spring 2001isat 430 dr. ken lewis1 things to know review isat 430
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Spring 2001 ISAT 430 Dr. Ken Lewis 1
Things to KnowThings to Know
Review
ISAT 430
Spring 2001 ISAT 430 Dr. Ken Lewis 2review
Process-Property-Product-Performance Continuum
Process-Property-Product-Performance Continuum
Understand howProduct performanceComposition and structureSynthesis and processingAssumed behavior
– interact
Spring 2001 ISAT 430 Dr. Ken Lewis 3review
Manufacturing ProcessesManufacturing Processes
Know what the processes are doingChanging the state, geometry, physical properties, appearance,…. Changing the value of the material
Know that (in principle) manufacturing adds value to the material.
Spring 2001 ISAT 430 Dr. Ken Lewis 4review
HistoryHistory
For millennia, stuff was madeOne of a kindLabor intensiveA person was a jack of all trades
Material discovery drove manufacturing processesWoodFibersClaymetals
Spring 2001 ISAT 430 Dr. Ken Lewis 5review
HistoryHistory
Industrial revolution (1760 – 1845)The steam engineMachine toolsTextile machineryThe factory system
Other forcesEli Whitney – interchangeable partsHenry Ford – the assembly line
Spring 2001 ISAT 430 Dr. Ken Lewis 6review
ConversionConversion
ExtractionBring it from the earth
Cast or formBring it to use
Spring 2001 ISAT 430 Dr. Ken Lewis 7review
Manufacturing ProcessesManufacturing Processes
ConversionRaw or natural to a more useful finished form
ProcessingTransform a material
AssembleMany parts into one.
Spring 2001 ISAT 430 Dr. Ken Lewis 8review
Process SelectionProcess Selection
If you can find or discover a process, there are bases for the choiceTechnical
– Do not violate the laws of physics in our area of the known UniverseEconomical
– Can I do it and make a profit? Compatibility
Know obvious incompatibilities– Forging a plastic– Blow mold aluminum
Spring 2001 ISAT 430 Dr. Ken Lewis 9review
Process SelectionProcess Selection
EconomicsNumbers –vs- cost
– Inspection– Reduction in versatility
Capital investmentConversion costs
EnvironmentalWaste production, release, and conversion costs
MiscellaneousMaterial availabilityTime linesAnd all others,… supply, labor, deadlines…
Spring 2001 ISAT 430 Dr. Ken Lewis 10review
The Effect of Numbers On Process SelectionThe Effect of Numbers On Process Selection understand
The total cost of a batch of a given number of pieces is:
P T xn Where:
P = total cost of a batch
T = cost of tools and equipment
n = number of pieces in a batch
x = the costs associated with each individual piece
Spring 2001 ISAT 430 Dr. Ken Lewis 11review
Processing of PolymersProcessing of Polymers
Know the three types of economic importanceThermoplasticThermosettingElastomeric
Know their assetsLight weightCorrosion resistantElectrically insulatingThermally insulating
Spring 2001 ISAT 430 Dr. Ken Lewis 12review
Fluid Mechanics 201Fluid Mechanics 201 Understand viscosity and shear
rate for a polymeric fluid
The shear force per unit area is proportional to the local velocity gradient.
The constant of proportionality is
called the viscosityxv y
Y
x
zy
0v
xyx
dvdy
This is Newton’s law of viscosity
Spring 2001 ISAT 430 Dr. Ken Lewis 13review
Shear Flow in a Cylinder Fluid velocity is zero at the wall. Fluid velocity remains constant on
concentric cylindrical surfaces. The flow is purely axial The fluid velocity reaches a
maximum at the center. This is called:
Laminar Flow
Spring 2001 ISAT 430 Dr. Ken Lewis 14review
Velocity Distribution in a Cylindrical Tube
There is friction, both at the wall of the tubeWithin the fluid itself
Thus, the fluid is:Accelerated by the pressure gradientRetarded by the frictional shearing stressPressure gradient
• The fluid moves under the influence of a pressure gradient.
Spring 2001 ISAT 430 Dr. Ken Lewis 15review
Shear Rates4
Shear rate 0 at the center (r = 0)Max at the wall (r = R)
Shear rate is an indication of the stress being seen by the fluid, and how fast it sees it!
