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Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006141
EISBN: 978-1-62708-175-7
..., fracture toughness, magnetic properties, etc.). The process of MIM consists of mixing a small amount of organic material (binder phase) with the desired amount of powders of appropriate metals and/or alloys to form what is known as the feedstock. This feedstock can flow like polymeric materials under...
Abstract
This article describes part selection, feedstock (powders and binders) characteristics and properties, tool design, and material and tooling for fabrication of metal powder injection molding (MIM) machines. It discusses the process parameters, operation sequence, molding machines, debinding techniques, consolidation (sintering) techniques, advantages, and limitations of MIM.
Series: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006555
EISBN: 978-1-62708-290-7
... laser and light sources. Metal parts are produced using electron and laser beam approaches. Virtually any pulverized material can be used in PBF when a suitable transient or permanent binder is mixed with the primary feedstock. Postprocessing may be used in the case of metal and ceramic parts to either...
Abstract
Additive manufacturing is a collection of manufacturing processes, each of which builds a part additively based on a digital solid model. The solid model-to-additive manufacturing interface and material deposition are entirely computer-controlled. The traditional additive manufacturing applications have been used for low production runs of parts with complex shapes and geometric features. Additive manufacturing is also used for topology optimization and it impacts the process and supply chain. This article discusses processes, including vat photopolymerization, material jetting, powder bed fusion, directed energy deposition, material extrusion, binder jetting, and sheet lamination.
Series: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006571
EISBN: 978-1-62708-290-7
... into powder bed with irregular particle morphology. (a) Schematic of large void formation. (b) Schematic of capillary cylinder model. Source: Ref 22 Processing mixed-material feedstock, commonly encountered in ceramic processing, also presents a challenge, especially in applications involving doping...
Abstract
The highly irregular morphologies of ceramic powder particles due to their process history present a challenge to binder jetting additive manufacturing (BJ-AM) ceramic powder feedstock processability, but knowledge of powder metallurgy of ceramics benefits the development and analysis of the BJ-AM ceramic processes. Understanding BJ-AM process principles and ceramics processing challenges requires reviewing a number of fundamental principles, which this article delineates. The discussion covers the processability considerations, a brief summary of some fundamental aspects of modeling of liquid permeation in the powder bed, and process capabilities and advantages of BJ-AM technology.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001462
EISBN: 978-1-62708-173-3
... be applied to a range of substrate materials, including metals, ceramics, plastics, and polymer composites. Thermal spray technology evolved and developed within the welding field because of similarities in the electrical and combustion equipment and the feedstock materials used in thermal spray with those...
Abstract
Thermal spray coatings (TSCs) are surface coatings engineered to provide wear-, erosion-, abrasion-, and corrosion-resistant coatings for original equipment manufacture and for the repair and upgrading of in-service equipment. This article presents an overview of five thermal spray processes and the specific flame and arc spray processes used to preserve large steel components and structures. It describes the TSC selection guide and an industrial process procedure guide for applying aluminum and zinc TSCs onto steel.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003471
EISBN: 978-1-62708-195-5
... of ASR is the variability of the feedstock. Unlike pyrolyzing SMC prompt scrap, pyrolyzing ASR requires dealing with a constantly varying mix of polymers and other materials, making the process difficult to control. Hydrolysis Recycling through hydrolysis can be used for recovering the monomers...
Abstract
This article begins with a discussion on the driving forces for recycling composites. It reviews the recycling process of thermoset-matrix composites and thermoplastic-matrix composites. The recycling of thermoset-matrix composites includes regrind, chemical, energy recovery, and thermal processes. Thermoplastic-matrix composites are recycled by regrinding, compounding/blending and reprocessing. The article concludes with discussion on the properties of recycled composite fibers.
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005503
EISBN: 978-1-62708-197-9
..., because of the low overall cost in a high level of shape complexity. Powder injection molding (PIM) builds on the long-recognized success of plastic molding by using a high-particle-content thermoplastic as feedstock. The steps in PIM involve first mixing selected small powders (usually smaller than 20 µm...
