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thin-melting interface
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Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005620
EISBN: 978-1-62708-174-0
... is a hybrid process based on a thin-melting interface for a lap joint of dissimilar-metal sheets using a roller and one-sided laser heating. The article discusses the types, advantages, and applications of roll welding and laser roll welding. It also provides a detailed discussion on the laser roll welding...
Abstract
This article describes two methods based on rolling of sheet. The first is roll welding, where two or more sheets or plates are stacked together and then passed through rolls until sufficient deformation has occurred to produce solid-state welds. The other is laser roll welding, which is a hybrid process based on a thin-melting interface for a lap joint of dissimilar-metal sheets using a roller and one-sided laser heating. The article discusses the types, advantages, and applications of roll welding and laser roll welding. It also provides a detailed discussion on the laser roll welding of dissimilar metals.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003593
EISBN: 978-1-62708-182-5
... of the solute to form separate oxide particles in the salt would not contribute to any protection. This scale fluxing mechanism is consistent with observed corroded microstructures (porous oxide in a salt matrix) and is applicable to either a deep salt melt or a thin salt film hot corrosion. This scale fluxing...
Abstract
Metals and ceramics exposed to high-temperature salt solutions are susceptible to a form of corrosion caused by fused salts accumulating on unprotected surfaces. This article examines the electrochemistry of such hot corrosion processes, focusing on sodium sulfate systems generated by the combustion of fossil fuels. It explains how salt chemistry, including acid/base and oxidizing properties, affects corrosion rates and mechanisms. The article also provides information on electrochemical testing and explains how Pourbaix methods, normally associated with aqueous corrosion, can be used to study fused-salt corrosion.
Book Chapter
Solidification Structures of Pure Metals
Available to PurchaseSeries: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003784
EISBN: 978-1-62708-177-1
... if the melt is undercooled. This is because dendritic growth results from instability of the solid/liquid interface due to a diffusion process, which for a pure material can only be thermal diffusion. In an alloy, interface instabilities from chemical diffusion often result in dendritic growth. Although...
Abstract
Pure metals normally solidify into polycrystalline masses, but it is relatively easy to produce single crystals by directional solidification from the melt. This article illustrates the dislocations present in a metal crystal, which is often polygonized into sub-boundaries during grain growth after solidification. It provides a description of small-angle and large-angle grain boundaries of polycrystalline metals.
Book Chapter
Fundamentals of Solidification
Available to PurchaseSeries: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003724
EISBN: 978-1-62708-177-1
... undercooled by a quantity: (Eq 2) Δ T T = T e − T * where Δ T T is the thermal undercooling, T e is the equilibrium (melting) temperature of the flat interface, and T * is the interface temperature. Constitutional (Solutal) Undercooling During alloy solidification, solute...
Abstract
This article provides information on four different length scales at which surface morphology can be viewed: macro, meso, micro and nanoscale. Elementary thermodynamics demonstrates that a liquid cannot solidify unless some undercooling below the equilibrium (melting) temperature occurs. The article details five types of solidification undercooling, namely, kinetic, thermal, constitutional (solutal), curvature, and pressure undercooling. It explains the types of nucleation which occur in the melt during solidification. The effects of local instabilities at the solid/liquid interface during growth are illustrated. The article also describes the solidification structures of pure metals, solid solutions, eutectics, peritectics, and monotectics.
Book Chapter
Solidification During Casting of Metal-Matrix Composites
Available to PurchaseBook: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005227
EISBN: 978-1-62708-187-0
..., and the presence of solute. The shape of the interface becomes curved after the interaction. The critical interface velocity in a pure melt, above which the particles are engulfed by the moving interfaces, is given by the following equation ( Ref 13 ): (Eq 1) V c = Δ σ a 0 18 μ ( k R...
Abstract
This article discusses the solidification of a matrix alloy in cast metal matrix composites (MMCs). It begins with a discussion on the mixing techniques in reinforcement incorporation and wettability of reinforcement. It describes the solidification processes, such as stir mixing and melt infiltration, used in the synthesis of MMCs. The article also considers the fundamentals of the process and presents a computational modeling of particle/solidification front interactions in metal-ceramic systems. The article concludes with information on nanocomposites.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005226
EISBN: 978-1-62708-187-0
... spinning to yield thin (approximately 100 μm) ribbon or fiber, 2) atomization to produce powder (100 to 200 μm), and 3) surface melting/deposition and resolidification to produce thin surface layers (0.1 to 200 μm). Each of these classes includes methods with a variety of names reflecting the significant...