The shear rate at the wall for a Newtonian fluid is:
r
L
PP
dr
dv ambientpumpz
2
3
32QD
Q = volumetric flow rate
D = diameter
Spring 2001 ISAT 430 Dr. Ken Lewis 16review
Volumetric Newtonian Flow in a Tube
The laminar flow of a Newtonian fluid in a pipe or tube may be expressed:
4
8PR
QL
Where:
Q = the volumetric flow rate [=] m3/s or gal/min
P = the pressure drop or driving force [=] kg/m2 or Pa
R = the radius of the tube [=] m or cm
L = the length of the pipe [=] m or cm
= the Newtonian viscosity [=] Pa s
Spring 2001 ISAT 430 Dr. Ken Lewis 17review
Fluid mechanics -- viscosityFluid mechanics -- viscosity
Understand the effect of viscosity on pressure drop through a cylindrical pipe.
Realize that for a Newtonian fluid, the viscosity is independent of shear rate
But….Most polymeric fluids are not NewtonianThus, the viscosity is NOT constant
There is an important family of fluids called POWER LAW FLUIDS
Spring 2001 ISAT 430 Dr. Ken Lewis 18review
Newton’s Law of Viscosity
xyx
dvdy
or
constantyx
Spring 2001 ISAT 430 Dr. Ken Lewis 19review
Power Law Fluids The deviation of n from unity
indicates the degree of Non-Newtonian behavior.
If n < 1, material behavior is pseudoplasticIf n> 1, material behavior is dilatant.
1n
x xyx
dv dvm
dy dy
xyx
dvdy
Spring 2001 ISAT 430 Dr. Ken Lewis 20review
Power Law Viscosity
For most polymers, the isothermal viscosity decreases with increasing shear rate.
Effect of shear on the entangled polymer chains
Usually, in the literature, the viscosity is not shown as “”,
but rather “”
So:1n
x xyx
dv dvm
dy dy
xyx
dvdy
Spring 2001 ISAT 430 Dr. Ken Lewis 21review
Viscosity
Velocity Gradient
Non-NewtonianPower Law Flow
NewtonianFlow
Newtonian FluidViscosity (slope) constant
Non-Newtonian FluidViscosity is not constantProfound affect on processing
Spring 2001 ISAT 430 Dr. Ken Lewis 22review
The Effect of Shear Rate on Viscosity
The effect can be enormous
In this case the zero shear viscosity is about 1000 Pa s.
At a shear rate of 1000 sec-1, the viscosity has dropped to about 5 Pa s
0.1
1
10
100
1000
10000
0.1 1 10 100 1000 10000 100000
Shear Rate (sec-1)
Zero Shear Viscosity
Slope = n - 1
Spring 2001 ISAT 430 Dr. Ken Lewis 23review
Shear RatesShear Rates
3
3 1n Qn r
3
4Qr
Power Law n = 1Newtonian Law
Spring 2001 ISAT 430 Dr. Ken Lewis 24review
Volumetric Flow RatesVolumetric Flow Rates
3 1 1
3 1 2
nn nr P
Qn mLn
4
8PR
QmL
Power Law Fluid N = 1Newtonian Fluid
Spring 2001 ISAT 430 Dr. Ken Lewis 25review
Synthetic FibersSynthetic Fibers
Predates recorded history Early fibers were plant or animal
WoolSilkCottonLinen
1910 – first commercial rayon 1938 – nylon 1959 – Lycra® spandex 1974 – Kevlar® aramid
Spring 2001 ISAT 430 Dr. Ken Lewis 26review
DenierDenier
Measure of the fineness of a yarn
Denier = weight in grams of 9,000 meters of yarn
Essentially a linear density
Spring 2001 ISAT 430 Dr. Ken Lewis 27review
SpinningSpinning
Things common to all spinning systemsMetering pump
– Precise volumetric flow control
Spinneret– Extrusion of the filaments
Spin cell– Manipulation and protection of the forming filaments
Spring 2001 ISAT 430 Dr. Ken Lewis 28review
Methods of Spinning fibersMethods of Spinning fibers
There are three main methods of spinning fibers
Melt spinning
Wet spinning
Dry spinning
Spring 2001 ISAT 430 Dr. Ken Lewis 29review
Melt Spinning
Not the oldest spinning method More straight forward
removal of heatno solvents to worry about.