Abstract
This article focuses on the axisymmetric 2.5-dimensional approach used in metal powder injection molding (PIM) simulations. It describes three stages of PIM simulations: filling, packing, and cooling. The article discusses the process features of numerical simulation of PIM, such as filling and packing analysis, cooling analysis, and coupled analysis between filling, packing, and cooling stages. It explains the experimental material properties and verification for filling, packing, and cooling stages in the PIM simulations. The article presents simulation results from some of the 2.5-dimensional examples to demonstrate the usefulness of the computer-aided engineering analysis and optimization capability of the PIM process.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003013
EISBN: 978-1-62708-200-6
... chemical feedstocks and household/industrial fuel. Fig. 2 How tertiary recycling affects the life cycle of a plastic The mechanical processes of secondary recycling have limited ability to separate and purify extremely contaminated or mixed plastics. Limitations also exist in product...
Abstract
This article discusses postconsumer plastics recyclate quantities, the classification of plastics recycling into primary, secondary, tertiary, and quaternary categories, and how the life cycle of plastics is affected by recycling. The recycling processes of polyethylene terephthalate (PET), which accounts for the largest percentage of plastic recycling, high-density polyethylene (HDPE) plastics, the other large-volume plastic recyclate, as well as vinyl resins and polycarbonate resins are described. The life cycle of plastics has four phases: poly formation, part fabrication, product service, and disposal. Landfilling is still the primary method of final disposal, and incineration is another option, but recycling has become a viable alternative. The article presents a comparison between secondary and tertiary recycling.
Series: ASM Handbook
Volume: 1
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v01.a0001053
EISBN: 978-1-62708-161-0
... such as chemicals. Recycled scrap is a major raw material for the metals industry, supplying up to 100% of the feedstock for some products. Consequently, the scrap metal recycling industry is very important to the economy, providing tens of thousands of jobs across the United States. In addition, the significant...
Abstract
A significant amount of the worldwide demand for metals is met with recycled materials acquired by metal producers in the form of purchased scrap. This article focuses primarily on the methods and technology used to process and repurpose the vast amounts of purchased scrap that recirculate in the industrial supply chain. It describes the U.S. market for iron and steel scrap, providing information on scrap use by industry, factors influencing demand, and the purchased scrap supply. Iron and steel recycling is discussed separately from stainless steel and superalloy recycling in this article, as the scrap industry treats them differently. The scrap processing of iron involves collection, separation and sorting, size reduction and compaction, detinning, blending, and incineration. The recycling of stainless steels and superalloys follows the same process, but requires several additional steps, including secondary nickel refining, degreasing, and separation of metallurgical wastes.
Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006053
EISBN: 978-1-62708-175-7
..., and surfactants with a dried grade powder to achieve the desired solids loading, injecting the thermoplastic feedstock into a die, removing from the die, and debinding in one or more stages prior to sintering ( Ref 4 , 5 , 6 , 7 ). The additional steps of mixing and debinding, as well as a longer cycle time...
Abstract
Consolidation and shaping of grade powders is carried out using several methods, depending on the size, complexity, shape, and quantity of parts required. This article details the powder consolidation methods of carbide powders: uniaxial pressing, cold isostatic pressing, extrusion, green machining, and injection molding.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006838
EISBN: 978-1-62708-329-4
... properly defining load and service conditions for a part, materials selection is key. Most metal AM processes are highly constrained in terms of what feedstocks are viable. For example, laser PBF requires that metal powder feedstocks have a relatively prescribed size distribution and shape and a certain...
Abstract
This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.
Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006021
EISBN: 978-1-62708-175-7
...Abstract Abstract This article discusses the process details of metal powder injection molding of microcomponents and the powder particle characteristics of feedstock and property requirements of binders. It reviews important characteristics to be considered in the processing steps: venting...
Abstract
This article discusses the process details of metal powder injection molding of microcomponents and the powder particle characteristics of feedstock and property requirements of binders. It reviews important characteristics to be considered in the processing steps: venting, channel diameters, binder segregation, binder degradation, feedstock supply, temperature control, demolding, debinding, and sintering. Finally, the article provides information on powder injection molding mold-filling simulation and two-component powder injection molding, offering a method for high-volume production of microcomponents made of multifunctional materials.
