Search Results for process development

Integrated computational materials engineering (ICME) is a relatively new discipline that shows great promise for reducing the cost and time required to design and deploy new materials, manufacturing technologies, and products. This article introduces an ICME implementation framework for product development using modeling of a friction stir welding process as an example.

Automated mineralogical analysis using near-infrared spectroscopy and X-ray diffraction can improve ore control and process efficiency resulting in reduced processing costs and higher yields.

Early consideration of scale-up requirements can help circumvent downstream problems when implementing thermal processes for the production of new materials and product forms. Examples are given showing how success is achieved when scaling opportunities and challenges are identified early in the development process.

In order to expand the choice of materials available for use in additive manufacturing, parameters that consider welding metallurgy, laser powder interaction, and post processing must be developed. This article describes the outcomes of process development for a steel and stainless steel alloy that are not standard materials for laser powder bed fusion equipment.

Temperature measurement, unvented cavities, loose powder, and direct contact of certain metals must be considered during process development for vacuum heat treatment of additively manufactured parts.

Binder jet 3D metal printing is the ultimate bridge between prototypes and production of metal injection molded parts.

Research conducted at a brass-strip plant in Zutphen, Netherlands shows how nonlinear modeling can be used to predict the grain size and hardness of annealed strip based on composition and process variables. Production data gathered over the course of a year were used to train a feed-forward neural network that achieved a correlation coefficient of more than 86% when presented with new input data. The standard deviation between predicted and measured grain size was about 4.2 µm.

Cross-linked low density polyethylene (LDPE) foams are used for applications such as packaging and thermal insulation. Relating composition, process, and dimensional variables with materials properties using nonlinear modeling provides a valuable tool for efficient LDPE materials and product development.

Single crystal and directionally solidified casting processes are among the most complex techniques available, requiring stringent process control and a thorough understanding of engineered materials and specialty alloys. This article examines how an aerospace material company utilizes advanced investment casting techniques to create components that meet the increasingly demanding requirements of modern aerospace and gas turbine engines. The article highlights how solidification modeling and integrated computational materials engineering (ICME) have accelerated development processes by predicting material behaviors and optimizing casting parameters without extensive experimental testing.

Profile of the 2012-2013 President of ASM International, Gernant E. Maurer.

This article highlights some of the best metallographic practices from a laser powder bed fusion laboratory and provides practical observations of the more universal aspects of powder testing.

Significant advancements in metallurgy were highlighted at a special symposium presented at the Materials Science & Technology 2016 conference in Salt Lake City. This article summarizes the topics presented. All six speakers shared examples of the importance of understanding how the specific manufacturing process affects microstructure development in metals. The fundamental understanding of microstructure allows metallurgists to select manufacturing processes and schedules to tailor the microstructure, and therefore mechanical properties and performance, for a particular component.

This guide outlines recent advances in the various methods of laser technology and appropriate manufacturing applications. Each process has unique requirements and matching the laser source to the project is essential for developing a robust solution.

Developments in titanium technology and opportunities for increased use in several markets were highlighted at the 13th World Conference on Titanium. This article reviews some of the key technical topics covered at the conference, including new alloy development and innovative characterization methods.

Profile of David Furrer, the 2018-2019 President of ASM International

This article reports on work at the Center for Thermal Spray Research over the past 25 years to develop and commercialize a new technology for digital printing of mesoscale circuits directly from a CAD file onto plates, cylinders, and complex 3D components and structures. With the evolution of cold spray technology and new powder materials, as well as advancements in control and robotics, innovative thermal spray applications are on the horizon.

The July and September issues of the Journal of Materials Engineering and Performance (JMEP) were special issues focused on additive manufacturing. The issues were guest edited by William E. Frazier, FASM, Pilgrim Consulting LLC and editor of JMEP; Rick Russell, NASA; Yan Lu, NIST; Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock. The highlighted articles described in this article were selected by Dr. Frazier to showcase the varied topics covered in the special issues.

For parts made by direct metal laser melting, heat treatment is important to set the final microstructure, which impacts mechanical properties.

An ultrafast, efficient industrial-scale boriding process can drastically reduce costs, increase productivity, and improve the performance and reliability of a variety of machine parts. This article describes a novel, environmentally friendly technology that enables treating thousands of industrial components in one batch, without creating solid or liquid waste and gaseous emissions.

This article summarizes the outcomes from a NIST-sponsored workshop that examined the additive manufacturing (AM) data management pain points experienced by small- and medium-sized enterprises in interacting with larger organizations and government procurement agencies. Three prominent themes emerged: cost of compliance, technology gaps associated with uncertainty and AM process qualification, and a desire for government leadership to address these issues. The article includes lists of specific action items proposed at the workshop to address these challenges.