Metals Process Simulation

Edited by D.U. Furrer; S.L.. Semiatin

ASM International
Volume 22B
Publication date: 2010

Covers the problems of simulation of processes of melting, casting, powder metallurgy, heat treatment, welding, grinding, diffusion coating, forming, bending, forging and other deformation processes.

  • Describes the methods, models, and tools used to simulate manufacturing processes and predict the microstructure and mechanical properties of metals and metal parts.
  • Covers a wide range of processes
  • Also addresses
    • powder metallurgy
    • additive manufacturing
    • diffusion coating
    • forming
    • bending
    • forging
    • other deformation processes.
  • Offers guidance on how to develop and assess input data for simulations, including
    • thermophysical property data
    • grain-boundary data
    • flow stress
    • texture data
    • 3D microstructure data.
  • Discusses the integration of modeling and simulation in design, particularly as it applies to
    • design optimization
    • uncertainty
    • error propagation.
  • Includes a review of commercial tools and their application to industrial alloys.

Table of Contents

Input Data for Simulations

  • Introduction to Metals Process Simulation
  • Thermophysical Properties of Liquids and Solidification Microstructure Characteristics—Benchmark Data Generated in Microgravity
  • Thermophysical Properties
  • Measurement of Thermophysical Properties at High Temperatures for Liquid, Semisolid, and Solid Commercial Alloys
  • Measurement and Interpretation of Flow Stress Data for the Simulation of Metal-Forming Processes
  • Grain-Boundary Energy and Mobility
  • Texture Measurement and Analysis
  • Three-Dimensional Microstructure Representation

Simulation of Phase Diagrams and Transformations

  • Commercial Alloy Phase Diagrams and Their Industrial Applications
  • The Application of Thermodynamic and Material Property Modeling to Process Simulation of Industrial Alloys

Simulation of Solidification

  • Modeling of Transport Phenomena during Solidification Processes
  • Modeling of Casting and Solidification Processes
  • Computational Analysis of the Vacuum Arc Remelting (VAR) and Electroslag Remelting (ESR) Processes
  • Formation of Microstructures, Grain Textures, and Defects during Solidification
  • Modeling of Dendritic Grain Solidification
  • Modeling of Laser-Additive Manufacturing Processes
  • Modeling of Porosity Formation during Solidification

Simulation of Metal Forming Processes

  • Finite Element Method Applications in Bulk Forming
  • Sheet Metal Forming Simulation

Simulation of Powder Metallurgy Processes

  • Modeling of Powder Metallurgy Processes
  • Modeling and Simulation of Press and Sinter Powder Metallurgy
  • Modeling of Hot Isostatic Pressing
  • Modeling and Simulation of Metal Powder Injection Molding

Simulation of Machining Processes

  • Modeling and Simulation of Machining
  • Modeling Sheet Shearing Processes for Process Design
  • Modeling of Residual Stress and Machining Distortion in Aerospace Components

Simulation of Joining Operations

  • Introduction to Integrated Weld Modeling Simulation of Rotational Welding Operations
  • Simulation of Friction Stir Welding
  • Modeling of Diffusion Bonding

Simulation of Heat Treatment Processes

  • Heating and Heat-Flow Simulation
  • Simulation of Induction Heating Prior to Hot Working and Coating
  • Simulation of Induction Heat Treating
  • Modeling of Quenching, Residual-Stress Formation, and Quench Cracking
  • Simulation of Diffusion in Surface and Interface Reactions

Integration of Modeling and Simulation in Design

  • Solid Modeling
  • Design Optimization Methodologies
  • Uncertainty Management in Materials Design and Analysis
  • Manufacturing Cost Estimating

Reference Information

  • Software for Computational Materials Modeling and Simulation
  • Useful Formulas for Metals Processing
  • Glossary of Terms: Metals Process Simulation

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