Series: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003790
EISBN: 978-1-62708-177-1
... the macroscopic examination of defects, which occur in semisolid metalworking with illustrations. It discusses the macroscopic examination of gating systems and semisolid feedstocks. The article also provides information on feedstock microstructures, direct semisolid metalworking component microstructures...
Abstract
This article begins with a description of indirect and direct semisolid metalworking processes. It then provides information on alloy compositions of common aluminum semisolid metalworking alloys and primary die-cast magnesium alloys in a tabular form. The article describes the macroscopic examination of defects, which occur in semisolid metalworking with illustrations. It discusses the macroscopic examination of gating systems and semisolid feedstocks. The article also provides information on feedstock microstructures, direct semisolid metalworking component microstructures, and indirect semisolid metalworking component microstructures of series 300 aluminum casting alloys and magnesium die-casting alloys.
Book: Thermal Spray Technology
Series: ASM Handbook
Volume: 5A
Publisher: ASM International
Published: 01 August 2013
DOI: 10.31399/asm.hb.v05a.a0005727
EISBN: 978-1-62708-171-9
... to thermal spraying, and offers an understanding for choosing particular feedstock materials that are classified based on the thermal spray process, material morphology, chemical nature of the material, and applications. Sieving, the most common method of separating powders into their size fractions, is also...
Abstract
This article discusses three types of powder-feeder systems that are commonly used throughout the thermal spray (TS) industry: gravity-based devices, rotating wheel devices, and fluidized-bed systems. It provides information on the various mechanical methods for producing powders, namely, crushing, milling, attriting, and machining. The article describes two prime methods of agglomeration. One method uses a binder by way of agglutination, while the other relies on a sintering operation. The article discusses the technology and principles of the processes that relate to thermal spraying, and offers an understanding for choosing particular feedstock materials that are classified based on the thermal spray process, material morphology, chemical nature of the material, and applications. Sieving, the most common method of separating powders into their size fractions, is also reviewed. The article also provides information on the topical areas and precautions to be undertaken to protect the operator from safety hazards.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005204
EISBN: 978-1-62708-187-0
... at the end of 2007. Electron beam melting and casting includes melting, refining, and conversion processes for metals and alloys. In electron beam melting, the feedstock is melted by impinging high-energy electrons. Electron beam refining takes place in vacuum in the pool of a water-cooled copper...
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003015
EISBN: 978-1-62708-200-6
... shape commonly used in processing. Raw materials with the correct final properties are purchased from resin manufacturers. These are generally in final feedstock form, although when large tonnages are involved, such as in pipe manufacture, materials may need to be compounded to obtain the desired...
Abstract
This article describes the extrusion process, which converts soft, plastic material into a particular form using an extruder, or screw conveyer. It discusses the two main types of plastic extruders, twin-screw and single-screw, estimation of extruder capacity, and design and operations (heating, cooling, downstream sizing, corrugating, and crossheading) of the screw, the most important component of any extruder. It discusses the shapes produced by screw extrusion and the types of extrusion products produced by extrusion processes, including blown-film extrusion, flat-film or sheet extrusion, chill-roll film extrusion, pipe or tube extrusion, wire and cable coverings, extrusion coating, and profile extrusion, and provides some discussion on multiple-screw extruders. The article describes the dimensional accuracy of extrusion products, and lists common defects that occur frequently in the extrusion process.
Series: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006562
EISBN: 978-1-62708-290-7
... Prairie, MN, USA) fused deposition modeling (FDM) system to extrude ceramic-loaded thermoplastic filaments. The feedstock filament was liquefied (melt), extruded, deposited, and resolidified by cooling to retain its shape. Since then, the process was further improved and is capable of producing high...
