Comprehensive materials processing, Vol. 6: Welding and bonding technologies

Comprehensive Materials Processing, (2014) 275pp. 978-0-08-096532-1 Binder1a 1 e9780080965321v1 1 Front Cover 1 Comprehensive Materials Processing 4 Copyright 5 Editor-In-Chief 6 Editorial Board 8 Contributors to Volume 1 12 Contents of Volume 1 14 Contents of All Volumes 16 Preface 28 1.01 - Introduction to Materials Testing and Specialized Materials 30 1.02 - Techniques for Assessing the Properties of Advanced Ceramic Materials 32 1.02.1 Introduction 2650 1.02.2 Evaluation of Microstructural, Chemical, and Physical Properties 33 1.02.3 Evaluation of Mechanical Properties 42 1.02.4 Evaluation of Tribological Properties 46 1.02.5 Evaluation of Thermal Properties 47 1.02.6 Evaluation of Electrical and Magnetic Properties 51 1.02.7 Evaluation of Optical Properties 56 1.02.8 Evaluation of Nuclear Properties 57 1.02.9 Evaluation of Biomedical Properties 58 1.02.10 Conclusions and Future Outlook 60 References 61 1.03 - Testing of Polymeric Materials 553 1.03.1 Introduction 2839 1.03.2 Polymeric Materials 453 1.03.3 Characterization of Basic Physical Properties 3584 1.03.4 Polymer Rheology 73 1.03.5 Solid-State Mechanical Properties 3305 1.03.6 Fracture and Impact Testing 2123 1.03.7 Fiber-Reinforced Polymer Composites (FRPs) 2003 1.03.8 Environmental Testing 96 1.03.9 Conclusions 98 References 297 1.04 - Stress-Based Forming Limit Curves 4375 1.04.1 Introduction 3641 1.04.2 Strain-Based Forming Limit Criteria 2080 1.04.3 Stress-Based Forming Limit Criteria 3392 1.04.4 Summary and Conclusions 112 References 112 1.05 - Sheet Bulge Testing 1848 1.05.1 Introduction 5214 1.05.2 Bulge Test Equipment and Specimens 114 1.05.3 Measurement Equipment 2390 1.05.4 Stress–Strain Curve Calculation 4592 1.05.5 Summary 2064 1.05.6 Acknowledgments 1515 References 1226 1.06 - Biaxial Stress Testing Methods for Sheet Metals 164 1.06.1 Introduction 3365 1.06.2 Biaxial Compression Test 5291 1.06.3 Biaxial Tensile Testing Method Using a Cruciform Specimen 5221 1.06.4 Combined Tension–Compression Testing Method 112 1.06.5 In-plane Stress Reversal Testing Method 133 1.06.6 Multiaxial Tube Expansion Testing Method 136 1.06.7 Combined Tension-Shear Testing Method 2439 References 4396 1.07 - Residual Stress Measurements 142 1.07.1 Introduction 279 1.07.2 Powder Diffraction 2839 1.07.3 Introduction to Hole-Drilling 3392 1.07.4 Introduction to Piezospectroscopy 393 References 3771 1.08 - Testing of Small-Sized Specimens 164 1.08.1 Introduction 3968 1.08.2 Tensile Testing 4863 1.08.3 Impact (Charpy) Testing 4380 1.08.4 Fracture Toughness Testing 4199 1.08.5 Fatigue Testing 133 1.08.6 Creep Testing 178 1.08.7 Creep Crack Growth Testing 2003 1.08.8 Extreme Miniaturization (Part 1): Small Disk Testing 180 1.08.9 Extreme Miniaturization (Part 2): Use of Microfabrication Technology 187 1.08.10 Concluding Remarks and Future Trends 3424 Acknowledgments 189 References 1771 1.09 - Advanced High Strength Bainitic Steels 553 1.09.1 Introduction 3600 1.09.2 Theory for Bainite Phase Transformation 494 1.09.3 First Approaches to the Design of Carbide-Free Bainitic Steels, AHSS-GEN3 for Automotive Applications 196 1.09.4 A New Steel Concept for the Twenty-First Century: Nanostructured Bainitic Steels (NANOBAIN) 73 1.09.5 Accelerating Low-Temperature Bainite Transformation 272 1.09.6 Advanced Characterization of Nanostructured Steels 178 1.09.7 Understanding the Mechanical Properties of Advanced Bainitic Steels 3238 Acknowledgments 216 References 4653 1.10 - Thermomechanical Processed Steels 1094 1.10.1 Overview of Thermomechanical Processing 3365 1.10.2 Properties and Composition of TMCP Steels 2321 1.10.3 Austenite Conditioning during Thermomechanical Treatment 