Abstract
Rapid solidification is a tool for modifying the microstructure of alloys that are obtained by ordinary casting. This article describes the fundamentals of the four microstructural changes, namely, microsegregation, identity of the primary phase, identity of the secondary phase, and the formation of noncrystalline phases. It considers three factors to understand the fundamentals of these changes: heat flow, thermodynamic constraints/conditions at the liquid-solid interfaces, and diffusional kinetics/microsegregation. These factors are described in detail.
Book Chapter
Solid-State Welding Processes
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003209
EISBN: 978-1-62708-199-3
... the need for a liquid interface (brazing) or the creation of a cast product via melting and resolidification (welding). In its most narrow definition, which is used to differentiate it from other joining processes such as deformation bonding or transient liquid phase joining, diffusion bonding is a process...
Abstract
This article describes the mechanism, advantages and disadvantages, fundamentals, capabilities, variations, equipment used, and weldability of metals in solid-state welding processes, including diffusion bonding, explosion welding, friction welding, ultrasonic welding, upset welding, and deformation welding.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001384
EISBN: 978-1-62708-173-3
... is completed without having fully melted metal at the interface when the correct combination of force, power, and time parameters are used. Interface temperature rise is greater for metals with low thermal conductivity (for example, steel) than it is for metals of high conductivity (for example, aluminum...
Abstract
This article begins with a discussion on the advantages and limitation of ultrasonic welding (USW). It describes variations of the USW process which can produce different weld geometries. These variations are helpful in producing spot welds, line welds, continuous seam welds, ring welds, and microelectronic welds. The article provides information on the functions of USW personnel and describes the special conditions in USW which include the condition of the surface, the use of an interlayer, and the control of resonance. It concludes with a description on the weld quality, the influencing factors, surface appearance and deformation, and metallographic examination.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005220
EISBN: 978-1-62708-187-0
... with a macroscopic unbonded interface) and defects and inclusions grown in the melt is of central significance for the failures of metals by mechanical or corrosion-type mechanisms. Analysis of bifilms provides a simple, powerful, and elegant concept to explain many features of the metallurgy of castings. Since...
Abstract
Analysis of bifilms provides a simple, powerful, and elegant concept to explain many features of the metallurgy of castings. This article describes the effects of bifilms in metals. Mechanisms for the entrainment of bifilms are reviewed. The article describes the effect of furling and unfurling on mechanical properties of the solidified cast metal. It provides a discussion on the mechanisms of unfurling to determine the casting properties of the metals. These include gas precipitation, shrinkage, linear contraction, dendrite pushing, and nucleation and growth of intermetallics. The article also describes the role of bifilm defects in fracture.
Book Chapter
Abbreviations and Symbols: Casting
Available to PurchaseBook: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005348
EISBN: 978-1-62708-187-0
... (casting) SIC standard industry codes min minimum; minute SIMA strain induced melt activated wt% weight percent MINT metal in-line treatment SIMS secondary ion mass spectrometry mips million instructions per second SLQ slack quenched y coordinate parallel to interface mL milliliter SMAW shielded metal arc...
Book Chapter
The Liquid State and Principles of Solidification of Cast Iron
Available to PurchaseSeries: ASM Handbook
Volume: 1A
Publisher: ASM International
Published: 31 August 2017
DOI: 10.31399/asm.hb.v01a.a0006311
EISBN: 978-1-62708-179-5
... of heat extraction. The liquid is said to be thermally undercooled by a quantity: (Eq 2) Δ T T = T e − T * where Δ T T is the thermal undercooling, T e is the equilibrium (melting) temperature of the interface, and T * is the S/L interface temperature. Constitutional (Solutal...
Abstract
Solidification processing is one of the oldest manufacturing processes, because it is the principal component of metal casting processing. This article discusses the fundamentals of solidification of cast iron. Undercooling is a basic condition required for solidification. The article describes various undercooling methods, including kinetic undercooling, thermal undercooling, constitutional undercooling, and pressure undercooling. For solidification to occur, nuclei must form in the liquid. The article discusses the various types of nucleation: homogeneous nucleation, heterogeneous nucleation, and dynamic nucleation. It reviews the classification of eutectics based on their growth mechanism: cooperative growth and divorced growth. The article concludes with a discussion on the solidification structures of peritectics.
