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aluminum
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410001
EISBN: 978-1-62708-280-8
... Abstract Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides...
Abstract
Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides information on the process of conversion of steel and iron parts to aluminum.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.9781627082808
EISBN: 978-1-62708-280-8
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410029
EISBN: 978-1-62708-280-8
... Abstract This chapter discusses the advantages, limitations, and applications of various aluminum casting processes, namely green sand casting process, air set or no-bake molding process, vacuum molding process, evaporative foam casting process, and die casting process. The processes covered...
Abstract
This chapter discusses the advantages, limitations, and applications of various aluminum casting processes, namely green sand casting process, air set or no-bake molding process, vacuum molding process, evaporative foam casting process, and die casting process. The processes covered also include gravity permanent molding, low-pressure permanent molding, counter pressure, squeeze casting, investment casting, rapid prototype casting, cast forge hybrid, and semisolid metal processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410021
EISBN: 978-1-62708-280-8
... Abstract This chapter provides information on comparative attributes of sand molds and metal molds for aluminum casting. The cooling rates and microstructures obtained with each mold type are discussed. In addition, the chapter explains why sand castings work successfully in certain...
Abstract
This chapter provides information on comparative attributes of sand molds and metal molds for aluminum casting. The cooling rates and microstructures obtained with each mold type are discussed. In addition, the chapter explains why sand castings work successfully in certain applications.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410091
EISBN: 978-1-62708-280-8
... Abstract This chapter is a collection of tables listing: cast alloy designations of Aluminum Association, along with their general applications; the chemical compositions of the frequently used alloys for gravity permanent molds, low-pressure permanent molds, squeeze castings, and die castings...
Abstract
This chapter is a collection of tables listing: cast alloy designations of Aluminum Association, along with their general applications; the chemical compositions of the frequently used alloys for gravity permanent molds, low-pressure permanent molds, squeeze castings, and die castings; the typical tensile properties of die cast alloys; and the designations of different heat treatments and their description. The tables also list the temperatures and times of typical heat treatment cycles for different permanent mold cast alloys; typical components in sand, gravity, and low-pressure permanent mold castings and die castings, the functional requirements of each process, and the corresponding suitable alloys and heat treatments; and alloys that are high vacuum die cast for structural castings. The chapter also presents examples of photomicrographs of some alloys cast by different processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410151
EISBN: 978-1-62708-280-8
... mold (GPM) and low pressure permanent mold casting (LLPM), a refractory barrier between steel molds and molten aluminum is essential to prevent mold–metal interaction at the interface. Mold coatings have influences in both GPM and LPPM, including: The coating acts as an interfacial barrier to...
Abstract
This chapter discusses the various factors pertinent to gravity permanent mold (GPM) castings, along with their advantages, limitations, and significance. The discussion covers the geometric factors, process and manufacturing elements, gating practices, and feeding principles of and pouring systems in GPM. The influences of mold coatings on GPM and low pressure permanent mold castings are described. The chapter also discusses various processes involved in the engineering of core boxes and cooling of GPM for casting integrity and cycle time control. It provides information on some of the processes involved in post-casting operations, namely de-coring and de-gating. The key design aspects for consideration in water quenching during the T6 heat treatment are reviewed. The chapter also provides information on two critical cycle events important in engineering at the manufacturing facility: tipper cycle planning and table or cell cycle planning.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410215
EISBN: 978-1-62708-280-8
... of the highest integrity have been successfully produced using this process. Aluminum furniture manufacturers have found the low-pressure process to be suitable for large furniture, such as table tops and frames. Machine tool manufacturers depend on the low-pressure process for large bed frames...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410247
EISBN: 978-1-62708-280-8
..., mechanical properties, tooling cost per piece, and overall cost factors. The chapter contains tables listing several markets, products, popular processes, and common alloys and the common processes used for a variety of markets and products. casting process selection engineering design aluminum...
Abstract
This chapter presents guidelines for product designers to choose the best process and alloys while designing a casting. The discussion covers some of the factors pertinent to the selection of the best process for the product function and performance, namely geometric factors, mechanical properties, tooling cost per piece, and overall cost factors. The chapter contains tables listing several markets, products, popular processes, and common alloys and the common processes used for a variety of markets and products.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410009
EISBN: 978-1-62708-280-8
Abstract
This chapter is a brief account of various factors pertinent to the development of an engineering component. The discussion covers the disciplines and interactions of design development, engineering of component design, validation of design and process analysis, and matrix of design and manufacturing elements.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410103
EISBN: 978-1-62708-280-8
.... per linear in. is more common for aluminum die castings. Typically, die castings have the highest tolerance capability compared to other casting processes. Tool builders need some tolerances for die manufacture. Variances in ejection and quenching temperatures also contribute to tolerances...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410253
EISBN: 978-1-62708-280-8
... suspension casting. It ends with an overview of the contents of a program launch manual. product launch process product-process flow diagram process failure mode and effects analysis manufacturing control plan engineering design aluminum castings A comprehensive and structured...