5104 1.10.4 Phase Transformations during Accelerated Cooling 2999 1.10.5 Summary and Outlook 241 References 112 1.11 - Quenched and Partitioned Steels 2737 1.11.1 The Quenching and Partitioning Process Concept 5214 1.11.2 Microstructure Development Fundamentals and Alloy Designs 248 1.11.3 Mechanical Behavior, Potential Applications, and Implementation Status 248 Acknowledgements 4199 References 253 1.12 - Material Properties for Numerical Calculations 2724 1.12.1 Introduction 329 1.12.2 Material Characterization 258 1.12.3 Material Modeling for Warm Forming 263 1.12.4 Numerical Modeling 1167 1.12.5 Summary 272 Acknowledgments 2547 References 4619 e9780080965321v2 276 Front Cover 276 Comprehensive Materials Processing 279 Copyright 1848 Editor-In-Chief 281 Editorial Board 283 Contributors to Volume 2 287 Contents of Volume 2 289 Preface 291 2.01 - Introduction to Materials Characterization and Modeling 4010 2.01.1 Introduction 293 2.01.2 Volume Scope and Objective 1633 References 297 2.02 - Phase Transformations and Characterization of α + β Titanium Alloys 5290 2.02.1 Introduction 279 2.02.2 Phase Transformations 2839 2.02.3 Characterization of Phases 5363 2.02.4 The Effect of Microstructure on Mechanical Properties of Two-Phase Titanium Alloys 3871 2.02.5 Development of Microstructure and Plasticity of α + β Titanium Alloys in Plastic Working and Heat Treatment Processes 964 2.02.6 The Influence of Deformation Conditions and Morphology of Phases on the Plasticity of α + β Titanium Alloys 996 2.02.7 Superplasticity of Titanium Alloys 322 2.02.8 Summary 3417 References 297 2.03 - Polymeric Materials Characterization and Modeling 32 2.03.1 Introduction 329 2.03.2 Rubberlike Material Characterization and Modeling 2321 2.03.3 Adhesively Bonded Joints Characterization and Modeling 2583 2.03.4 Melt Rheology of Multiphase Polymeric Systems 2633 References 965 2.04 - Ultrasonic Characterization of Anisotropic Materials 164 2.04.1 Introduction 2650 2.04.2 Acoustic Waves in Elastic and Piezoelectric Media 2737 2.04.3 Elastic Constants Determination Using Large-Aperture PVDF Receivers 2545 2.04.4 Piezoceramic Characterization Using an Iterative Numerical Simulation 393 References 372 2.05 - Application of Optical Techniques to Materials Characterization and Modeling 2409 2.05.1 Introduction 2480 2.05.2 Measurement of Color 376 2.05.3 Materials and Methods 3548 2.05.4 Results and Discussion 3250 2.05.5 Conclusions and Further Research 2064 References 644 2.06 - Material Behavior at a Wide Range of Strain Rates 2737 2.06.1 Introduction 2480 2.06.2 Stress–Strain Definitions 1323 2.06.3 Quasistatic Tensile Tests 4900 2.06.4 Quasistatic Compressive Tests 393 2.06.5 Midrange Strain Rate Tests 5331 2.06.6 High-Strain-Rate Tests 2045 2.06.7 Discussion 487 References 3165 2.07 - Damage Modeling in Composite Structures 3389 2.07.1 Introduction 527 2.07.2 Intralaminar Damage Modeling 5370 2.07.3 Interlaminar Damage Modeling 248 2.07.4 Formulation 3919 2.07.5 Applications 2856 2.07.6 Summary and Conclusions 4061 Acknowledgments 1955 References 438 2.08 - Creep Age Forming Modeling and Characterization 1094 2.08.1 Introduction 1686 2.08.2 CAF Process 4863 2.08.3 Aluminum Alloy for CAF 2545 2.08.4 Phenomenological Approach 3162 2.08.5 Microstructural Characterization Techniques 3652 2.08.6 Concluding Remarks on CAF Process Modeling 1086 References 3505 2.09 - Use of Neural Networks and Artificial Intelligence Tools for Modeling, Characterization, and Forecasting in Material ... 