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Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006498
EISBN: 978-1-62708-207-5
... Abstract Semisolid casting is a near-net shape manufacturing process capable of producing thick- and thin-walled complex-shaped components having excellent mechanical and functional performance. This article begins with a discussion on the history of semisolid processing and the advantages...
Abstract
Semisolid casting is a near-net shape manufacturing process capable of producing thick- and thin-walled complex-shaped components having excellent mechanical and functional performance. This article begins with a discussion on the history of semisolid processing and the advantages claimed for semisolid casting. It describes the four notable processes used to produce semisolid castings: thixocasting, rheocasting, thixomolding, and wrought processes. Most commercial aluminum semisolid casters use either thixocasting or rheocasting. The article discusses the die design, process conditions, and simulation for semisolid casting. It concludes with a review of several components produced by each of the various semisolid casting processes.
Book Chapter
Solidification Structures of Titanium Alloys
Available to PurchaseSeries: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003728
EISBN: 978-1-62708-177-1
... of above 1" at room temperature and reasonable room temperature ductility in the as-cast condition. Finally, it provides information on the microstructures produced through various near-net shape manufacturing processes. directional solidification ductility grain refinement heat-resistant titanium...
Abstract
This article describes the development of heat-resistant titanium-base alloys and their classification into several microstructure categories based on their strengthening mechanisms. It explains the phase transformation in titanium-aluminum-base alloys and two peritectic reactions that take place in the titanium-aluminum system. The article also describes two approaches for controlling the orientation of the high-temperature alpha phase to achieve the required lamellar orientation by directional solidification in order to improve the strength and ductility of titanium-aluminum alloys. One approach is by seeding the alpha phase in the alloys, and the other is without seeding, by controlling the solidification path of alloys through appropriate alloying. The article discusses the grain refinement technique used to improve the ductility of cast titanium-aluminum alloys to a level of above 1" at room temperature and reasonable room temperature ductility in the as-cast condition. Finally, it provides information on the microstructures produced through various near-net shape manufacturing processes.
Book Chapter
Nontraditional Applications of Electron Beams
Available to PurchaseSeries: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005611
EISBN: 978-1-62708-174-0
.... Electron beam additive manufacturing (EBAM), electron beam free-form fabrication (EBFFF or EBF 3 ), electron beam melting (EBM), and electron beam direct manufacturing (EBDM) are several of the acronyms used to describe various processes that correlate to the use of an EB power source for near-net shape...
Abstract
This article focuses on the use of electron beam (EB) for near-net shape processing based on the wire feed material-delivery method. EB deposition processes start with a 3-D model designed in a computer-aided design (CAD) environment, where the deposition path and process parameters are generated. The article provides a description of the electron beam direct manufacturing (EBDM) system used for manufacturing of target parts with the aid of a case study. The control of the essential variables of dynamic beam deflection is also reviewed. The article also includes information on the applications of high-frequency multibeam processes, namely, selective surface treatment, multiple-pool welding, and pre- and post-heat treating.
Book Chapter
Introduction to Materials and Processes for Additive Manufacturing/Alloy Design and Materials Selection
Available to PurchaseSeries: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006973
EISBN: 978-1-62708-439-0
... Abstract Additive manufacturing (AM) is a highly desired layer-by-layer fabrication process capable of creating near-net-shaped three-dimensional components for a wide range of industries, such as the automotive and aerospace industries. This article focuses on aluminum, titanium, and stainless...
Abstract
Additive manufacturing (AM) is a highly desired layer-by-layer fabrication process capable of creating near-net-shaped three-dimensional components for a wide range of industries, such as the automotive and aerospace industries. This article focuses on aluminum, titanium, and stainless steel alloys that are commonly used or highly desired for use with AM due to their widespread applicability and favorable mechanical properties. It presents an overview of two of the major AM processes: powder-bed and powder-fed. The article discusses processability using AM. It also provides an overview of material microstructures, defects, and the impact on mechanical behaviors.