Example -- nylon
Spring 2001 ISAT 430 Dr. Ken Lewis 30review
Nylon Either cross flow or radial gas flow.
staple yarn uses radial
filament yarn uses crossflow
Uniformity of the air flow is critical
Minimum air necessary is used to reduce
turbulence. Three forces resist the feed roll
Resistive inertial
Rheological stresses
Aerodynamic or drag forces (important
for spinning speeds > 5000 m/min
Spring 2001 ISAT 430 Dr. Ken Lewis 31review
Wet Spinning
If a polymerdoes not meltdissolves only in non-volatile or thermally unstable solvents
We wet spin Polymer solution is extruded into a liquid bath
miscible with the solventdoes not solvate the polymer.
Example: Kevlar®
Spring 2001 ISAT 430 Dr. Ken Lewis 32review
Kevlar® Air Gap Spinning
4 ºC water
SpinneretMetering pump
Neutralization & Washing bath
To drying and constant tension winder
Spring 2001 ISAT 430 Dr. Ken Lewis 33review
Solution is extruded into a hot gas As the filaments pass down the cell, the hot gas causes the
solvent to vaporize This process is complex
Heat transferMass transfer
– through the filament– into the gas
Gas - solvent management Example: Lycra®
Dry SpinningDry Spinning
Spring 2001 ISAT 430 Dr. Ken Lewis 34review
Polymer is dissolved in dimethylacetamide (DMAc) and
then pumped to the top of the cell
Hot Nitrogen (300 - 450 ºC)inserted
Gas is made uniform andPasses into the filaments
And Down The cell
Gas heats the solvent, drivingIt from the filaments.
Spring 2001 ISAT 430 Dr. Ken Lewis 35review
Vacuum Box
Near the bottom of the cell there is a vacuum box.
The solvent rich gas is extracted.The solvent is recovered.
Just at the cell exitRecycle gas is inserted into the cell– DMAc >15% flammable– Keeps solvent/gas from the
room– Acts as a curtain
The fibers exit the cell and pass to the winders.Recycle
Long cell
Spring 2001 ISAT 430 Dr. Ken Lewis 36review
Cell limits
Drying rate limitationsHow fast we can transfer heat into the filaments and mass out of the filaments.
How fast solvent can diffuse through the filament and across the surface
DMAcNu Dk
hDN and , • Is the limitation
The persistence of the solvent / gas boundary layer.
Spring 2001 ISAT 430 Dr. Ken Lewis 37review
Fiber Tenacities
Spring 2001 ISAT 430 Dr. Ken Lewis 38review
Fiber Elongation
Spring 2001 ISAT 430 Dr. Ken Lewis 39review
Polymer Processing
Processing Methods and OperationsChoice is dictated by the product desired and the quantity desired.
– Fiber, film, sheet, tube– Cup, bucket, car bumper, chair.
Fiber manufacture is different, it is continuous.Large quantities usually use extrusion or injection moldingSmaller quantities use compression molding or transfer molding
Spring 2001 ISAT 430 Dr. Ken Lewis 40review
ExtrusionExtrusion
Used mostly for thermoplastics Products
Piping, tubes, hosesWindow and door moldingsSheet and filmContinuous filament (spinning)Coated electrical wire and cable
ElementsA hopperA barrelA screw
Spring 2001 ISAT 430 Dr. Ken Lewis 41review
Extruder
The die is not part of the extruder
Usually ~ 1 – 6 in. dia.
Up to 60 rpm
Flight clearance of only 0.002 in.
Spring 2001 ISAT 430 Dr. Ken Lewis 42review
Screw details
Helical flights with space between them
Carries the polymer.Flight land is hardened and barely clears the barrel.The Pitch (distance the flight travels in one complete rotation) is usually about equal to the diameter.
pitchtan
DA
Spring 2001 ISAT 430 Dr. Ken Lewis 43review
Extruder detailsExtruder details
Understand melt flow in the extruderFlow forward occurs because of friction between the fluid and the screw flights.Axial flow (z – direction) provides the pumpingCross flow provides the mixing
Spring 2001 ISAT 430 Dr. Ken Lewis 44review
Extruder transport – back pressure.
This is the maximum possible output for an extruder. Conveyance of the polymer through
Smaller and smaller cross sectionsthe screen pack and die…
Creates a back pressure, Qbp.
2 20.5 sin cosdr cQ D Nd A A
3 2sin12c
bp
Dd A dpQ
dl
Spring 2001 ISAT 430 Dr. Ken Lewis 45review
net dr bpQ Q Q
3 22 2 sin
0.5 sin cos12
cnet c
p Dd AQ D Nd A A
L
Qnet is what finally comes out of the die!