3389 2.09.1 Introduction 5396 2.09.2 Artificial Intelligence Tools Used in Material Engineering 453 2.09.3 The Scope of Applications of Neural Networks in Material Engineering 1043 2.09.4 Artificial Neural Network Design Methodology 1404 2.09.5 Engineering Materials Properties Modeling and Simulation 2342 2.09.6 Neural Networks Aided Prediction of Development Trends in Materials Surface Engineering 477 2.09.7 Summary 487 References 2718 2.10 - Structure and Mechanical Properties of High-Manganese Steels 3892 2.10.1 Introduction 3547 2.10.2 Thermo-Mechanical Treatment of High-Manganese Austenitic Steels 494 2.10.3 Mechanical Properties of High-Manganese Austenitic Steels 1522 2.10.4 Summary 655 References 253 2.11 - Modeling and Characterization of Residual Stresses in Material Processing 511 2.11.1 Introduction and Definitions 3547 2.11.2 Physical Basis for Residual Stresses and Its Sources 4530 2.11.3 Modeling Techniques and Challenges for Residual Stress Prediction 2891 2.11.4 A Brief Overview of Experimental Methods for Characterizing Residual Stresses and Their Limitations 517 2.11.5 Exploratory Comparison between X-Ray and Hole-Drilling Methods 519 2.11.6 Concluding Remarks 477 Acknowledgments 2003 References 1179 2.12 - Modeling of Plastic Yielding, Anisotropic Flow, and the Bauschinger Effect 4399 2.12.1 Motivation 527 2.12.2 Plasticity at Different Scales 2737 2.12.3 Yielding and Flow Potentials for Isotropic Metals 555 2.12.4 Anisotropic Yield Functions 4370 2.12.5 Kinematic Hardening and Bauschinger Effect 682 2.12.6 Homogeneous Potential and the Bauschinger Effect 541 2.12.7 Application to Springback Simulations 1955 Conclusions 2440 Acknowledgments 4937 Appendix 3424 References 2505 2.13 - Modeling of Functionally Graded Materials 553 2.13.1 Introduction 3728 2.13.2 Functionally Graded Materials 593 2.13.3 Modeling of Graded Structures by Using FEM 555 2.13.4 Examples 2428 2.13.5 Conclusions 2292 Acknowledgments 3034 References 573 e9780080965321v3 575 Front Cover 575 Comprehensive Materials Processing 578 Copyright 2409 Editor-In-Chief 580 Editorial Board 582 Contributors to Volume 3 586 Contents of Volume 3 588 Preface 590 3.01 - Introduction to Advanced Forming Technologies 164 3.01.1 Historical Developments 4621 3.01.2 Metalworking: Basic Concepts 593 3.01.3 Classification of Metalworking Processes 1189 3.01.4 Preview of the Contents of Volume 3 1950 3.01.5 Conclusion 2342 Further Reading 596 3.02 - Incremental Sheet Forming 2737 3.02.1 Introduction 5396 3.02.2 Incremental Sheet-Forming Processes 1323 3.02.3 Materials for Incremental Sheet-Forming Processes 1981 3.02.4 Modeling 517 3.02.5 Experimental Assessment of Analytical and FE Models 1954 3.02.6 Examples of Applications 477 3.02.7 Conclusions and Future Trends 3484 References 1226 3.03 - Hot Stamping 618 3.03.1 Introduction 1163 3.03.2 Process 619 3.03.3 Material and Microstructural Properties 5104 3.03.4 Material Formability 1791 3.03.5 Boundary Conditions 2384 3.03.6 FE Modeling 639 3.03.7 Product Characteristics 640 3.03.8 New Developments 642 3.03.9 Conclusions 644 References 644 3.04 - Tube Hydroforming (Internal High-Pressure Forming) 2409 3.04.1 Types and Characteristics of IHPF 2650 3.04.2 Main Process Parameters for IHPF 2433 3.04.3 Defects in IHPF 1189 3.04.4 Forming Limits for IHPF 655 3.04.5 Thickness Distribution Law in IHPF 658 3.04.6 Tubes for IHPF and Lubrication 996 3.04.7 Equipment and Dies for IHPF 487 3.04.8 IHPF Processes for Typical Components 642 References 2897 3.05 - Development of Microstructures and Textures by Cross Rolling 672 3.05.1 Introduction 3547 3.05.2 Scope 2080 3.05.3 Process Details 1522 3.05.4 Science of Microstructure Formation 2633 3.05.5 Texture Formation 682 3.05.6 Mechanics of the Processes 3165 3.05.7 Technological Importance 695 3.05.8 Concluding Remarks 2597 Bibliography 596 3.06 - Multipoint Forming 1094 3.06.1 Introduction 698 3.06.2 Basic Principles 2583 3.06.3 Types of Punch Adjustment 1522 3.06.4 Deformation