Materials Processing Fundamentals

Materials Processing Fundamentals provides researchers and industry professionals with complete guidance on the synthesis, analysis, design, monitoring, and control of metals, materials, and metallurgical processes and phenomena. Along with the fundamentals, it covers modeling of diverse phenomena in processes involving iron, steel, non-ferrous metals, and composites. It also goes on to examine second phase particles in metals, novel sensors for hostile-environment materials processes, online sampling and analysis techniques, and models for real-time process control and quality monitoring systems.

Table of Contents:
Preface  xi About the Editors xiii Process Metallurgy of Steel Evolution of Inclusions in Ti-Bearing Ultra-Low Carbon Steel during RH Refining Process 3 W. Yang, S. Li, Y. Li, X. Wang , L. Zhang, X. Liu, and Q. Shan Mass Action Concentration Model of CaO-MgO-FeO-Al2O3-SiO2 Slag Systems and Its Application to the Formation Mechanism of MgO?EAl2O3 Spinel Type Inclusion in Casing Steel 17 H. Tang, J. Li, and C. Ji Theory Analysis of Steel Cleanliness Control during Electroslag Remelting 31 C. Shi, X. Chen, Y. Luo, and H. Guo Formation and Drop of Metal Droplets in Slag Bath of Electroslag Remelting Processes 39 B. Li, R. Li, and B. Wang Study on Flow-Reaction Desulfurization of RH by Physical Experiment 45 H. Yang, J. Li, Z. Gao, F. Song, and W. Yang Modeling of Transient Fluid Flow, Solidification Processes and Bubble Transport in Continuous Casting Mold 53 Z. Liu, B. Li, and M. Jiang Numerical Analysis of Coupled Fluid Flow, Heat Transfer and Solidification in Ultra-thick Slab Continuous Casting Mold 63 X. Xie, D. Chen, M. Long, L. Zhang, J. Shen, and Y. Ma Measurement and Observation of the Filling Process of Steel Castings 73 J. Kang, G. Nie, H. Long, R. You, X. Hao, T. Wang, and C. Zheng Physical Metallurgy of Metals Influence of Load Paths and Bake Hardening Conditions on the Mechanical Properties of Dual Phase Steel 83 M. Asadi, and H. Palkowski The Effect of Phosphorus and Sulfur on the Crack Susceptibility of Continuous Casting Steel 89 W. Wang, S. Luo, Z. Cai, and M. Zhu Mathematical Modeling of Heat Transfer and Thermal Behaviour of Tool Steel H13 in Molten Aluminum Alloy A380 99 T. Ding, J. Su, H. Hu, X. Nie, and R. Barron Optimization Investigation on the Soft Reduction Parameters of Medium Carbon Microalloy Steel 109 C. Xiao, J. Zhang, Y. Luo, L. Wu, and S. Wang Effect of Microstructure Evolution on Hot Cracks of HSLA Steel during Hot Charge Process 117 J. Li, Q. Wang, Y. Lu, B. Wang, and S. Zhang A New Method for Ultrasonic Treatment on the Melt of Steel 125 G. Nie, J. Kang, Y. Hu, R. You, J. Ma, Y. Hu, and T. Huang Metallurgy of Non-Ferrous Metals Corrosion Resistance of Zn-Sn Alloys Horizontally Directionally Solidified 135 M. Parra, C. Mendez, C. Schvezov, and A. Ares High Speed Twin Roll Casting of Al-33 wt. % Cu Strips with Layered Structure-Inspired by Mathematical Modeling 143 S. Sahoo, and S. Ghosh Finite Element Modeling of Material Removal Rate in Powder Mixed Electrical Discharge Machining of Al-SiC Metal Matrix Composites 151 U. Vishwakarma, A. Dvivedi, and P. Kumar Multicriteria Optimization of Rotary Tool Electric Discharge Machining on Metal Matrix Composite 159 M. Cheema, A. Dvivedi, A. Sharma, and S. Biswas Characterization of Pore Formation in A356 Alloy with Different Oxide Levels during Directional Solidification 169 H. Liao, W. Song, and Q. Wang Process Metallurgy of Non-Ferrous Metals TMAH Wet Etching of Silicon Micro- and Nano-Fins for Selective Sidewall Epitaxy of III-Nitride Semiconductors 185 L. Liu, D. Myasishchev, V. Kuryatkov, S. Nikishin, H. Harris, and M. Holtz Purification of Indium by Vacuum Distillation 193 Y. Deng, B. Yang, D. Li, B. Xu, and H. Xiong Investigating Current Efficiency of Aluminum Electrolysis in NaF-KF-AlF3 System 199 H. Ma, J. Xue, J. Li, and Y. Zhang Recirculation of Materials and Environments Effects of Ca and Na Containing Additives on WO3 Content in Sheelite Concentrates after Floatation Separation Process 209 J. Zhu, J. Xue, and K. Liu Copper Removal from Molybdenite by Sulfidation-Leaching Process 217 R. Padilla, H. Letelier, and M. Ruiz Physical Chemistry of Roasting and Leaching Reactions for Chromium Chemical Manufacturing and Its Impact on Environment - A Review 225 S. Sanchez-Segado, and A. Jha Electrophoretic Classification of Ultrafine Silica Particles in Dilute Aqueous Suspension 237 R. Corpuz, and L. De Juan QEMSCAN Analysis of Wadi-Shatti Iron Ore (Libya) 243 A. Tajouri, P. Taylor, C. Anderson, and M. Abozbeda Removal of Arsenic from Enargite Rich Copper Concentrates 249 M. Ruiz, R. Bello, and R. Padilla Effect of Calcium on the Solubility of Zinc Oxide in the Sodium Hydroxide Solution 257 C. Ai-Liang, X. Dong, C. Xing-Yu, L. Xu-Heng, and Z. Wei-Xiong Poster Session Luminescence Enhancement of Sky-blue ZnS:Tm Phosphor by Promoter Doping 267 S. Yang, and Y. Ling Effect of Thermal History on the Hot Ductility and Fracture Mechanisms of Low Carbon Peritectic Steel 273 Z. Dong, D. Chen, X. Zhang, and M. Long Influence of Coriolis Force on the Flow Field of Combined Top and Bottom Blown Converter 281 H. Tang, T. Zhang, J. Li, and Y. Chen Motion Characteristics of a Powder Particle through the Injection Device with Slats at Finite Reynolds Number 291 Z. Cheng, and M. Zhu Study on Internal Cracks on Continuous Casting Slabs of AH36 Steel 305 S. Yang, and L. Zhang Author Index 315 Subject Index 317

