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Solidification
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Book Chapter
Comparing the Microstructure of Components Prepared by Various Powder Metallurgy and Casting Methods
Series: ASM Technical Books
Publisher: ASM International
Published: 30 September 2024
DOI: 10.31399/asm.tb.pmamfa.t59400141
EISBN: 978-1-62708-479-6
Abstract
This chapter examines the microstructure of metallic components produced by casting and compares them with microstructures achieved by means of powder metallurgy. It shows how metals and alloys obtained by various processing routes differ in terms of grain size, secondary phases, oxide and carbide dispersions, porosity, dendritic formation, and properties such as hardness, toughness, tensile strength, and yield strength.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 31 January 2024
DOI: 10.31399/asm.tb.pdktmse.t56100019
EISBN: 978-1-62708-470-3
Abstract
This appendix contains sample problems with worked solutions pertaining to the use of binary phase diagrams. The problems require the determination of favorable temperatures and compositions, the amount and composition of phases in an alloy at a given temperature, the amount of a certain phase in different steels, and the microstructure developed in different alloys.
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2023
DOI: 10.31399/asm.tb.ceeg.9781627084475
EISBN: 978-1-62708-447-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.tb.atia.t59340083
EISBN: 978-1-62708-427-7
Abstract
This chapter describes the processes and alloys used in the casting of aluminum components, the advantages and disadvantages of the different shape-casting methods, and the major factors that influence alloy selection for shape-casting applications. An overview of the heat treatment of cast products is also included.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.9781627083324
EISBN: 978-1-62708-332-4
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320031
EISBN: 978-1-62708-332-4
Abstract
This chapter discusses the crystal structures of steel and cast iron, the iron-iron carbide equilibrium diagram, microconstituents or phases in the iron-iron carbide phase diagram, the iron-carbon carbide-silicon equilibrium diagram of cast irons, and the influence on microstructure by base elements and alloying elements. Graphitization, cooling rates, and heat treatment effects are covered. There also is discussion on inoculation benefits, flake graphite types and typical applications, evolution of cast iron types, ASTM specification A247 for graphite shapes, and selection of the best molding process. A large table lists typical material choices for various applications.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320063
EISBN: 978-1-62708-332-4
Abstract
The casting engineer contributes to a successful component design by offering expertise in molding, core making, and material characteristics and by recommending the most suitable casting process to use to meet quality and cost targets. The casting engineer's responsibilities include recommending locator positioning; advising about lugs, hooks, or holes for casting handling through all processes; determining the choice of a parting plane and pouring orientation; designing cores for accurate positioning, suitable venting, and proper cleaning; guiding decisions about wall thicknesses and junctions; making suggestions about casting design to eliminate distortion; optimizing the gating design for slag-free metal; and establishing the feeding techniques to eliminate shrink porosity. This chapter provides the guidelines for these responsibilities. In addition, the guidelines for the use of chaplets and chills in cast iron castings; guidelines for drafts, machine stock, tolerances, and contraction or shrink rule; and guidelines for pattern layouts and nesting are also covered.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320163
EISBN: 978-1-62708-332-4
Abstract
Ductile iron has far superior mechanical properties compared to gray iron as well as significantly improved castability and attractive cost savings compared to cast steel. This chapter begins with information on graphite morphology and matrix type. It then discusses the advantages and applications of ductile iron. Next, the effects of various factors on the grades, chemistry, matrix, and mechanical properties of ductile iron are covered. This is followed by a section detailing the ductile iron treatment methods and the quality control methods used. Guidelines for gating and feeder design are then provided. Further, the chapter addresses the technology of ductile iron castings, including the performance and geometric attributes, molding and core-making processes used, material grades, mechanical properties, and chemical compositions of a few applications. Finally, it describes ductile iron casting defects and presents practical cases of problem-solving.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320207
EISBN: 978-1-62708-332-4
Abstract
Compacted graphite iron (GCI) is a cast iron grade that is engineered through graphite morphology modifications to achieve a combination of thermal and mechanical properties that are in between those of flake graphite iron and ductile iron. This chapter discusses the advantages of compacted graphite iron over gray iron and ductile iron. It presents examples of low- and high-frequency thermal cycling, both of which affect the thermal stresses that castings are exposed to during temperature fluctations. Information on optimum carbon and silicon ranges as well as mechanical property standards for CGI are provided. The chapter describes the critical factors that control CGI and discusses methods of CGI manufacturing.
