ASM Handbook, Volume 22B: Metals Process Simulation

This Handbook provides insight into the integration of modeling for simulation of manufacturing processing. The metals industry is moving toward an integrated computational materials engineering approach (ICME). This provides engineers with accurate predictions of material and process behavior to avoid or reduce costly trial-by-error and prototyping methods of development. The table of content illustrates the depth and berth of the processes addressed. The rate of change within this area of engineering has continued to increase with increasing industrial benefits from the use of such engineering tools, and the reduced cost and increased speed of computing systems required to perform the extensive model calculations. This book serves as a reference to these developments.This Volume joins the companion, Volume 22A, Fundamentals of Modeling for Metals Processing to provide a complete authoritative reference for the modeling practicioner, or the student or engineer beginning their quest of information. Foreword ......Page 3 Preface......Page 5 Policy on Units of Measure......Page 6 Authors and Contributors......Page 8 Reviewers......Page 10 Contents......Page 11 Introduction to Metals Process Simulation......Page 15 Thermophysical Properties of Liquidsand Solidification MicrostructureCharacteristics—Benchmark DataGenerated in Microgravity......Page 20 Thermophysical Properties......Page 30 Measurement of Thermophysical Properties at High Temperatures for Liquid, Semisolid, and Solid Commercial Alloys ......Page 45 Measurement and Interpretation ofFlow Stress Data for the Simulation ofMetal-Forming Processes......Page 58 Grain-Boundary Energy and Mobility......Page 79 Texture Measurement and Analysis ......Page 104 Three-Dimensional Microstructure Representation ......Page 112 Commercial Alloy Phase Diagrams andTheir Industrial Applications......Page 127 The Application of Thermodynamic and Material Property Modeling to Process Simulation of Industrial Alloys......Page 142 Modeling of Transport Phenomena duringSolidification Processes......Page 164 Modeling of Casting and Solidification Processes......Page 175 Computational Analysis of the Vacuum Arc Remelting (VAR) and Electroslag Remelting (ESR) Processes ......Page 203 Formation of Microstructures, GrainTextures, and Defects duringSolidification......Page 221 Modeling of Dendritic Grain Solidification......Page 235 Modeling of Laser-Additive Manufacturing Processes......Page 247 Modeling of Porosity Formation during Solidification......Page 260 Finite Element Method Applications in Bulk Forming*......Page 271 Sheet Metal Forming Simulation......Page 294 Modeling of Powder Metallurgy Processes......Page 310 Modeling and Simulation of Press andSinter Powder Metallurgy......Page 324 Modeling of Hot Isostatic Pressing......Page 336 Modeling and Simulation of Metal Powder Injection Molding......Page 344 Modeling and Simulation of Machining......Page 359 Modeling Sheet Shearing Processes for Process Design......Page 370 Modeling of Residual Stress andMachining Distortion in AerospaceComponents......Page 384 Introduction to Integrated WeldModeling......Page 406 Simulation of Rotational Welding Operations......Page 427 Simulation of Friction Stir Welding......Page 438 Modeling of Diffusion Bonding......Page 447 Heating and Heat-Flow Simulation......Page 451 Simulation of Induction Heating Prior toHot Working and Coating......Page 467 Simulation of Induction Heat Treating......Page 493 Modeling of Quenching, Residual-Stress Formation, and Quench Cracking......Page 539 Simulation of Diffusion in Surface and Interface Reactions......Page 578 Solid Modeling......Page 592 Design Optimization Methodologies......Page 603 Stress-Relief Simulation......Page 614 Uncertainty Management in MaterialsDesign and Analysis......Page 620 Manufacturing Cost Estimating*......Page 629 Software for Computational Materials Modeling and Simulation......Page 636 Metric Conversion Guide......Page 644 Useful Formulas for Metals Processing......Page 646 Glossary of Terms......Page 655 Index......Page 680 ASM Handbook, Volume 22 Metals Process Simulation provides insight into the integration of modeling for simulation of manufacturing processing. The metals industry is moving toward an integrated computational materials engineering approach (ICME). This provides engineers with accurate predictions of material and process behavior to avoid or reduce costly trial-by-error and prototyping methods of development. The table of content illustrates the depth and berth of the processes addressed. The rate of change within this area of engineering has continued to increase with increasing industrial benefits from the use of such engineering tools, and the reduced cost and increased speed of computing systems required to perform the extensive model calculations. This book serves as a reference to these developments. This Volume joins the companion, Volume 22A, Fundamentals of Modeling for Metals Processing to provide a complete authoritative reference for the modeling practicioner, or the student or engineer beginning their quest of information. This handy index eliminates the need to search through multiple back-of-the-book indexes to find where a subject is addressed. The comprehensive A-to-Z listing will help users find important handbook content in volumes where they may not have thought to look. This volume is a composite of all of the indexes in the complete 26-volume series, from Volume 1 through 22B. These volumes cover the properties, processing, and applications of metals and nonmetallic engineering materials. They are designed to provide the authoritative information and data necessary for the appropriate selection of materials to meet critical design and performance criteria