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dimensional control
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.t59290169
EISBN: 978-1-62708-319-5
... practices adopted as well as provides information on dimensional control and related concerns of sintering. Cost issues associated with sintering are finally covered. density dimensional control sintering sintering densification After shaping and first-stage binder removal, the component...
Abstract
After shaping and first-stage binder removal, the component (with remaining backbone binder) is heated to the sintering temperature. Further heating induces densification, evident as dimensional shrinkage, pore rounding, and improved strength. This chapter begins with a discussion on the events that are contributing to sintering densification, followed by a discussion on the driving forces, such as surface energy, and high-temperature atomic motion as well as the factors affecting these processes. The process of microstructure evolution in sintering is then described, followed by a discussion on the tools used for measuring bulk properties to monitor sintering and density. The effects of key parameters, such as particle size, oxygen content, sintering atmosphere, and peak temperature, on the sintered properties are discussed. Further, the chapter covers sintering cycles and sintering practices adopted as well as provides information on dimensional control and related concerns of sintering. Cost issues associated with sintering are finally covered.
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
... coupon/holder 100 % pass 8 Heat Treat See the section on heat treatment in section 10.3.2 in this chapter 100 % pass See the section on heat treatment in section 10.3.2 in this chapter 100 % pass 9 Casting Process See the section on dimensional control in section 10.3.2 in this chapter 100...
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: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.t59290001
EISBN: 978-1-62708-319-5
..., distortion is calculated using size measurements at several locations, giving the standard deviation in size divided by the mean size. Dimensional control is captured by examining the same dimension but performing the measurement over repeated components. The resulting quantification is via the coefficient...
Abstract
This chapter provides an introduction to powder processing of binders and polymers. It sets the context for the remainder of the book by providing an overview of the topics discussed in the subsequent chapters and by providing introduction to powder-binder fabrication and customization of feedstock and describing the challenges in component production. The chapter also summarizes alphabetically a few key concepts in powder-binder processing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.t59290261
EISBN: 978-1-62708-319-5
...-temperature sintering. Binder chemistry impacts the binder-removal process. binder jet. An additive manufacturing technique where computer-controlled binder jets bond particles into a green body, layering powder with binder deposited on each layer. A three-dimensional object forms the layer stack. Bingham ow...
Series: ASM Technical Books
Publisher: ASM International
Published: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.9781627083195
EISBN: 978-1-62708-319-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 June 2007
DOI: 10.31399/asm.tb.pmsspmp.t52000039
EISBN: 978-1-62708-312-6
... in the dimensional change within a part, which is usually caused by green density variations, can lead to distortion of the part. Factors Affecting Dimensional Change Dimensional change is influenced by a large number of material- and process-related parameters, not all of which can be monitored or controlled...
Abstract
This chapter discusses the methods by which stainless steel powders are shaped and compacted prior to sintering, including rigid die compaction, metal injection molding, extrusion, and hot isostatic pressing. It explains where each process is used and how processing parameters, such as temperature and pressure, and powder characteristics, such as particle size and shape, influence the quality of manufactured parts. It describes the various stages of metal powder compaction, the role of lubricants, and how to account for dimensional changes in the design of tooling and process sequences.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2013
DOI: 10.31399/asm.tb.imub.t53720393
EISBN: 978-1-62708-305-8
... Abstract Fabricated powder metallurgy (P/M) parts are evaluated and tested at several stages during manufacturing for part acceptance and process control. The various types of tests included are dimensional evaluation, density measurements, hardness testing, mechanical testing...
Abstract
Fabricated powder metallurgy (P/M) parts are evaluated and tested at several stages during manufacturing for part acceptance and process control. The various types of tests included are dimensional evaluation, density measurements, hardness testing, mechanical testing, and nondestructive testing. This chapter is a detailed account of these testing methods. It describes the four most common types of defects in P/M parts, namely ejection cracks, density variations, microlaminations, and poor sintering. The chapter discusses the capabilities and limitations of various nondestructive evaluation methods to flaw detection in P/M parts. The nondestructive evaluation methods covered are mechanical proof testing, metallography, liquid penetrant crack detection, filtered particle crack detection, magnetic particle crack inspection, direct current resistivity testing, x-ray radiography, computed tomography, gamma-ray density determination, and ultrasonic techniques.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2013
DOI: 10.31399/asm.tb.ahsssta.t53700225
EISBN: 978-1-62708-279-2
... to stamping inconsistencies or even failure. High-strength steel and AHSS are less formable than mild steel, and parts made from them lack dimensional control because of the significant amount of springback that they produce after forming. The increased use of AHSS to achieve weight reduction...