Book Chapter
Braiding
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003040
EISBN: 978-1-62708-200-6
... stability, and damage resistance. Many intricate material placement techniques can be transferred to and modified for composite prepreg fabrication processes. The extension of two-dimensional braiding to three-dimensional braiding has opened up new opportunities in the near-net shape manufacturing of high...
Abstract
Braiding is a textile process that is known for its simplicity and versatility. Braided structures are unique in their high level of conformability, torsional stability, and damage resistance. This article describes the braiding process and the mechanical properties of two-dimensional and three-dimensional braiding.
Book Chapter
Fabrication of Near-Net Shape Cost-Effective Titanium Components by Use of Prealloyed Powder and Hot Isostatic Pressing
Available to PurchaseBook: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006140
EISBN: 978-1-62708-175-7
... of the manufacturing process compared with the weight of the component installed in the aircraft. The technique is used to fabricate complex near net shapes with initial shape created using ceramic molds and in the past ten years utilizing carefully shaped metal cans and mild steel inserts. HIP process simulation...
Abstract
Prealloyed (PA) powder metallurgy is a technique where complex near-net shape titanium aircraft components are fabricated with low buy-to-fly ratios. This article describes the physical principle, mechanism, and simulation and modeling of metal can and hot isostatic pressing (HIP) processes involved in the PA powder metallurgy technique. It discusses the technical problems addressed in shape control and their solutions for understanding the advantages of powder metallurgy HIP.
Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003361
EISBN: 978-1-62708-195-5
.... The extension of two-dimensional braiding to three-dimensional braiding has opened up new opportunities in the near-net shape manufacturing of damage-tolerant structural composites. In the braiding process, two or more systems of yarns are intertwined in the bias direction to form an integrated structure...
Abstract
Braided structures are unique in their high level of conformability, torsional stability, and damage resistance. This article describes the classifications of braiding such as two-dimensional braiding and three-dimensional braiding. It presents the governing equations for computer-controlled braiding in a table. The article lists the applications of braided fabrics and composites. It discusses the formation, structure, and properties of two-dimensional braid composites and three-dimensional braid composites: the damage tolerance and the impact damage limitation.
Book Chapter
Isothermal and Hot-Die Forging
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003985
EISBN: 978-1-62708-185-6
... 2. Shah S.N. and McKeogh J.D. , “Status of Near Net Shape Forging for Major Aerospace Applications,” Paper MF83-908, Society of Manufacturing Engineers , 1983 3. Kuhlman G.W. and Nelson J.W. , “Precision Forging Technology: A Change in the State-of-the-Art...
Abstract
Hot-die forging and isothermal forging are unique forging methods developed to forge materials that are difficult or impossible to forge by conventional means. This article presents a comparative study on hot-die forging and isothermal forging. It discusses forging parameters, process selection considerations, design guidelines, alloy types and selection, and the advantages and disadvantages of hot-die forging and isothermal forging. The article discusses the application of the finite-element analysis modeling to design.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005632
EISBN: 978-1-62708-174-0
... deposition, and LAM (laser additive manufacturing). Fig. 9 Laser-engineered net shape process. Courtesy of Castle Island Co. In comparison with conventional cladding methods, a near-net-shaped feature or part is designed and the control sequence for deposition of the feature is planned using...
Abstract
Laser deposition involves the articulation of a laser beam and the introduction of material into the beam path to fuse the material onto a substrate or into a functional shape. It can be divided into two broad categories: cladding and near-net shape processing. This article provides a discussion on the material combinations, characteristics of laser cladding, and the comparison with arc cladding. It reviews the characteristics and applications of near-net shape processing and explains the process involved in powder bed methods and direct powder methods.
Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006074
EISBN: 978-1-62708-175-7
... of the preform, refine the sintered grain structure, and produce deformation texture allowing production of a part with mechanical properties dependent primarily on chemistry and heat treatment. Both forging preforms and near-net-shape parts produced by CIP facilitate production of prototype parts with reduced...