Spring 2001 ISAT 430 Dr. Ken Lewis 46review
Net flowNet flow
Some parameters we control (design parameters) Some we can’t control (operating parameters)
3 22 2 sin
0.5 sin cos12
cnet c
p Dd AQ D Nd A A
L
Spring 2001 ISAT 430 Dr. Ken Lewis 47review
Design Parameters
These we control at conception time and are fixed thereafter.
Barrel diameterFlight or Helix angleChannel depth dc
Barrel length L
Spring 2001 ISAT 430 Dr. Ken Lewis 48review
Operating Parameters
These we can fiddle with to optimize the process.Rotational speed, NThe head pressure (change the die, slow the screw, change the temperature)The hidden variable … TEMPERATURE.The viscosity
– But only to the extent that the shear rate and temperature will allow!
Spring 2001 ISAT 430 Dr. Ken Lewis 49review
Extruder characteristicsExtruder characteristics
A given extruder will have known operating characteristics.
2 20.5 sin coscdrQ D Nd A A N
3 2sin
12c
bp
p Dd A pQ
L
or
e
pQ N
Spring 2001 ISAT 430 Dr. Ken Lewis 50review
Extruder Characteristics
Extrusion PressurePmax
Extruder CharacteristicCurve
Increasing N orincreasing viscosityE
xtruder Flow Rate
Flow up withIncreasing NDecreasing pIncreasing
Ignores non-Newtonian flow behavior
Ignores friction
e
pQ N
Spring 2001 ISAT 430 Dr. Ken Lewis 51review
Die Characteristics
Flow through a die generates back pressure For a simple cylindrical flow channel the flow rate is given
by the famous Hagen – Poiseuille equation:
4
128d
cl
p DQ
L
D = diameter
= melt viscosity [=]
Spring 2001 ISAT 430 Dr. Ken Lewis 52review
Die characteristics
So flow increases with p Look at the power of the die diameter! This gives the linear die characteristic curve. Note: some people write the above equation as:
4
128d
cl
p DQ
L
c sQ K p
Spring 2001 ISAT 430 Dr. Ken Lewis 53review
Extrusion PressurePmax
Extruder CharacteristicCurve
Die characteristiccurve
IncreassingL, n,decreasingD
Increasing N orincreasing viscosityE
xtruder Flow Rate
OperatingPoint
Extrusion Curve
Spring 2001 ISAT 430 Dr. Ken Lewis 54review
Go to page 78
Spring 2001 ISAT 430 Dr. Ken Lewis 55review
Stress StrainStress Strain
Curves obtained from tensile tests Information obtained
StrengthDuctilityToughnessElastic modulusStiffnessRange of workable properties
Spring 2001 ISAT 430 Dr. Ken Lewis 56review
Stress -- StrainStress -- Strain
Know a lot about the material just from a glance at the S – S curve
Know the elastic region Understand strain hardening
Grain boundary movement and blockage Understand the effect of temperature on the stress strain
properties.
Spring 2001 ISAT 430 Dr. Ken Lewis 57review
Know what’sGoing on here
Spring 2001 ISAT 430 Dr. Ken Lewis 58review
CompositesComposites
Know what a composite is. Know the benefits of a composite
Using different materials to affect the bulk propertiesWeightStrength…
Spring 2001 ISAT 430 Dr. Ken Lewis 59review
CompositesComposites
Know the function of the matrix Know the function of the reinforcement Know the various types of reinforcement and why you would
choose eachContinuousDiscontinuousparticulate
Spring 2001 ISAT 430 Dr. Ken Lewis 60review
CompositesComposites
Have a knowledge of the various fibers used in most composites
GlassAramidCarbon and graphite
– Know difference
Boron…
Spring 2001 ISAT 430 Dr. Ken Lewis 61review
CompositesComposites
Understand the effect on properties that occurs using different types of reinforcements
Understand the importance of the reinforcement / matrix interface / bond
Understand anisotropy in composites and why it occurs
Spring 2001 ISAT 430 Dr. Ken Lewis 62review
CompositesComposites
The rule of MixturesKnow that it uses the volume fractionKnow why
Other types of compositesSandwichesFoam cores
Spring 2001 ISAT 430 Dr. Ken Lewis 63review
FRPs…..MMCs…..& CMCs….FRPs…..MMCs…..& CMCs….