Abstract
This article is a review of the material extrusion-based ceramic additive manufacturing (MECAM) processes. The discussion begins with details of extrusion with filament and paste, covering the most popular variants of paste extrusion-based MECAM techniques that can be differentiated based on paste type and the method of shape retention of the deposited layer: extrusion freeforming, robocasting ceramic on-demand extrusion, and freeze-form extrusion fabrication. The article then focuses on post-processing considerations and the mechanical properties of sintered ceramic parts. It concludes with information on innovation opportunities in ceramic additive manufacturing, such as incorporating UV-curing and gelation in the process and producing geometrically complex structures from shapeable green bodies.
Book: Thermal Spray Technology
Series: ASM Handbook
Volume: 5A
Publisher: ASM International
Published: 01 August 2013
DOI: 10.31399/asm.hb.v05a.a0005736
EISBN: 978-1-62708-171-9
...Abstract Abstract Thermal spray processes involve complete or partial melting of a feedstock material in a high-temperature flame, and propelling and depositing the material as a coating on a substrate. This article describes the properties of sprayed electronic materials, including dielectrics...
Abstract
Thermal spray processes involve complete or partial melting of a feedstock material in a high-temperature flame, and propelling and depositing the material as a coating on a substrate. This article describes the properties of sprayed electronic materials, including dielectrics, conductors, and resistors, and discusses their implications and associated limitations for device applications and potential remedial measures. The article presents specific examples of electrical/electronic device applications, including electromagnetic interference/radio-frequency interference shielding, planar microwave devices, waveguide devices, sensing devices, solid oxide fuel cells, heating elements, electrodes for capacitors and other electrochemical devices.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003700
EISBN: 978-1-62708-182-5
.... Sulfide and other sulfur species contained in the hydrocarbon stream can also be corrosive at high concentrations and at high temperatures. Many processes in the refinery involve distillation, often fractional, of hydrocarbons. In most of these distillation processes, water is present in the feedstock...
Abstract
This article provides useful information on the occurrence of corrosion in crude oil refinery units, namely, crude unit, catalytic and thermal cracking units, hydroprocessing units, amine sweetening units, and sour water units. Types and applications of corrosion inhibitors, namely, neutralizers, filming inhibitors, scavengers, microbiocides, and anti-foulants and scale inhibitors, are reviewed. The article describes the direct and indirect corrosion monitoring methods used to reduce equipment damage due to corrosion events and to assess the reliability and useful service life of process equipment.
Series: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006543
EISBN: 978-1-62708-290-7
... is the ability to nest parts in a single build easily, which increases part-packing density; parts also build faster without supports. Polymer PBF feedstock is generally certain types of semicrystalline polymers, with the most popular being polyamide (nylon), with or without composite additions such as flame...
Abstract
Powder bed fusion (PBF) of polymers is a collection of additive manufacturing processes that melt and fuse polymer in a powder bed. This article provides a complete suite of materials and processes involved in PBF of polymers. The discussion includes details of thermal and manufacturing issues, and safety, postprocessing, and finishing considerations, as well as of principal defects in PBF polymer parts and the mechanical properties of the parts produced by PBF. The article provides case studies on the applications of polymer PBF.
Book Chapter
Series: ASM Handbook
Volume: 17
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.hb.v17.a0006465
EISBN: 978-1-62708-190-0
.... However, examination and identification of these defects in finished components can be useful for determining and remedying defect sources, particularly for materials or processes that may not be thoroughly characterized. This review is primarily focused on full melting processes that use powder feedstock...
Abstract
Additive manufacturing (AM) is the process of joining materials to make parts from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies. This article discusses various defects in AM components, such as porosity, inclusions, cracking, and residual stress, that can be avoided by using vendor recommended process parameters and approved materials. It describes the development of process-structure-property-performance modeling. The article explains the practical considerations in nondestructive evaluation for additively manufactured metallic parts. It also examines nondestructive testing (NDT) inspection and characterization methods for each of the manufacturing stages in their natural order. The article provides information on various inspection techniques for completed AM manufactured parts. The various electromagnetic and eddy current techniques that can be used to detect changes to nearsurface geometric anomalies or other defects are also discussed. These include ultrasonic techniques, radiographic techniques, and neutron imaging.