Abstract
This article describes the unique aspects of cold isostatic pressing (CIP) in comparison with die compaction, for powder metallurgy parts. It details the components of CIP equipment, including pressure vessels, pressure generators, and tooling material. The article reviews the part shapes and their influence in determining tap density of the filled mold. It provides a discussion on process parameters, such as dwell time, depressurization rate, evaluation of green strength and density, and thermal processing, and illustrates a process flowchart for the production of CIP parts.
Book Chapter
Modeling of Hot Isostatic Pressing
Available to PurchaseSeries: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005509
EISBN: 978-1-62708-197-9
..., and manufactured into a near-net shape using commercial Ti-6Al-4V powder. The casing, as shown in Fig. 5 , consists of an axial-symmetric cylindrical body with two bosses, two edge flanges, two body rings, and two reinforced ribs. The whole design and manufacturing process involved the initial prediction...
Abstract
This article discusses the two major applications of hot isostatic pressing (HIP), such as healing of inherent internal defects in castings and welds, and consolidation of powder materials. It describes the design principles of the HIP tooling, as well as the problems associated with mathematical modeling of HIP. The article presents an example for the modeling process of the HIP. It reviews the numerical modeling and tooling design of a casing component demonstration.
Book Chapter
Rapid Tooling for Forging Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004024
EISBN: 978-1-62708-185-6
... <xref rid="a0004024-ref9" ref-type="bibr">(Ref 9)</xref> Hot isostatic pressing (HIP) is a powder metallurgical process for consolidating materials such as ceramics and refractory metals. A major benefit of using P/M molds is the ability to produce near net shape cavities directly by HIP. Hot isostatic pressing has great potential...
Abstract
This article describes two rapid tooling technologies, namely, direct rapid tooling and indirect rapid tooling, for forging-die applications. Commonly used direct rapid tooling technologies include selective laser sintering, three-dimensional printing, and laser-engineered net shape process. The indirect rapid tooling technologies include 3D Keltool process, hot isostatic pressing, rapid solidification process tooling, precision spray forming, and radially constricted consolidation process.
Book Chapter
Pressing and Sintering of Titanium Powders
Available to PurchaseBook: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006045
EISBN: 978-1-62708-175-7
... controlled near-net shape components of desirable compositions. The advantages of this technique are high productivity, minimum or no machining required, low scrap rate, and low cost. The disadvantage is the limitation in the size of die pressed parts. In order to achieve desired levels of mechanical...
Abstract
Consolidation of titanium powders at room temperature may be performed by low-cost conventional powder metallurgy processes. This article provides information on various consolidation methods, namely, die pressing, direct powder rolling, and cold isostatic pressing. It also describes the sintering of blended elemental powders, high-strength titanium alloys, and porous material as well as the sintering of titanium powders by microwave heating.
Book Chapter
Introduction to Full Density Powder Metallurgy
Available to PurchaseBook: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006142
EISBN: 978-1-62708-175-7
..., to a large extent, as a near net-shape process offering remarkable cost advantage over traditional, ingot based metalworking processes. Application of PM technology continues to expand, with growth rates faster than other metalworking technologies. Powder Metallurgy processed components are being used...
Abstract
This article provides a basic introduction to the various aspects of full density powder metallurgy, including properties, applications, processing methods, and process parameters.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005337
EISBN: 978-1-62708-187-0
...-shape or near-net-shape technologies to make titanium alloy components more competitive ( Ref 3 ). These titanium net-shape technologies include powder metallurgy (P/M), superplastic forming (SPF), precision forging, and precision casting. Precision casting is by far the most fully developed...
Abstract
The combination of high strength-to-weight ratio, excellent mechanical properties, and corrosion resistance makes titanium the best material choice for many critical applications. This article begins with a description of the historical perspective of titanium casting technology. It discusses the types of molding methods, such as rammed graphite molding and lost-wax investment molding. The article provides information on the casting design, melting, postcasting, and pouring practices. It describes the microstructure and mechanical properties of Ti-6AI-4V alloy. The article examines the product applications of titanium alloy castings. The tensile properties, standard industry specifications, and chemical compositions of various titanium alloy castings are tabulated.