Know the differencesAdvantages and disadvantages of eachApplications for eachGeneral material used in each
Spring 2001 ISAT 430 Dr. Ken Lewis 64review
Composite ProcessingComposite Processing
Understand preforms Know the various ways of laying up a composite FRP’s
By hand Spray moldingFilament winding
– Mandrels– Helical, polar, braid
pultrusion
Spring 2001 ISAT 430 Dr. Ken Lewis 65review
Composite ProcessingComposite Processing
MMC’sCermetsCemented carbides
CMC’sMixingCompactionsintering
Spring 2001 ISAT 430 Dr. Ken Lewis 66review
Metal CastingMetal Casting
Know history (in general) Sand casting
Know the process steps Investment casting
Know the process steps Know the advantages of each
Spring 2001 ISAT 430 Dr. Ken Lewis 67review
Phase DiagramsPhase Diagrams
Understand phases Understand solutions and compounds
InterstitialSubstitutional
Understand how phase diagrams are made Know what they are good for
Spring 2001 ISAT 430 Dr. Ken Lewis 68review
Phase DiagramsPhase Diagrams
Know what phases are present Function of compositionFunction of temperature
Spring 2001 ISAT 430 Dr. Ken Lewis 69review
Phase DiagramsPhase Diagrams
Understand and be able to use the inverse lever rule
Ends of the line give the compositionRatios of the line tell how much of each
Spring 2001 ISAT 430 Dr. Ken Lewis 70review
Heat TreatmentHeat Treatment
Know the principal ways of heat treating Know why heat treating is done For the Fe – C system
Know where iron, steels, and cast irons existKnow what the various important phases of Fe—C are; ferrite, iron, iron, austenite, bainite, Pearlite, and
cementite
Spring 2001 ISAT 430 Dr. Ken Lewis 71review
Heat TreatmentHeat Treatment
AnnealingKnow the principals
MartensiteKnow what it is,How it is formedWhat is its structure
Spring 2001 ISAT 430 Dr. Ken Lewis 72review
Heat TreatmentHeat Treatment
Understand the TTT curvesTheir usesHow they work
QuenchingWhy quenchWhy different fluids are used
Spring 2001 ISAT 430 Dr. Ken Lewis 73review
Heat TreatmentHeat Treatment
Surface hardeningKnow the common proceduresKnow the different uses
Spring 2001 ISAT 430 Dr. Ken Lewis 74review
Extra CreditExtra Credit
Be able to derive the matter – energy relationship first proposed by Albert Einstein
Oh Yeah!!!!!!!!!!!!
E = ma2 E = mb2
E = mc2
Spring 2001 ISAT 430 Dr. Ken Lewis 75review
Spring 2001 ISAT 430 Dr. Ken Lewis 76review
Spring 2001 ISAT 430 Dr. Ken Lewis 77review
Spring 2001 ISAT 430 Dr. Ken Lewis 78review
Dies Dies
The die determines the extruded shape Two important factors
Die swellbambooing
Spring 2001 ISAT 430 Dr. Ken Lewis 79review
Effect of Die Swell
Knowing that die swell will occur is importantAfter the polymer leaves the die it is rapidly cooling and becoming fixed in shapeFor each polymer, if we know
– Viscosity– Temperature– Shear rate
We can account for the die swell in the shape of our die
Spring 2001 ISAT 430 Dr. Ken Lewis 80review
Die shapes
The dies The finished shapes
Spring 2001 ISAT 430 Dr. Ken Lewis 81review
Pipe extrusion
The central mandrel is supported by spider legs
These disrupt the flow of polymerThe polymer rejoins itself because
– the flow rate is low – The conditions haven’t
changed (temperature)To minimize the effect of the spiders, the mandrel is tapered.
Spring 2001 ISAT 430 Dr. Ken Lewis 82review
Tubing Die
Note the expansion to the spider legs and the reduction afterwards.
If the extrusion is too rapid, the spider leg openings will not heal.
Spring 2001 ISAT 430 Dr. Ken Lewis 83review
Wire Coating Die
The wire runs straight through Polymer comes in vertically into
a distribution cavity Used for wire diameters of 1
mm up to submarine cables with diameters of 150 mm.