Characteristics and Forming Technology 393 3.06.5 Application Examples 3652 3.06.6 New Developments 2547 3.06.7 Conclusions and Prospects 2477 Acknowledgments 736 References 2897 3.07 - Dieless Drawing of Bars, Rods, Tubes, and Wires 3242 3.07.1 Introduction 740 3.07.2 Overview of Conventional Wire and Rod Manufacturing 3225 3.07.3 Dieless Drawing 196 3.07.4 Concluding Remarks 1791 References 438 3.08 - Forming of Metal Matrix Composites 1774 3.08.1 Introduction 750 3.08.2 Extrusion 248 3.08.3 Forging 1981 3.08.4 Rolling 4592 3.08.5 Superplasticity 2384 3.08.6 Friction Stir Processing 5320 3.08.7 Conclusions 772 References 4762 3.09 - Development of Ultrafine-Grained Metals by Equal-Channel Angular Pressing 778 3.09.1 Introduction 778 3.09.2 Basic Principles of ECAP Processing 2583 3.09.3 Application of ECAP for Processing of Low-Ductile and Hard-to-Deform Materials 555 3.09.4 Recent Developments of ECAP Techniques for Processing UFG Materials 790 3.09.5 Summary 4871 Acknowledgments 2765 References 4685 3.10 - Cross-Wedge Rolling 2409 3.10.1 Introduction 802 3.10.2 Basic Information 1413 3.10.3 States of Stress and Strain 2632 3.10.4 Forces in the CWR Process 4592 3.10.5 CWR Process Limitations 3652 3.10.6 CWR Tools 840 3.10.7 Outline of the CWR Technology 5333 3.10.8 Conclusion 3931 References 3771 3.11 - Improvement of Mechanical and Physical Properties in Powder Metallurgy 4010 3.11.1 Brief Introduction to Powder Metallurgy 329 3.11.2 How to Improve the Properties without Increasing the Density Level 3270 3.11.3 Improving Properties by Increasing the Density from High Green Density Levels 555 3.11.4 Improving Properties by Sintering Activation 3919 3.11.5 Inhibiting the Grain Growth during Sintering 4419 3.11.6 Additive Technologies 996 3.11.7 Summary 883 References 5434 3.12 - Peen Forming 3389 3.12.1 Introduction 527 3.12.2 Shot Peening and Peen Forming Principles 887 3.12.3 Historical Account 1693 3.12.4 Peen Forming Equipment 892 3.12.5 Peen Forming Procedures 899 3.12.6 Advantages and Limitations 840 3.12.7 Typical Uses of Peen Forming 904 3.12.8 Research on Peen Forming 1289 3.12.9 Analytical Explanation of Conventional and Stress Peen Forming Processes 913 3.12.10 Conclusion 3174 References 1179 Further Reading 920 3.13 - High-Speed Forming of Magnesium Alloy Sheets 3581 3.13.1 Introduction 4011 3.13.2 Material Characterization at High Strain Rates 5370 3.13.3 Numerical Modeling of EM Forming 2545 3.13.4 Experimental Results of EM Forming of AZ31 Sheets 3250 3.13.5 Conclusions 964 Acknowledgments 1515 References 965 3.14 - Hot Rolling and Direct Cooling 3242 3.14.1 Introduction 968 3.14.2 Thermo-Mechanical-Metallurgical Modeling during Hot Rolling 2321 3.14.3 Materials Response during Hot Slab Rolling of Mild Steel 263 3.14.4 Outlook 73 References 987 3.15 - Advanced Techniques to Evaluate Hot Workability of Materials 30 3.15.1 Introduction 988 3.15.2 Stress–Strain Behavior in Hot Deformation 989 3.15.3 Materials Modeling in Hot Deformation 990 3.15.4 Hot Deformation Mechanisms 993 3.15.5 Processing Maps – How to Develop and Interpret 4100 3.15.6 Applications of Processing Maps 996 3.15.7 Validation of Processing Maps 1008 3.15.8 Design of Bulk Metal Working Processes 1013 3.15.9 Summary 4043 References 2910 3.16 - Near-Net and Net Shape Forging 1848 3.16.1 Introduction into Forming Technology 1625 3.16.2 Process Design 3225 3.16.3 Tool Design 5221 3.16.4 Summary 1036 References 3725 3.17 - Texture Control in Aluminum Sheets by Conventional and Asymmetric Rolling 511 3.17.1 Introduction 527 3.17.2 TMP of Al Alloys: Hot Rolling 1040 3.17.3 Cold Rolling 1043 3.17.4 Annealing 1167 3.17.5 Texture-Dependent Properties of Rolled Al Alloys 2418 Acknowledgments 1086 References 4619 