Abstract
The increased use of advanced high-strength steels to achieve weight reduction in automobiles has led to the development of innovative tool designs and manufacturing processes. Among these technologies and processes are: real-time process control, active drawbeads, active binders, flexible binders, and flexible rolling. This chapter presents the implementation, advantages, disadvantages, and applications of these processes and technologies.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.tpmpa.t54480075
EISBN: 978-1-62708-318-8
... Abstract Titanium alloys respond well to heat treatment be it to increase strength (age hardening), reduce residual stresses, or minimize tradeoffs in ductility, machinability, and dimensional and structural stability (annealing). This chapter describes the phase transformations associated...
Abstract
Titanium alloys respond well to heat treatment be it to increase strength (age hardening), reduce residual stresses, or minimize tradeoffs in ductility, machinability, and dimensional and structural stability (annealing). This chapter describes the phase transformations associated with these processes, explaining how and why they occur and how they are typically controlled. It makes extensive use of phase diagrams and cooling curves to illustrate the effects of alloying and quenching on beta-to-alpha transformations and the conditions that produce metastable phases. It also examines several time-temperature-transformation diagrams, which account for the effect of cooling rate.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2003
DOI: 10.31399/asm.tb.pnfn.t65900119
EISBN: 978-1-62708-350-8
... unpredictable dimensional change in a component due to thermal processing or temperature variations and loading in service. This chapter describes two types of distortion: size distortion and shape distortion. It addresses how distortion can be managed by controlling certain factors. The chapter discusses...
Abstract
Distortion is defined as an irreversible and usually unpredictable dimensional change in a component due to thermal processing or temperature variations and loading in service. This chapter describes two types of distortion: size distortion and shape distortion. It addresses how distortion can be managed by controlling certain factors. The chapter discusses the cause and effect of distortion during nitriding, the processes involved in stock removal prior to nitriding, and the criteria for post-machining operations.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040107
EISBN: 978-1-62708-300-3
... Abstract Forging machines vary based on factors such as the rate at which energy is applied to the workpiece and the means by which it is controlled. Each type has distinct advantages and disadvantages, depending on lot size, workpiece complexity, dimensional tolerances, and the alloy being...
Abstract
Forging machines vary based on factors such as the rate at which energy is applied to the workpiece and the means by which it is controlled. Each type has distinct advantages and disadvantages, depending on lot size, workpiece complexity, dimensional tolerances, and the alloy being forged. This chapter covers the most common types of forging machines, explaining how they align with basic forging processes and corresponding force, energy, throughput, and accuracy requirements.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2013
DOI: 10.31399/asm.tb.imub.t53720293
EISBN: 978-1-62708-305-8
... and dimensional inspections, weight testing, and hardness testing. However, for castings that are to be used in critical applications, such as automotive or aerospace components, additional methods of nondestructive inspection are used to determine and to control casting quality. Visual Inspection Visual...
Abstract
The inspection of castings normally involves checking for shape and dimensions, coupled with aided and unaided visual inspection for external discontinuities and surface quality. This chapter discusses methods for determining surface quality, internal discontinuities, and dimensional inspection. Casting defects including porosity, oxide films, inclusions, hot tears, metal penetration, and surface defects are reviewed. Liquid penetrant inspection, magnetic particle inspection, eddy current inspection, radiographic inspection, ultrasonic inspection, and leak testing for castings are discussed. The chapter provides information on the procedures involved in the inspection of castings that are limited to visual and dimensional inspections, weight testing, and hardness testing. It also discusses the use of computer equipment in foundry inspection operations.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250077
EISBN: 978-1-62708-345-4
... of the melt. This shrinkage can continue for a period of time after the part is removed from the mold. It is important that the shrinkage be repeatable, so the mold can be appropriately sized. For parts requiring tight dimensional control or optimal mechanical properties, uniform cooling is essential...