Book Chapter
Procedure Development and Practice Considerations for Ultrasonic Welding
Available to PurchaseSeries: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001448
EISBN: 978-1-62708-173-3
.... Source: American Welding Society In ultrasonic welding, the temperature at the weld is not raised to the melting point. Therefore, there is no nugget similar to that formed in resistance welding. Weld strength is equal to the strength of the base metal. However, ultrasonic welding is typically...
Abstract
Ultrasonic welding (USW) is effectively used to join both similar and dissimilar metals with lap-joint welds. This article describes procedure considerations for the ultrasonic welding of specific material types. It reviews difficult-to-weld alloys, such as carbon and low-alloy steels, high-strength steels, and stainless steel, and provides information on the applications of weldable alloys such as aluminum alloys and copper alloys. The article concludes with a discussion on welding of dissimilar metal (nonferrous-to-nonferrous) combinations and its applications.
Book Chapter
Microjoining in Medical Components and Devices
Available to PurchaseSeries: ASM Handbook
Volume: 23
Publisher: ASM International
Published: 01 June 2012
DOI: 10.31399/asm.hb.v23.a0005680
EISBN: 978-1-62708-198-6
... steel during RMW. During RMW, the applied force results in an initial deformation and a larger contact area ( Fig. 14a ). As the welding current increases, surface material and contaminants are melted and expelled from the interface. This expulsion aids in cleaning the interface by squeezing out...
Abstract
Microjoining methods are commonly used to fabricate medical components and devices. This article describes key challenges involved during microjoining of medical device components. The primary mechanisms used in microjoining for medical device applications include microresistance spot welding (MRSW) and laser welding. The article illustrates the fundamental principles involved in MRSW and laser welding. The article presents examples of various microjoining methods used in medical device applications, including pacemaker and nitinol microscopic forceps.
Book Chapter
Process Design for Induction Brazing and Soldering
Available to PurchaseSeries: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005856
EISBN: 978-1-62708-167-2
... ( B ), forming a thin layer called the joint interface ( AB ). This layer cools to form a totally different metal—actually an alloy of the base and filler metals. Thus, the brazed joint becomes a “sandwich” of different layers, each metallurgically linked to the next. This wetting of the surfaces...
Abstract
This article focuses on the process design set-up procedure for brazing and soldering. It provides a detailed account of the types of base metals that can be joined by these processes, and reviews the factors to be considered to enhance the joint design. Criteria for selection of the right induction heating equipment to carry out the brazing or soldering operation are also provided. The article describes the types of brazing filler metals and joint designs. It also presents the types of inspection methods, namely, mechanical and visual, used to determine the quality of the brazed joint. Important considerations for the automation of induction-heated brazing applications are also discussed. The article concludes by emphasizing the need for documenting an in-control process which is a vitally important reference for questions or problems arising in the machine settings or part quality.
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006519
EISBN: 978-1-62708-207-5
... defects ceramic shells investment casting melting pattern making Investment casting has been used for centuries and is also known as the lost wax process. It is used today to produce near net shape, complex thin-walled castings with smooth surfaces in a reliable and repeatable manner. Small parts...
Abstract
Investment casting, in which molten metal is poured into hot molds, allows for the production of aluminum parts with extremely thin sections, knife edges and sharp detail. This article describes the various steps in the investment casting process, including patternmaking and dimensioning, the design and manufacture of shell molds, melting and casting methods, and postcasting operations such as knockout, core removal, and cleaning. It also addresses a wide range of design considerations, discusses casting defects, and provides several design examples.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0009239
EISBN: 978-1-62708-173-3
... to lack of alloying elements. Simple reaction phases represented by intermetallic compounds in Ti-Cu, Ti-Ni, or Ti-Al phase diagrams (depending on the main component of the filler metal) are formed as thin layers at the base metal interfaces. Aluminum and β stabilizing elements such as molybdenum...
Abstract
This article discusses the effects of brazing temperature and thermal treatment on structure and mechanical behavior of different classes of titanium base metals such as commercially pure (CP) titanium, alpha or near-alpha alloys, alpha-beta alloys, and beta alloys. The classification, properties, and potential heat treatment of titanium base alloys are presented in tables. The article provides information on brazed joints of titanium with carbon steels, as well as ceramics and graphite. It discusses the risks involved in titanium brazing, including erosion of base metal, brittle intermetallics, and low ductility. The article reviews induction and torch brazing, infrared brazing, diffusion brazing, and brazing by heating with ion bombardment. It concludes by describing the design criteria and limitations of brazing.