e9780080965321v4 1090 Front Cover 1090 Comprehensive Materials Processing 1093 Copyright 1094 Editor-In-Chief 1095 Editorial Board 1097 Contributors to Volume 4 1101 Contents of Volume 4 1103 Preface 1105 4.01 - Introduction to Films and Coatings 5290 4.02 - Cathodic-Arc and Thermal-Evaporation Deposition 672 4.02.1 Introduction 1109 4.02.2 Thermal Evaporation 1323 4.02.3 Cathodic-Arc Deposition Process 1693 References 3725 4.03 - Magnetron Sputtering 1094 4.03.1 The Basics of Sputtering 1163 4.03.2 Sputtering from Planar Diodes 5291 4.03.3 Radio-Frequency Sputtering 263 4.03.4 The Magnetron Cathode 1167 4.03.5 High Target Utilization 241 4.03.6 Reactive Sputtering 477 4.03.7 Pulse Magnetron Sputtering 1175 4.03.8 Special Developments 4879 4.03.9 Concluding Remarks and Outlook 1179 References 1179 4.04 - High Power Impulse Magnetron Sputtering – HIPIMS 1181 4.04.1 Introduction to High Power Impulse Magnetron Sputtering 3365 4.04.2 HIPIMS Generation 5325 4.04.3 HIPIMS Process Technology 1189 4.04.4 HIPIMS Applications 112 4.04.5 Patent Situation 1872 4.04.6 Outlook 4205 References 1305 4.05 - Atomic Layer Deposition 1754 4.05.1 Introduction 3641 4.05.2 Characteristic Features of ALD 3225 4.05.3 ALD Chemistry 3548 4.05.4 ALD Reactors 4199 4.05.5 ALD Applications 4006 References 1226 4.06 - Laser Ablation 1231 4.06.1 Laser Ablation Technology: Introduction and Physical Fundamentals 2307 4.06.2 Applications of Laser Ablation in Material Processing I 114 4.06.3 Applications of Laser Ablation in Material Processing II 248 4.06.4 Pulsed Laser Ablation and Pulsed Laser Deposition Technology 2137 4.06.5 Thermodynamics of Laser Ablation 4006 References 3557 4.07 - Surface Processing Using Cold Atmospheric Pressure Plasmas 2771 4.07.1 Classification of Atmospheric Plasmas by Electron Temperature 3600 4.07.2 Classification of Atmospheric Plasmas Based on Discharge Type 1633 4.07.3 Surface Activation and Coating Deposition Using Cold Atmospheric Plasmas 2940 4.07.4 Surface Treatments 2633 4.07.5 Coating Deposition 1282 4.07.6 Organosilicon Precursors 2765 4.07.7 Plasma Medicine 1288 4.07.8 Summary 1289 Acknowledgments 4937 References 5434 4.08 - Ion Beam Deposition: Recent Developments 1181 4.08.1 Introduction 2307 4.08.2 Irradiation Effects of Ion Beam during Thin Film Depositions 3270 4.08.3 Ion Beam Assisted Deposition Systems 3938 4.08.4 Gas Cluster IBAD 2851 4.08.5 Focused Ion Beam Assisted Nanostructure Formation 4100 4.08.6 Conclusion 996 References 1305 4.09 - Plasma Polymer Deposition and Coatings on Polymers 672 4.09.1 Plasma Polymer Deposition 4621 4.09.2 Coatings on Polymers 1323 References 1331 4.10 - Thermal Spray Coating Processes 1335 4.10.1 Introduction 279 4.10.2 Spray Materials 1323 4.10.3 Thermal Spray Processes 263 4.10.4 Formation of Sprayed Coatings 3145 4.10.5 Coating Materials and Properties 4100 4.10.6 Industrial Applications 178 4.10.7 Development Trends 1955 4.10.8 Concluding Remarks 1381 References 3505 4.11 - Electroplating and Electroless Plating 1754 4.11.1 Introduction 3600 4.11.2 Principal Elements of Plating 1834 4.11.3 Electrolytic Plating 5104 4.11.4 Alloy Plating 1404 4.11.5 Aluminum Finishing 1406 4.11.6 Electroless Plating Solutions 4386 References 1179 4.12 - Plasma Sources in Thin Film Deposition 5290 4.12.1 Introduction 293 4.12.2 Pressure and Power Source Frequency of Plasma Sources 1413 4.12.3 Plasma Sources for CVD Processes 1414 4.12.4 Plasma Sources for PVD Processes 1421 4.12.5 Plasma Source for Large-Area Process 2292 4.12.6 Summary 4205 References 2505 4.13 - Hard Nanocomposite Coatings 3242 4.13.1 Present State of the Knowledge in the Field of Nanocomposite Coatings 4263 4.13.2 Advanced Hard Nanocomposite Coatings 5291 4.13.3 Trends of the Present and the