Series: ASM Technical Books
Publisher: ASM International
Published: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.9781627083195
EISBN: 978-1-62708-319-5
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.t59220129
EISBN: 978-1-62708-259-4
Abstract
Many of the structural characteristics of steel products are a result of changes that occur during solidification, particularly volume contractions and solute redistribution. This chapter discusses the solidification process and how it affects the quality and behaviors of steel. It explains how steel shrinks as it solidifies, causing issues such as pipe and voids, and how differences in the solubility of solid and liquid steel lead to compositional heterogeneities or segregation. It describes the dendritic nature of solidification, peritectic and eutectic reactions, microporosity, macro- and microsegregation, and hot cracking, as well as the effects of solidification and remelting on castings, ingots, and continuous cast products. It explains how to determine where defects originate in continuous casters and how to control alumina, sulfide, and nitride inclusions.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.t59220193
EISBN: 978-1-62708-259-4
Abstract
Heat treatment is the most common way of altering the mechanical, physical, and even chemical properties of steels. This chapter describes the changes that occur in carbon and low-alloy steels during conventional heat treatments. It explains how austenite decomposition largely defines the final microstructure, and how the associated phase transformations are driven by nucleation and growth processes. It describes diffusionless and diffusive growth mechanisms and provides detailed information on the properties, structure, and behaviors of the transformation products produced, namely martensite and bainite. It also discusses the formation of austenite, the control and measurement of austenitic grain size, the characteristics of ferritic microstructures, and the methods used to classify ferrite morphology.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.t59220353
EISBN: 978-1-62708-259-4
Abstract
This chapter discusses the effects of hot working on the structure and properties of steel. It explains how working steels at high temperatures promotes diffusion, which helps close cavities and pores, and how it changes the shape and distribution of segregates, offsetting their effect. It describes the effect of hot working on nonmetallic inclusions and the many properties influenced by them. It discusses the recrystallization mechanism by which hot working produces microstructural changes and explains how to control it by adjusting temperature, degree of reduction, and cooling rates. It describes special cases of segregation, including banding and why it occurs, and the application of closed die forging. The chapter also presents several examples of hot working defects, including forging laps, cracks, and overheated or burned steel.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.9781627082594
EISBN: 978-1-62708-259-4
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2017
DOI: 10.31399/asm.tb.sccmpe2.t55090191
EISBN: 978-1-62708-266-2
Abstract
Irradiation-assisted stress-corrosion cracking (IASCC) has been a topic of engineering interest since it was first reported in the 1960s, having been observed in stainless steel cladding on light water reactor fuel elements. This chapter summarizes the results of decades of investigation, showing that IASCC can essentially be defined as the intergranular cracking of austenitic alloys in high-temperature water, where both the material and its environment have been altered by radiation. Of the many interactions that can occur when metals and water are exposed to radiation, the international consensus is that the three with the greatest impact on crack growth rates are the formation of material defects, radiation-induced segregation, and chemical reactions that increase the corrosion potential of water. The chapter discusses each of these in great detail, and includes information on predictive modeling as well.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2016
DOI: 10.31399/asm.tb.ascaam.9781627082969
EISBN: 978-1-62708-296-9
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.spsp2.t54410133
EISBN: 978-1-62708-265-5
Abstract
Austenite is the key to the versatility of steel and the controllable nature of its properties. It is the parent phase of pearlite, martensite, bainite, and ferrite. This chapter discusses the importance of austenite, beginning with the influence of austenitic grain size and how to accurately measure it. It then describes the principles of austenite formation and grain growth and examines several time-temperature-austenitizing diagrams representing various alloying and processing conditions. The chapter concludes with a discussion on hot deformation and subsequent recrystallization.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.spsp2.t54410163
EISBN: 978-1-62708-265-5
Abstract
Inclusions and chemical segregation are factors in many process-induced failures involving steel parts. Inclusions are nonmetallic compounds introduced during production; segregation is a type of chemical partitioning that occurs during solidification. This chapter discusses the origins of segregation and inclusions and their effect on the mechanical properties and microstructure of steel. It explains how to identify various types of inclusions and characteristic segregation patterns, such as banding. It also describes the effect of hot work processing on solidification structure and the chemical variations produced by interdendritic segregation.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.tpmpa.9781627083188
EISBN: 978-1-62708-318-8
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.tpmpa.t54480031
EISBN: 978-1-62708-318-8
Abstract
This chapter describes the structures, phases, and phase transformations observed in metals and alloys as they solidify and cool to lower temperatures. It begins with a review of the solidification process, covering nucleation, grain growth, and the factors that influence grain morphology. It then discusses the concept of solid solutions, the difference between substitutional and interstitial solid solubility, the effect of alloying elements, and the development of intermetallic phases. The chapter also covers the construction and use of binary and ternary phase diagrams and describes the helpful information they contain.
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