Book Chapter
Fundamentals of Diffusion Bonding
Available to PurchaseSeries: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001350
EISBN: 978-1-62708-173-3
... Abstract Diffusion bonding is only one of many solid-state joining processes wherein joining is accomplished without the need for a liquid interface (brazing) or the creation of a cast product via melting and resolidification. This article offers a qualitative summary of the theory of diffusion...
Abstract
Diffusion bonding is only one of many solid-state joining processes wherein joining is accomplished without the need for a liquid interface (brazing) or the creation of a cast product via melting and resolidification. This article offers a qualitative summary of the theory of diffusion bonding. It discusses factors that affect the relative difficulty of diffusion bonding oxide-bearing surfaces. These include surface roughness prior to welding, mechanical properties of the oxide, relative hardness of the metal and its oxide film, and prestraining or work hardening of the material. The article describes the mechanism of diffusion bonding in terms of microasperity deformation, diffusion-controlled mass transport, and interface migration. It concludes with a discussion on diffusion bonding with interface aids.
Book Chapter
Growth and Growth-Related Properties of Films Formed by Physical Vapor Deposition
Available to PurchaseBook: Surface Engineering
Series: ASM Handbook
Volume: 5
Publisher: ASM International
Published: 01 January 1994
DOI: 10.31399/asm.hb.v05.a0001286
EISBN: 978-1-62708-170-2
... it is desirable to form an interface that is defect-free so that electronically active sites are not generated. Such an interface can be formed if there is lattice parameter matching between the deposited material and the substrate, or if the deposited material is thin enough to allow lattice strains...
Abstract
This article describes eight stages of the atomistic film growth: vaporization of the material, transport of the material to the substrate, condensation and nucleation of the atoms, nuclei growth, interface formation, film growth, changes in structure during the deposition, and postdeposition changes. It also discusses the effects and causes of growth-related properties of films deposited by physical vapor deposition processes, including residual film stress, density, and adhesion.
Book Chapter
Modeling for Polymer Additive Manufacturing Processes
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006546
EISBN: 978-1-62708-290-7
...-set methods treat the interface between fluid phases as sharp (i.e., infinitesimally thin). The methods differ in that the VOF method requires a careful geometric reconstruction of the interface shape so the interface curvature can be computed accurately. Both methods depend on the fluid domain being...
Abstract
This article focuses on four industrial additive manufacturing approaches that are used to create polymer parts. The first section focuses on material extrusion, providing information on lumped-parameter material flow models and higher-fidelity models developed to estimate temperature distribution. The second section covers polymer powder-bed sintering/ fusion, discussing the different levels of scale used to address modeling and the impact of process settings: thermodynamics at the powder-bed surface, consolidation of adjacent particles in the fusion process, and fusion and molecular-level behavior within particles. The third section on vat photopolymerization (VPP) discusses two primary approaches to modeling VPP processes, namely a lumped-parameter approach to estimate cured regions in the vat, known as the Jacobs model, and a high-fidelity, continuum approach that uses finite-element methods. The final section is devoted to material jetting, focusing on simulations used to study droplet generation at the nozzle and droplet impact.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001333
EISBN: 978-1-62708-173-3
... ) = q ˙ ; r ⩽ r a Another is represented by the conditions at the solid-liquid interface: (Eq 17) θ l = θ s = θ m (Eq 18) n ⋅ ( λ ∇ θ ) s − n ⋅ ( λ ∇ θ ) l = ± ρ s L d s d t where + indicates the melting process...
Abstract
During fusion welding, the thermal cycles produced by the moving heat source cause physical state changes, metallurgical phase transformation, and transient thermal stress and metal movement. This article presents an analysis of heat flow in the fusion welding process. The primary objective of welding heat flow modeling is to provide a mathematical tool for thermal data analysis, design iterations, or the systematic investigation of the thermal characteristics of any welding parameters. The article addresses analytical heat-flow solutions and their practical applications. It describes the effects of material property and welding condition on the temperature distribution of weldments. The thermal properties of selected engineering materials are provided in a table.
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