Abstract
This chapter is a detailed account of various factors pertinent to the development and launch of a product. It begins by describing the five phases in the product launch process, namely product design and development, process design and development, product and process validation, product launch, and continuous improvement. This is followed by sections covering product-process flow diagrams and also the process elements considered for process failure mode and effects analysis. Some of the aspects covered by the engineering specifications to meet the product performance requirements are then reviewed. Details on product validation requirements and definitions of parameters related to the launch process are also provided. The chapter discusses the purpose of manufacturing control plan, along with an illustration of a manufacturing control plan outlined for a safety-critical suspension casting. It ends with an overview of the contents of a program launch manual.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250107
EISBN: 978-1-62708-287-7
... Abstract This chapter discusses the development of aluminum, its industry growth, and its modern uses in manufacturing. It begins with the biography of Charles Martin Hall, who invented the process for reducing aluminum from its ore. The evolution of aluminum production from the Pittsburgh...
Abstract
This chapter discusses the development of aluminum, its industry growth, and its modern uses in manufacturing. It begins with the biography of Charles Martin Hall, who invented the process for reducing aluminum from its ore. The evolution of aluminum production from the Pittsburgh Reduction Company to a pilot plant on Smallman Street in Pittsburgh, to a production plant in New Kensington, and to Niagara Falls, New York, is then described. This is followed by a discussion on early aluminum applications and the usage of lower-cost raw materials. The chapter provides information on aluminum production process integrated by Aluminum Company of America (Alcoa) and the numerous technical problems and solutions related to Alcoa's research from World War I to World War II. The aerospace applications for aluminum alloys are also presented. The chapter concludes with a section on aluminum alloys developed by Alcoa.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250047
EISBN: 978-1-62708-287-7
..., the time-honored jacket material for ammunition cartridges, with an aluminum alloy for weight savings. None of the aluminum alloys up to this time were strong enough for the application. Wilm, who was familiar with heating and quenching steel, attempted to combine both alloying and heat treating in...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250153
EISBN: 978-1-62708-287-7
... metallurgist in America, for his work on tungsten for lamp bulbs, his research into grain size and its influence on mechanical properties, his invention of many alloys of aluminum, and his work on the behavior of high-speed tool steels during secondary hardening. He also trained many young metallurgists who...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250129
EISBN: 978-1-62708-287-7
.... Titanium is element No. 22 in the periodic table. Its density is 4.5 g/cm 3 , midway between aluminum at 2.7 and iron at 7.86. It has a melting point of 1812 °C (3290 °F), compared with 1535 °C (2785 °F) for iron. The low density and high melting point compared with iron indicated a metal with structural...
Abstract
This chapter is a detailed account of the history of development of titanium and its modern applications in the aerospace market. It begins by discussing the attempts made to produce titanium metal. This is followed by a discussion on the invention of a process for making titanium by William Kroll. Various studies on the properties on titanium and research programs related to the production of titanium sponge and titanium metal products are then described. The chapter concludes with a discussion of titanium use in jet engines.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250093
EISBN: 978-1-62708-287-7
... strengths. Before 1895, there was no process for producing low-carbon chromium to be added to iron, an important factor in chromium steels. At this time, German chemist Hans Goldschmidt invented the thermite process, a process that combines chromium ore with aluminum powder to generate enough heat to...
Abstract
This chapter discusses the development of stainless steel. It begins with some information on the discovery of stainless steel. This is followed by a discussion on the most important patents issued for stainless steel. Applications of stainless steel beyond their original use in cutlery and tableware are then presented. Information on the development of alloys for specific applications and on the argon oxygen decarburization process is also provided. The chapter ends with a discussion on the major use for stainless steel after WWII.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250001
EISBN: 978-1-62708-287-7
Abstract
This chapter provides an account of the pre-Columbian history of metal discovery in America and then reviews the development of metallurgy in the Middle Ages from early wrought iron practices to the use of coke in iron casting. It discusses the influence of the family of Abraham Darby in England in the development of ironmaking.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250013
EISBN: 978-1-62708-287-7
Abstract
This chapter is a chronological account of the development of ironmaking in colonial America from 1645 to 1870. The discussion covers the spread of ironmaking in many of the colonies in the northeast, canal building in Pennsylvania, the replacement of charcoal by anthracite coal in ironmaking, the life of ironmaking pioneer John Fritz, and the rapid increase in ironmaking for the railroads.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250025
EISBN: 978-1-62708-287-7
Abstract
This chapter focuses on the evolution of steel production from 1870 to 1900. It begins with a review of the life of the inventor of the air-boiling process, William Kelly. This is followed by a discussion on how Bessemer's air-blowing process entered the steel production industry and the development of the Kelly-Bessemer process by Alexander Holley. The chapter then discusses how Andrew Carnegie lowered the cost to produce steel, how he entered the iron and steelmaking industry, and how Captain Billy Jones joined Carnegie to expand Carnegie steel. The chapter further provides information on the great strike of 1892 at Homestead and the rapid growth in steel markets. It ends with a discussion about the factors that led Carnegie to sell his steel empire.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250059
EISBN: 978-1-62708-287-7
Abstract
This chapter discusses the evolution of engineering alloy steels, namely chromium, nickel, and nickel-chromium alloy steels. The discussion includes the automotive demand and development of specifications for the alloy steels. It also covers various research on heat treatment of alloy steels, providing information on hardening, transformation of austenite, hardenability testing, and tempering of as-quenched martensite.