important basic aspects of the manufacturing process, including process design, wax pattern, ceramic molds, casting and solidification, heat treatment, repair casting and dimension precision control. The correlation of casting defects, structural characteristics and performance of castings is revealed through a range of tests. It also discusses the latest technologies and advances in this field - such as imaging the solidification process by means of synchrotron radiography, 3D computerized tomography and reconstruction of microporosity defects, analysis and diagnosis of error sources for dimension over-tolerance and adjusted pressure casting technology - which are of particular interest. Providing essential insights, the book offers a valuable guide to the design and manufacture of superalloy casting parts for aircraft engines.

This book describes in great detail the semi-solid processing of aluminum alloys. The authors examine the fundamentals of semi-solid metal processing, provide guidelines for research, illustrate the tools that are employed, and explain the measured parameters for semi-solid processing characterization.

The automotive industry requirements for vehicle weight reduction, weight containment, improved part functionality and passenger safety have resulted in the increased use of steel grades with a fully martensitic microstructure. These steel grades are essential to improve the anti-intrusion resistance of automotive body parts and the related passenger safety during car collisions. Standard advanced high strength steel (AHSS) grades are notoriously difficult to be formed by cold stamping; they are characterized by elastic springback, poor stretch flangeability and low hole expansion ratios. Hot stamping has therefore received much attention recently as an alternative technology to produce AHSS automotive parts.In this book, selected articles from the Fourth International Conference on Advanced High Strength Steel and Press Hardening held on August 20-22th, 2018 in Hefei, China, are compiled. It focuses on AHSS for the development of press hardening of high performance sheet metal for lightweight vehicle, advanced digital manufacturing technology, as well as the physical metallurgy principles of the hot stamping process.Aiming at the process design and industrial application for hot stamping of press hardened steel and high strength aluminium alloy sheet, the effect of temperature and strain rate on the formability and mechanical properties of the products is discussed. In addition, more practical cases are provided concerning accurate modelling and multi-physics coupling simulation of the hot stamping process. Furthermore, the influence of tool design on forming process, more precise process control strategies to increase production efficiency, and the improvement of hot stamping equipment by advanced design methods will also be presented.