Next Development of Hard Nanocomposite Coatings 4900 Acknowledgments 3871 References 965 4.14 - Protective Transition Metal Nitride Coatings 3892 4.14.1 Introduction 4263 4.14.2 Transition Metal Nitride Coatings 2080 4.14.3 Thermal and Chemical Stability of Nitride Coatings 1468 4.14.4 Oxidation and Oxidation Protection 1471 4.14.5 Simultaneous Investigation of Nanostructure and Chemistry 133 4.14.6 Multinary Transition Metal Aluminium Nitrides 4104 4.14.7 Summary and Outlook 1488 Acknowledgments 3931 References 987 4.15 - Advanced Carbon-Based Coatings 511 4.15.1 Introduction 1686 4.15.2 Bonding Configurations in Carbon Films 1323 4.15.3 Carbon Nitride Films 1498 4.15.4 Phosphorous-Carbide Films 1791 4.15.5 Carbon Fluoride Films 2300 4.15.6 Concluding Remarks 1515 Acknowledgments 2477 Bibliography 987 4.16 - Photocatalytic Coatings 672 4.16.1 Introduction 4168 4.16.2 Fundamentals of Photocatalysis 248 4.16.3 Generalities on Photocatalytic Coatings 1522 4.16.4 Peculiarities of Photocatalytic Coatings Depending on the Application 3898 4.16.5 Peculiarities of Photocatalytic Coatings Depending on the Shape of the Materials 1406 4.16.6 Conclusions 3165 References 1305 4.17 - Biocompatible Coating 3389 4.17.1 Introduction 1531 4.17.2 Hemocompatible Coatings 3040 4.17.3 Cytocompatible and/or Immunomodulatory Coatings 5104 4.17.4 Antibacterial Coatings 1950 4.17.5 Summary and Perspectives 682 Acknowledgment 1086 References 253 4.18 - Antimicrobial Bioactive Polymer Coatings 618 4.18.1 Introduction 329 4.18.2 Current Thin-Film Approaches 494 4.18.3 Summary 2583 References 438 4.19 - Thin-Film Diffusion Barriers for Electronic Applications 142 4.19.1 Background 5214 4.19.2 Definitions and Basic Equations of Permeation 1834 4.19.3 Permeation Models for a Thin-Film Diffusion Barrier 1574 4.19.4 Methods for Permeation Measurement 1791 4.19.5 Ultrabarrier Coating Strategies 241 4.19.6 Concluding Remarks 1621 Acknowledgments 1603 References 438 4.20 - Diffusion Barrier Layers for Edible Food Packaging 618 4.20.1 Introduction 1625 4.20.2 Packaging Films 3225 4.20.3 Edible Coating 1468 4.20.4 Added Value and Limitations of Edible Coatings: Sensory Properties 1036 4.20.5 Toxicity of Polymeric Films into Contact with Foodstuff 4100 4.20.6 Conclusion 1621 References 1621 4.21 - Large-Scale Industrial Coating Applications and Systems 4765 4.21.1 Different Equipment Aspects Classified after Their Application 1625 4.21.2 Equipment Aspects Based on Applications 1633 4.21.3 Design Phases 248 4.21.4 Maintenance of Batch and In-Line Systems 1950 4.21.5 Project Management Organization 2856 Acknowledgment 3008 References 5369 e9780080965321v5 1669 Front Cover 1669 Comprehensive Materials Processing 1672 Copyright 1774 Editor-In-Chief 1674 Editorial Board 1676 Contributors to Volume 5 1680 Contents of Volume 5 1682 Preface 1684 5.01 - Introduction to Casting, Hot Metal Forming, and Semisolid Processing 3242 5.01.1 Casting 1686 5.01.2 Hot Metal Forming 4863 5.01.3 Semisolid Processing 263 Acknowledgments 1687 5.02 - Advanced Casting Methodologies: Inert Environment Vacuum Casting and Solidification, Die Casting, Compocasting, and Roll Casting 2409 5.02.1 Introduction by Plato Kapranos 1689 5.02.2 Inert Environment Vacuum Casting and Solidification by Dermot Brabazon 3040 5.02.3 Recent Advances in Die Casting by Steve Midson 1693 5.02.4 Compocasting by Sumsun Naher 4592 5.02.5 Roll Casting by Toshio Haga and Plato Kapranos 4419 Acknowledgments 3092 References 5369 5.03 - Advanced Casting Methodologies: Investment Casting, Centrifugal Casting, Squeeze Casting, Metal Spinning, and Batch Casting 2771 5.03.1 Introduction by Plato Kapranos 2650 5.03.2 Investment Casting by Crispen Carney 1725 5.03.3 Centrifugal Casting by