Wire helps to draw the melt through the die
Coated wire speeds up to 10,000 ft/min
Spring 2001 ISAT 430 Dr. Ken Lewis 84review
Injection Molding
Polymer is heated, mixed, the then forced to flow into a mold cavity
Similar to extrusionHopper, barrel, screw
Screw rotation is the principal motion only in one part of the cycle
Mixes, compacts, plasticizes, and heatsPressures may reach 10 – 20 MPa (1450 – 2900 psi)
In the injecting stage, the screw is driven axially by a piston to generate the working pressure 150 – 250 MPa (21,756 – 36,260 psi)
Spring 2001 ISAT 430 Dr. Ken Lewis 85review
Injection Molding Sequences
(1) Close the mold (2) Inject the melt
(3) Retract the screw (4) Open mold – eject part
Spring 2001 ISAT 430 Dr. Ken Lewis 86review
Thermoforming
A flat thermoplastic sheet is softened and deformed into the desired shape.
Used for large items– Bathtubs– Skylights– Freezer interior walls– Bumpers
Two steps– Heating– Deforming / forming
Spring 2001 ISAT 430 Dr. Ken Lewis 87review
Three major types of thermoforming
Vacuum
»Pressure limit of 1 atmosphere
Pressure
»Higher allowable pressures
Mechanical
Spring 2001 ISAT 430 Dr. Ken Lewis 88
General plastic considerationsGeneral plastic considerations
Spring 2001 ISAT 430 Dr. Ken Lewis 89review
Product design Considerations In general
Strength– Plastics are not metals– Should not be used in strength or creep critical applications.
Impact resistance– Good, better than many ceramics
Service temperature– Much less than metals or ceramics
Degradation– Radiation– Oxygen or ozone– Solvents
Corrosion resistance– Better than metals
Spring 2001 ISAT 430 Dr. Ken Lewis 90review
Extrusion Considerations
Desirable product traitsWall thickness should be uniformHollow sections seriously complicate the extrusion processCorners
– Avoid as they cause uneven polymer flow and are stress concentrators
Spring 2001 ISAT 430 Dr. Ken Lewis 91
Forming and ShapingForming and Shaping
Spring 2001 ISAT 430 Dr. Ken Lewis 92review
Forming and ShapingForming and Shaping
Forming – changing the shape of an existing solid body
Shaping – usually is creating a desired shape by casting or molding
Spring 2001 ISAT 430 Dr. Ken Lewis 93review
FormingForming Rolling flat
Plate, sheet, and foilGood surface finishHigh capital
Rolling shapedStructural shapes, bar, I – beams, t – beamsShaped rolls, high capital
ForgingProduction of discrete parts with a set of dies.Material is stampedUsually at elevated temperaturesSome finishing is neededHigh capital
Spring 2001 ISAT 430 Dr. Ken Lewis 94review
FormingForming Extrusion
Long lengthsConstant cross section (solid or hollow)Not real high costs
DrawingLong rod and wire of some cross sectionSmaller cross section than extrusionGood finishModerate costs
Spring 2001 ISAT 430 Dr. Ken Lewis 95review
FormingForming Sheet metal forming
Variety of thin shapes and sizesModerate to high costsCan be complex
Spring 2001 ISAT 430 Dr. Ken Lewis 96review
Shaping Shaping Powder metallurgy
Compact SinterUsed to make pellets for diamond shots (except no sintering)
Plastics and compositesInvolves molding, shaping, extruding, spinning
CeramicsSimilar to powder metallurgyShaping and sintering (firing)
Spring 2001 ISAT 430 Dr. Ken Lewis 97review
Rolling Rolling is a process to reduce the thickness of a long workpiece
by compressive forces applied through a set of rolls.First developed in the late 1500’s
A steel ingot is cast into a rectangular mold Placed in a furnace while just solidified and held for many hours
(36) until the temperature is uniform. This process is called soaking
Furnaces are called soaking pits. Implies that properties will be uniform throughout the ingot and
process that way. The rolling temperature for steel is about 1200°C From here the ingot goes to the rolling mill.
Spring 2001 ISAT 430 Dr. Ken Lewis 98review
Rolling Starting material depends upon what you are producing.
Bloom– Square cross section 6 x 6 in or larger
Slab– Rolled from an ingot or a bloom– Rectangular cross section 10 x 1.5 in or more
Billet– Rolled from a bloom– Square cross section 1.5 x 1.5 in or larger.