About the Author :
Lifeng Zhang currently is a professor and the dean of the School of Metallurgical and Ecological Engineering at University of Science and Technology Beijing. Lifeng received his Ph.D. degree from University of Science and Technology Beijing in 1998 and has 15 years teaching and research work at different universities – University of Science and Technology Beijing, Missouri University of Science and Technology, Norwegian University of Science and Technology, University of Illinois at Urbana-Champaign, Technical University of Clausthal and Tohoku University. Lifeng has compound backgrounds in primary production, refining, casting, and recycling of metals; recycling of electronic wastes and solar grade silicon; and process modeling for metallurgical processes. Lifeng has published over 250 papers and gave over 170 presentations at meetings and conferences. He is a Key Reader (Member of Board of Review) for four journals and a reviewer for over 30 journals. Lifeng is a member of TMS, AIST and ISIJ. He has received several best paper awards from TMS and AIST. Antoine Allanore is Assistant Professor of Metallurgy at the Massachusetts Institute of Technology (Cambridge, Massachusetts), in the Department of Materials Science and Engineering where he currently holds the Thomas B. King Chair. He earned a chemical engineering degree from the Ecole Nationale Superieure des Industries Chimiques de Nancy and a M.Sc. and Ph.D. in chemical engineering from the Institut National Polytechnique de Lorraine. Prior joining MIT, he worked as a research engineer at ArcelorMittal R&D on the development of new electrolytic processes for primary steel production. Dr. Allanore was a TMS Extraction and Processing Division Young Leader Professional Development Award winner in 2011 and co-recipient of the Vittorio de Nora Prize awarded at TMS 2012. Cong Wang is Senior Research Engineer of Saint-Gobain Innovative Materials R&D. Prior to joining Saint-Gobain, he worked at the Alcoa Technical Center. He obtained his Ph.D. from the Carnegie Mellon University; M.S. from the Institute of Metal Research, Chinese Academy of Sciences; and B.S. from Northeastern University with distinctions, respectively. His specialties are in materials processing, micro-structure characterization, mechanical testing, and electrochemistry. James A. Yurko is a Principal Technologist with Materion Brush Beryllium and Composites (Elmore, Ohio), the global leader in beryllium and non-beryllium based metal matrix composites. Dr. Yurko's primary technical focus is in the area of bulk metallic glass processing. Prior to joining Materion, he cofounded Electrolytic Research Corporation (ERC) LLC with Prof. Don Sadoway of MIT to commercialize molten oxide electrolysis (MOE) technology. Before working with ERC, Jim was the R&D team leader and staff metallurgist of BuhlerPrince, Inc. where he was responsible for commercializing the Semi-Solid Rheocasting (SSR) process and various die casting development projects of aluminum, magnesium, and bulk-metallic glass alloys. Dr. Yurko received a Ph.D. in metallurgy from the Massachusetts Institute of Technology and a B.S.E. in materials science and engineering from the University of Michigan. He is currently a member of TMS and ASM and serves on the University of Michigan Materials Science and Engineering External Advisory Board. In 2010, Dr. Yurko was selected as the TMS EPD Young Leader Professional Development Award winner and was a co-recipient of the Vittorio de Nora Prize awarded at TMS 2012. Justin Crapps attended Mississippi State University, studying Mechanical Engineering. As an undergraduate, Justin was very involved in leadership and extracurricular activities with several organizations including the student chapter of the American Society of Mechanical Engineers (ASME), Engineering Student Council, and Bulldog Toastmasters. Justin also participated in the Cooperative education and professional internship programs, spending three semesters working at Georgia Pacific Paper in Monticello, MS and three summers working at Eaton Aerospace in Jackson, Mississippi. In 2005, Justin was awarded the prestigious ASME Charles T. Main silver medal for leadership and service to his student section over a period of more than one year. After in the Ph.D. program at Mississippi State University. During graduate school, Justin's research focused on using finite element modeling for process simulation and developing a combined roughness and plasticity induced closure modified strip-yield model to simulate fatigue crack growth. After graduate school, Justin accepted a postdoctoral appointment at Los Alamos National Laboratory where he is working on projects focused on manufacturing process development for bonding cladding to nuclear fuel, reprocessing fuel through a casting process, multiphysics models for nuclear fuel performance, and development of testing methodologies and specimens for nuclear fuel-cladding bond strength measurement.

Review :
“The book is a good addition in the libraries of Institutes of Higher Learning, Research Institutes and development divisions of steel and nonferrous plants.”  (Scientific.net, 1 July 2013)