Annalisa Pola 1043 5.03.4 Squeeze Casting by Annalisa Pola 3919 5.03.5 Spin Casting by Annalisa Pola 4707 5.03.6 Batch Casting by Mark Jolly 3034 References 644 5.04 - Rapid Solidification Processing and Bulk Metallic Glass Casting 1754 5.04.1 Introduction 3968 5.04.2 Glass Forming Ability in BMG Alloys 4863 5.04.3 Rapid Casting of Bulk Metallic Glass 2390 5.04.4 Supercooled Alloys 4868 5.04.5 Phase Crystallinity and Transformation 4298 5.04.6 Conclusion 3309 References 1771 5.05 - Single-Crystal Casting/Directional Solidification 1774 5.05.1 Directional Solidification 1774 5.05.2 Investment Casting Techniques 1633 5.05.3 Grain Selection and Single-Crystal Casting 4694 5.05.4 Conclusions 1791 References 2718 5.06 - Semisolid Processes 2771 5.06.1 Introduction 1795 5.06.2 Thixoprocessing 1834 5.06.3 Rheoprocessing 2390 5.06.4 Forming Methods 1839 5.06.5 Thixomolding 1817 5.06.6 Semisolid Free Forming Technology 840 5.06.7 Summary 5333 References 3165 5.07 - Routes to Spheroidal Starting Material for Semisolid Metal Processing 1181 5.07.1 Introduction 3365 5.07.2 Liquid Metal Routes 2056 5.07.3 Solid-State Routes 1189 5.07.4 Combinations of Methods 1829 5.07.5 Concluding Remarks 2584 References 3725 5.08 - Rheology of Semisolid Metallic Alloys 32 5.08.1 Introduction 2650 5.08.2 Origins of Thixotropy 1834 5.08.3 Background Rheology 5439 5.08.4 Measurement of Steady-State Rheological Behavior 1839 5.08.5 Exemplar Results for Rheological Behavior 3652 5.08.6 Measurement of Transient Rheological Behavior 4205 5.08.7 Concluding Remarks 1603 References 2910 5.09 - Alloys for Semisolid Processing 1848 5.09.1 Fundamental Aspects 2579 5.09.2 Basics of Solid to Liquid Transition in Possible Alloys for Semisolid Processing 376 5.09.3 Commercially Processed Semisolid Alloys 5221 5.09.4 Alloys That Have Been Semisolid Processed in Research Units 2851 5.09.5 Scientific Issues for Alloy Design 1872 5.09.6 Concluding Remarks 1621 References 2910 5.10 - Modeling of Semisolid Flow 4399 5.10.1 Why Model Semisolid Flow? 1876 5.10.2 General Purpose 3199 5.10.3 One-Phase Modeling 1877 5.10.4 Two-Phase Modeling 1167 5.10.5 Conclusion 682 Acknowledgments 136 References 1893 5.11 - Tribology in Hot Forging 3802 5.11.1 Introduction 1686 5.11.2 Load Types for Forging Tools 593 5.11.3 Optimization of Tribological Conditions 1902 5.11.4 Numerical Simulation of the Tribological System in the Hot Forging Using FEM 4592 5.11.5 Summary 1917 References 3505 5.12 - Casting Simulation Methods 3802 5.12.1 Introduction 750 5.12.2 A Holistic Approach to Casting Simulation 114 5.12.3 Mathematical Modeling 1877 5.12.4 Simulation Models 3898 5.12.5 Special Topics in Casting Simulation 133 5.12.6 Recent Applications and Future Directions 178 Appendix A 1603 Finite Element Formulation 3353 References 3204 5.13 - Industrial Practice and Applications 2737 5.13.1 Introduction 2446 5.13.2 Induction Heating for Thixocasting 248 5.13.3 Controls Used with Semisolid Casting 1189 5.13.4 Die Design for Semisolid Castings 1950 5.13.5 Examples of Aluminium-Alloy Components Produced by Semisolid Casting 1954 5.13.6 Examples of Magnesium-Alloy Components Produced by Semisolid Casting 1621 5.13.7 Costing and Economics of Aluminium Rheocasting 1955 References 4762 5.14 - Hot Forging 4765 5.14.1 Open-Die Forging 527 5.14.2 Closed-Die Forging 376 5.14.3 Isothermal Forging for Complex Integral Component 263 5.14.4 Control Defect of Forgings 2633 References 1226 5.15 - Deformation Rules and Mechanism of Large-Scale Profiles Extrusion of Difficult-to-Deform Materials 553 5.15.1 Fundamentals of Extrusion (1) 968 5.15.2 Large-Scale Profiles Extrusion of Difficult-to-Deform Materials 2321 5.15.3 FE Modeling and Validation 1981 5.15.4 Deformation Rules and Mechanism 