Spring 2001 ISAT 430 Dr. Ken Lewis 99review
Spring 2001 ISAT 430 Dr. Ken Lewis 100
review
Spring 2001 ISAT 430 Dr. Ken Lewis 101
review
Metal Behavior in formingMetal Behavior in forming
As metal deforms, its strength increases (strain hardening) The strain rate is important
Higher the rate, the higher the average metal stressThe higher the temperature, the less the effect
Spring 2001 ISAT 430 Dr. Ken Lewis 102
review
Working temperaturesWorking temperatures
Cold working – room temperatureAdvantages
– Accuracy, good surface, some strain hardening, no heating
Disadvantages– High force and power needed, part must be clean, crazing or
stress fracture is a concern
Spring 2001 ISAT 430 Dr. Ken Lewis 103
review
Working temperaturesWorking temperatures
Warm working – 0.3 – 0.5 Tm
Advantages– Low force and power, material is more ductile, annealing may
not be needed
Disadvantages– Surface finish not as good, energy needed to heat
Spring 2001 ISAT 430 Dr. Ken Lewis 104
review
Working temperaturesWorking temperatures
Hot working – 0.5 – 0.7 Tm
Advantages– Low force and power, brittle material may be worked, properties
are isotropic
Disadvantages– Localized melting (maybe), scale formation, lower dimensional
stability, poorer surface, shorter tool life
Spring 2001 ISAT 430 Dr. Ken Lewis 105
review
Ring Rolling
Ring is placed between two rolls, of which one is driven
Volume of the ring is constant to the diameter increases during the process
Ring blanksCut from a plateCutting a thick walled pipe.
Spring 2001 ISAT 430 Dr. Ken Lewis 106
review
Thread Rolling
No loss in material Good strength (cold working) Surface finish is very good Process induces residual
compressive stresses on surface which improves fatigue life.
Spring 2001 ISAT 430 Dr. Ken Lewis 107
review
Thread properties Machining cuts through the
grains Rolling compresses them
Spring 2001 ISAT 430 Dr. Ken Lewis 108
JoiningJoining
Spring 2001 ISAT 430 Dr. Ken Lewis 109
review
Joining Technologies Joining is a many splendored thing.
Welding– Arc or melting– Resistance or other
Soldering & brazingMechanical fastening (bolts & nuts).Seaming and crimpingAdhesive bonding
All are important for different reasons.
Spring 2001 ISAT 430 Dr. Ken Lewis 110
review
Fusion Welding Oxyfuel gas welding
Uses a fuel gas and oxygen to produce the heat. Arc welding
Heating is accomplished by an electric arc Resistance welding
Heating is accomplished by the passage of an electric current Others
Electron beam and laser welding
Spring 2001 ISAT 430 Dr. Ken Lewis 111
review
Oxyfuel weldingOxyfuel welding
Most common fuel is acetylene, C2H2
Flame temperature can reach 3,300°C Flame heats the material
Low efficiencies .1 -- .3 Must control the fuel/oxygen mixture to protect the workpiece
CheapGood for repair jobsLow volume stuff
Spring 2001 ISAT 430 Dr. Ken Lewis 112
review
Fuel Temperatures and Heats.
Temperature Heat of Combustion
Fuel °F °C Btu/ft3 MJ/m3
Acetylene (C2H2) 5589 3087 1470 54.8
MAPP1 (C3H4) 5301 2927 5460 91.7
Hydrogen (H2) 4820 2660 325 12.1
Propylene (C3H6) 5250 2900 2400 89.4
Propane (C3H8) 4579 2526 2498 93.1
Natural Gas 4600 2538 1000 37.3
1) Methylacetylene propadiene
Just know that there are different fuels and obtainable temperatures.
Spring 2001 ISAT 430 Dr. Ken Lewis 113
review
Arc Welding
Spring 2001 ISAT 430 Dr. Ken Lewis 114
review
Arc Welding A fusion process wherein the coalescence of the metals is
achieved from the heat of an electric arc formed between an electrode and the work.
An electric arc is a discharge of electric current across a gap I a circuit.It is sustained by the presence of a thermally ionized column of gas (called a plasma).
Temperatures up to 30,000°C (54,000°F) a generated
Spring 2001 ISAT 430 Dr. Ken Lewis 115
review
Shielded Metal Arc Welding
Spring 2001 ISAT 430 Dr. Ken Lewis 116
review
Gas Metal Arc Welding
Spring 2001 ISAT 430 Dr. Ken Lewis 117
review
Gas Metal Arc Welding Originally called “MIG” welding (for metal inert gas) Used widely in factory fabrication
Better metal usage (no stubs)– Sticks or filler
High deposition ratesNo slag
Spring 2001 ISAT 430 Dr. Ken Lewis 118
review
Non-consumable Electrodes Gas Tungsten Arc Welding Known as “TIG” (tungsten inert gas) welding The electrode is W (tungsten)
Tm = 6170°F (3410°C)
Actually it is slowly consumed Shielding gases include Ar, He or a mixture
Spring 2001 ISAT 430 Dr. Ken Lewis 119
review
Gas Tungsten Arc Welding (TIG)
Spring 2001 ISAT 430 Dr. Ken Lewis 120
Resistance weldingResistance welding
Spring 2001 ISAT 430 Dr. Ken Lewis 121
review
Resistance Welding In order to obtain a strong bond
in the weld nugget pressure is applied until the current is turned off.