Book Chapter
Powder Metallurgy Processing by Hot Isostatic Pressing
Available to PurchaseBook: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006042
EISBN: 978-1-62708-175-7
... sensitive to residual porosity, and HIP PM materials typically have excellent fatigue resistance. Current HIP PM technology enables the production of both simple and complex net and near-net shapes. Thus, the HIP PM process route offers an alternative to casting and forging in metal parts production...
Abstract
This article discusses metal powder processing via hot isostatic pressing (HIP) and HIP cladding when metal powders are being employed in the cladding process. It traces the history of the process and details the equipment, pressing cycle, and densification mechanisms for HIP. The article describes the available process routes for fabricating products using HIP and the steps involved in the production of a part via direct HIP of encapsulated gas-atomized spherical powder. It concludes with information on the microstructures of 316L stainless steel HIP powder metallurgy valve body and a list of the mechanical properties of several powder metallurgy alloys.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003972
EISBN: 978-1-62708-185-6
.... In addition, the metallurgical changes in hot working are much different from those in cold working of the material. Benefits and Disadvantages of Deformation Processes Geometric Features A major benefit of deformation processing is the ability to produce a near-net shape. Since hard tooling is used...
Abstract
This article reviews the general aspects of product design and provides an overview of the manufacturing processes and their relationship to design, with an emphasis on deformation processes. It discusses the various classes of deformation processes to illustrate their impacts on product design while taking advantage of the benefits of deformation processing.
Book Chapter
Introduction to Manufacturing of Polymer-Matrix Composites
Available to PurchaseBook: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003401
EISBN: 978-1-62708-195-5
... compounds, and, in some cases, thermoplastic composites). Most often, the aim in composites manufacturing is to realize near-net-shape or, ideally, net-shape manufacturing, meaning that little or no post-manufacturing machining and trimming is needed, which improves both process economy and individual...
Abstract
This article explains the key features of the manufacturing techniques for polymer composites. It describes the selection of a technically and economically feasible manufacturing technique for a composite design. The article discusses widely accepted and emerging techniques to manufacture polymer composites such as open-mold techniques.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003986
EISBN: 978-1-62708-185-6
... the technology for forging spiral bevel gears with near-net teeth ( Ref 8 ). The focus of the program was to develop computer techniques to the design and manufacture of the gear dies. A flashless forging process was designed and forging trials were conducted that demonstrated: CAD/CAM methods could...
Abstract
Precision forging is defined as a closed-die forging process in which the accuracy of the shape, dimensional tolerances, and surface finish exceed normal expectations to the extent that some of the postforge operations can be eliminated. This article provides an overview of the key factors that impact the precision forging process. It provides information on the achievable tolerances and presents examples of precision forging. A discussion on forging of bevel gears/spiral bevel gears is also presented.
Series: ASM Handbook
Volume: 2
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v02.a0001101
EISBN: 978-1-62708-162-7
... processing offers a near-net-shape manufacturing capability, which is economically attractive. Developers have explored various liquid metal techniques that use multifilament yarns, chopped fibers, or particulates as the reinforcement. A castable ceramic/aluminum MMC is now commercially available ( Ref 6...
Abstract
Metal-matrix composites (MMCs) are a class of materials with potential for a wide variety of structural and thermal management applications. They are nonflammable, do not outgas in a vacuum, and suffer minimal attack by organic fluids, such as fuels and solvents. This article presents an overview of the status of MMCs, and provides information on physical and mechanical properties, processing methods, distinctive features, and various types of continuously and discontinuously reinforced aluminum, magnesium, titanium, copper, superalloy, and intermetallic-matrix composites. It further discusses the property prediction and processing methods for MMCs.
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