2851 5.15.5 Optimization Design Based on FE Virtual Orthogonal Experiment 1954 5.15.6 Summary and Conclusions 2648 Acknowledgment 2003 References 5266 Relevant Websites 2004 5.16 - Hot Tube-Forming 4399 5.16.1 Introduction 293 5.16.2 Hot Tube Forming for Billet Preparation 453 5.16.3 Tube Material Characterization at Elevated Temperatures 5104 5.16.4 Hot Tube Forming for Components 1839 5.16.5 Summary and Conclusions 658 References 3165 5.17 - Hot Stamping 1094 5.17.1 Concept of Hot Stamping 2036 5.17.2 Advantages and Disadvantages of Hot Stamping 1834 5.17.3 Material Requirements and Selection 3392 5.17.4 Process Design and Quality Control 3162 5.17.5 Tooling Fabrication 2292 5.17.6 Forming Behavior and Process Simulation 2045 5.17.7 Case Studies 2048 5.17.8 Future Outlooks 2052 References 3204 5.18 - Superplastic Forming 672 5.18.1 Introduction 293 5.18.2 Superplastic Forming/Diffusion Bonding of Titanium Alloy Multilayer Structure 2056 5.18.3 Superplastic Forming of Bellows Expansion 1693 5.18.4 Ceramic Die for Superplastic Forming Titanium Alloy 112 5.18.5 Superplastic Forming of Aluminium Alloy 2064 5.18.6 Superplastic Forming of γ-TiAl and Nb–Si–Fe Intermetallics 3092 5.18.7 Superplastic Forming of Inconel 718 Superalloy 3238 5.18.8 Concluding Remarks 2076 References 3725 5.19 - Hot Shape Rolling 164 5.19.1 Principle of Shape Rolling 4011 5.19.2 Characteristics of Shape Rolling 2080 5.19.3 Types of Shape Rolling 1877 5.19.4 Ring Rolling 2081 5.19.5 Summary and Conclusions 2418 Acknowledgments 2123 References 644 5.20 - Modeling of Hot Forging 4621 5.20.1 Introduction and Definitions 802 5.20.2 Fundamentals for Modeling of Hot Forging 3225 5.20.3 Macro Modeling for Hot Forging 5363 5.20.4 Microstructure Evolution Modeling for Hot Forging of Ti-Alloy 2137 5.20.5 3D-FE Modeling for Hot Forging of Blades 899 5.20.6 Through-Process Macro–Micro Modeling for Isothermal Local Loading Forming of Large-Scale Integral Component 2166 5.20.7 Summary and Conclusions 2176 Acknowledgments 2176 References 1226 Relevant Website 2178 e9780080965321v6 2180 Front Cover 2180 Comprehensive Materials Processing 2183 Copyright 4375 Editor-In-Chief 2185 Editorial Board 2187 Contributors to Volume 6 2191 Contents of Volume 6 2193 Preface 2195 6.01 - Introduction to Welding and Joining Technologies 32 6.01.1 Concluding Remarks and Acknowledgments 293 6.02 - Welding Processes and Technologies 30 6.02.1 General Introduction 968 6.02.2 Fusion Welding Processes 5470 6.02.3 Solid-State Welding Processes 3548 References 1305 6.03 - Manual Metal Arc Welding and Gas Metal Arc Welding 672 6.03.1 Introduction and General Problem Definition in Welding 5214 6.03.2 Manual Metal Arc Welding Also Known as Shielded Metal Arc Welding 5470 6.03.3 Gas Metal Arc Welding Also Known as Metal Inert Gas Welding 4694 Acknowledgments 3898 References 1226 6.04 - Robotic Welding Technology 3431 6.04.1 Introduction 329 6.04.2 Robotics in Welding 3270 6.04.3 Robotics in Different Welding Techniques 1043 6.04.4 Current Research Topics in Robotic Welding 73 6.04.5 Conclusions 2292 References 987 6.05 - Mathematical Modeling of Weld Phenomena, Part 1: Finite-Element Modeling 4621 6.05.1 Introduction 2839 6.05.2 Application of the FEM to the Welding Processes 2433 6.05.3 Thermal Analysis and the Weld Pool 3979 6.05.4 Mechanical and Metallurgical Analysis 1471 6.05.5 FEM Application to Fusion Welding 2300 6.05.6 FEM Application to the Solid-State Welding 996 6.05.7 Concluding Remarks 2741 References 4762 6.06 - Mathematical Modeling of Weld Phenomena, Part 2: Design of Experiments and Optimization 3242 6.06.1 Introduction 2307 6.06.2 ANN Analysis 593 6.06.3 DoE Analysis 1693 6.06.4 Concluding Remarks 4183 References 2505 6.07 - Welding Defects a