Abstract
Plastic gears are continuing to displace metal gears in applications ranging from automotive components to office automation equipment. This chapter discusses the characteristics, classification, advantages, and disadvantages of plastics for gear applications. It provides a comparison between the properties of metals and plastics for designing gears. The chapter reviews some of the commonly used plastic materials for gear applications including thermoplastic and thermoset gear materials. The chapter also describes the processes involved in plastic gear manufacturing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200206
EISBN: 978-1-62708-354-6
... and to dimensions controlled by the mold only. This equation is intended only to reflect relative effects of weight and length; the comments above concerning foundry-to-foundry differences continue to apply. Figure 16-10 presents data from the same study on the relation between casting weight and dimensional...
Abstract
Users of steel castings establish performance requirements for specific characteristics of the castings based on the planned use. They express tolerance for variation in those characteristics to the producer of the castings. One issue which should never be taken for granted in considering capability and tolerances is the ability to measure with accuracy and precision (repeatability and reproducibility). This chapter discusses the methods for measuring accuracy and precision. It describes the variation of process characteristics, capability indices in general use, and factors related to process performance and tolerance specification.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040237
EISBN: 978-1-62708-300-3
... dies are sometimes used in extrusion of safety parts, because they provide more uniform grain flow around corners and improved dimensional controls on net shape surfaces. Therefore, it is beneficial to investigate the occurrences of chevron cracks in extrusion with spherical dies. The objectives...
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040319
EISBN: 978-1-62708-300-3
... constant. These fluctuations affect the dimensional accuracy of the forming process. The billet dimensions and material properties (flow stress) can be controlled by involving the suppliers in the design process to ensure procurement of billets with consistent dimensions and flow stress. The variation...
Abstract
This chapter defines near-net shape forging as the process of forging parts close to their final dimensions such that little machining or only grinding is required as a final step. It then describes the causes of dimensional variations in forging, including die deflection, press deflection, and process inconsistencies, and discusses related innovations.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200197
EISBN: 978-1-62708-354-6
..., abrasive blast cleaning, removal of risers, ingates, and discontinuities, rough inspection, removal of discontinuities, finishing welding, heat treatment, and final visual, dimensional, and NDT inspection. This chapter provides a detailed discussion on these activities. finishing heat treatment...
Abstract
After pouring, castings are allowed to solidify and cool. They are later removed from the molds in the shakeout operation. A series of activities then follow, which are generally referred to as finishing and heat treatment. These activities can be broadly categorized as shakeout, abrasive blast cleaning, removal of risers, ingates, and discontinuities, rough inspection, removal of discontinuities, finishing welding, heat treatment, and final visual, dimensional, and NDT inspection. This chapter provides a detailed discussion on these activities.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 April 2020
DOI: 10.31399/asm.tb.bpapp.t59290111
EISBN: 978-1-62708-319-5
... rate of component production may be high, such as for die compaction, but hard tooling is required, which delays the start of production. The dimensional capability for each approach is tied to the mass variation. High-precision components require tight mass control in the forming step. Shaping...
Abstract
The conversion of feedstock into a shape involves the application of heat and pressure, and possibly solvents. This chapter discusses the operating principle, advantages, limitations, and applications of such shaping processes, namely additive manufacturing, cold isostatic pressing, die compaction, extrusion, injection molding, slip casting, slurry processes, and tape casting. Information on equipment setup, requirements, and the various factors influencing these processes are described. In addition, the chapter provides information on novel approaches and processing costs applicable to these shaping processes.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2006
DOI: 10.31399/asm.tb.ex2.t69980551
EISBN: 978-1-62708-342-3
... Ultrasonic testing Homogenization Extrusion Dimensional inspection Surface control Stretching Degree of stretching Dimensional control Age-hardening Tensile testing Conductivity Fig. 8.9 Comparison of the planning content Layout of an inspection report Table 8.7 Layout...
Abstract
The aim of every extrusion plant is the efficient production of competitive products that meet the appropriate quality requirements. This chapter discusses the processes involved in the selection and introduction of a quality management system, along with its application, advantages, and disadvantages. It describes the process chain for order processing within the quality circle and provides information on product liability legal issues. In addition, the chapter discusses the processes involved in quality control, along with its organization, responsibilities, audits, and testing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200001
EISBN: 978-1-62708-354-6
... is currently in the development phase for steel castings. Graphite Molding Graphite molding utilizes graphite molds which are semi-permanent. Dimensional control and surface appearance are excellent. This is a highly specialized process suited mainly to parts like railroad wheels. Permanent Mold...