Strength depends on the initial surface condition
SmoothnessCleanlinessPresence of uniform thin oxides is not critical
Spring 2001 ISAT 430 Dr. Ken Lewis 122
review
Resistance Welding The reason that the current is
so high is because the R is usually so low ~~ 0.0001 ohm
2Q I Rt
Where: I = current (amperes) R = resistance (ohms) T = time of current
(seconds) Q = heat in Joules
Spring 2001 ISAT 430 Dr. Ken Lewis 123
review
Resistance weldingResistance welding
Pay attention to the energy problemHow much heat is used and how much is dissipated.
Understand the current – pressure cycle
Spring 2001 ISAT 430 Dr. Ken Lewis 124
review
Brazing and Soldering
Spring 2001 ISAT 430 Dr. Ken Lewis 125
review
Brazing A process which a filler metal is placed at or between the
faying surfaces, the temperature is raised high enough to melt the filler metal but not the base metal.
The molten metal fills the spaces by capillary attraction. Two types
Ordinary brazing (above)Braze welding (similar to oxy-welding)
Faying surfaces = the surfaces to be joined.
Spring 2001 ISAT 430 Dr. Ken Lewis 126
review
Brazing Capabilities Typical joints
Dissimilar metals can be assembled with good joint strength.Shear strength can reach 120 ksi (800 MPa) using alloys containing silver.
ConcernsClearance too small, metal will not penetrateClearance to big, insufficient capillary attraction.
Spring 2001 ISAT 430 Dr. Ken Lewis 127
review
Soldering
Spring 2001 ISAT 430 Dr. Ken Lewis 128
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Soldering Used extensively in the electronics industry Soldering temperatures are low Not used in load bearing members Butt joints rarely made If strength is needed, the joint may be mechanically
interlocked
Spring 2001 ISAT 430 Dr. Ken Lewis 129
review
Solder joints Typical joints Note that the starred
examples are mechanically joined first.
Copper and silver are easy
Fe, Al hard to solder because of their tough oxide films.
Spring 2001 ISAT 430 Dr. Ken Lewis 130
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Adhesive Joints
Spring 2001 ISAT 430 Dr. Ken Lewis 131
review
Adhesive Bonding Joining process whereby a filler material is used to hold
two closely spaced parts together by surface attachment Filler material (adhesive)
Usually non-metalUsually a polymer
CuringProcess (usually chemical) whereby the adhesive physical properties are changed from a liquid to a solid.
Spring 2001 ISAT 430 Dr. Ken Lewis 132
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General Properties of some adhesives Acrylic
Thermoplastic, quick setting, tough bond at r.t.Tennis racquets, metal parts
EpoxyThermoset, strongest engineering adhesiveMetal, ceramic, rigid plastic parts
CyanoacrylateThermoplastic, touch“Crazy Glue”
Hot MeltThermoplastic, quick setting, easy to applyBonds most anything –Packaging, book binding, metal can joints
Spring 2001 ISAT 430 Dr. Ken Lewis 133
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General Properties of some adhesives Phenolic
Thermoset, strong, brittleBrake lining, clutch pads, honeycomb structures
SiliconeThermoset, slow curing, flexible, rubber likeGaskets sealants
Water base AnimalVegetableRubbers
Inexpensive, non-toxicWood, paper, fabricLeather, dry seal envelopes
Spring 2001 ISAT 430 Dr. Ken Lewis 134
review
Joint Design Usually not as strong as welding or brazing joints Design principles
Maximize joint contact areaJoints are strongest in shear and or tension so joints should be designed to accommodate thisJoints are weakest in cleavage or peel. Avoid these stresses
Spring 2001 ISAT 430 Dr. Ken Lewis 135
review
Adhesive bonding Disadvantages Joints are not as strong Adhesive must be compatible with materials being joined Service temperatures are limited Cleanliness and surface preparation prior to adhesive
application are important Curing times can impose a limit on production rates Inspection of the bonded joint is limited.