Volume 22B describes the methods, models, and tools used to simulate manufacturing processes and predict the microstructure and mechanical properties of metals and metal parts.

ASM Handbook, Volume 22B: 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 contents illustrates the depth and breadth of the processes addressed. This area of engineering has been advancing rapidly, accruing the benefits of reduced manufacturing costs and improved component design. 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 practitioner, or the student or engineer beginning their quest for information.

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
Stress-Relief Simulation
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