Professional Documents
Culture Documents
www.asminternational.org
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contents
17
ON THE COVER:
Montral skyline as seen from the
Parc Jean-Drapeau.
Courtesy of Tourisme Montral.
www.tourisme-montreal.org.
20
Performance Advances in
Copper-Nickel-Tin Spinodal Alloys
26
Anthony F. Giamei
An industry pioneer shares a historical overview of the early
days of single crystal superalloy development.
32
DEPARTMENTS
2
4
4
6
Editorial
Market Spotlight
Feedback
Of Material Interest
8 Industry News
8 Metals/Polymers/Ceramics
10 Testing/Characterization
12 Emerging Technology
13 Process Technology
14 Energy Trends
15 Surface Engineering
80 Products/Literature
8 1 Classifieds
8 1 Advertisers Index
8 1 Special Advertising Section
82 Editorial Preview
83 Pastimes
84 Stress Relief
36
ASM ANNIVERSARY
41
HTProDebut Issue!
71
ASM News
The official newsletter of the ASM Heat Treating Society (HTS). This
quarterly supplement focuses on heat treating technology, processes,
materials, and equipment, along with Heat Treating Society news
and initiatives.
ASM International serves materials professionals, nontechnical personnel, and managers worldwide by providing high-quality materials
information, education and training, networking opportunities, and professional development resources in cost-effective and user-friendly
formats. ASM is where materials users, producers, and manufacturers converge to do business.
Advanced Materials & Processes (ISSN 0882-7958, USPS 762080) is published monthly, except bimonthly November/December, by ASM
International, 9639 Kinsman Road, Materials Park, OH 44073-0002; tel: 440/338-5151; fax: 440/338-4634. Periodicals postage paid at Novelty, Ohio, and additional mailing offices. Vol. 171, No. 9, September 2013. Copyright 2013 by ASM International. All rights reserved.
Distributed at no charge to ASM members in the United States, Canada, and Mexico. International members can pay a $30 per year surcharge to receive printed issues. Subscriptions: $461. Single copies: $45. POSTMASTER: Send 3579 forms to ASM International, Materials
Park, OH 44073-0002.
Change of address: Request for change should include old address of the subscriber. Missing numbers due to change of address cannot
be replaced. Claims for nondelivery must be made within 60 days of issue. Canada Post Publications Mail Agreement No. 40732105. Return
undeliverable Canadian addresses to: 700 Dowd Ave., Elizabeth, NJ 07201. Printed by Publishers Press Inc., Shepherdsville, Ky.
materials witness
9639 Kinsman Road
Materials Park, OH 44073
Tel: 440/338-5151 Fax: 440/338-4634
Between 2000 and 2008, the number of engineering doctorates awarded in China
more than tripled to 15,000, according to the NSF. This compares to 8100 in the U.S.,
of which only 3200 went to U.S. citizens and permanent residents. I recently attended
a Center for Heat Treating Excellence meeting at Worcester Polytechnic Institute and
experienced this phenomenon firsthand. Imagine an audience of mostly American,
mid-career men from companies such as Oshkosh, Timken, and Caterpillar listening
to research presentations from young Chinese women and men working on graduate
degrees in the U.S. and you will have a sense of what the Innovation Deficit letter is
getting at. ASM commends every nations efforts toward technological advancement,
but one cant help but wonder what the future holds for the U.S. if its government
fails to invest in R&D and higher education. If you have an opinion on the matter, wed
like to hear it.
frances.richards@asminternational.org
2
EDITORIAL COMMITTEE
Ellen Cerreta, Chair, Los Alamos National Lab
Mario Epler, Vice Chair, Carpenter Technology Corp.
Scott Olig, Past Chair, Vision Point Systems
David Furrer, Board Liaison
Laura Addessio, PCC Structurals Inc.
Arvind Agarwal, Florida International University
David Bowden, The Boeing Co.
Adam Farrow, Los Alamos National Lab
Jaret Frafjord, IMR KHA Portland
Jacob Goldsmith, University of Michigan
Alan Luo, General Motors
Thomas Murphy, Hoeganaes Corp.
Roger Narayan, UNC-NCSU
Nina Pang, Boston University
Somuri Prassad, Sandia National Laboratories
Fei Ren, Oak Ridge National Laboratory
Satyam Sahay, John Deere Technology Center India
Jaimie Tiley, U.S. Air Force Research Lab
Cong Wang, Saint Gobain High Performance
Materials
Yu-Ping Yang, Edison Welding Institute
market
spotlight
feedback
of material
interest
Suture anchor offers knotless
fixation in rotator cuff repair
Mitek Sports Medicine, Chicago, part of the DePuy Synthes Companies of Johnson & Johnson,
launched the Healix Advance Knotless Anchor, a new suture anchor designed to provide optimal knotless fixation for rotator cuff repair. The device features dual-thread technology to maximize fixation
and pull-out strength in both cancellous and cortical bone, and a multi-thread design that enables
fast insertion into bone. The device eliminates the need for arthroscopic knot tying and the anHealix Advance
chors are available in three sizes, 4.75, 5.5, and 6.5 mm. They are made of either Biocryl Rapide,
Knotless anchor is
a suture anchor that
a biocomposite material that allows absorption and boney ingrowth at the implant
provides optimal
site, or radiolucent polyetheretherketone (PEEK), a biocompatible thermoplastic
knotless fixation for
material. The anchors hold up to six strands of the companys Orthocord high
rotator cuff repair.
strength orthopedic suture or two strands of high strength tape-suture. The knotless anchor requires no new instrumentation. www.depuy.com.
Berg | C.F. Mller architects are working in partnership with DinellJohansson and consultants Tyrns, all in Sweden, on their entry for HSB
Stockholms architectural competition 2023. The team designed a 34story residential building, which will be built over a wooden construction with a concrete core. Wood production has no waste products, binds
CO2, and has low weight but is very strong compared to its lightness.
Wood secures a proper indoor climate, has great acoustics, helps regulate
inside temperature, and can be exposed without being covered with plaster or other costly materials. In the design, pillars and beams are made of
solid woodand inside the apartments, all walls, ceilings, and window
frames are also made of wood, which will be visible from the exterior
through the windows.
Social and environmental sustainability is also integrated into the
Berg | C.F. Mller in partnership with
project. Each apartment will feature an energy-saving, glass-covered
DinellJohansson and consultants Tyrns will
veranda, while the building itself will be powered by rooftop solar panenter this 34-story wooden building in the HSB
Stockholm architectural competition 2023.
els. In addition, a new community center will house a market square, fitness center, and bicycle storage room. A communal winter garden will
provide residents with an opportunity to have allotment gardens. www.cfmoller.com.
industry
news
briefs
iemens Metals Technologies,
Scientists and engineers from the Materials and Surface Science Institute (MSSI) at the
University of Limerick, Ireland, invented a new metal that will make medical devices inside
the body more visible under x-ray. Many medical devices, such as stents and valves, are
placed in the body through minimally invasive surgical procedures that are usually performed with the help of medical imaging such as x-ray fluoroscopy. Current materials used
to make these devices do not show up well under x-ray.
An ideal solution is a device that is fully visible under x-ray, explains Syed Tofail, lead
scientist, but has to be based on approved alloys for medical devices. Many companies use
gold or platinum to modify existing alloys, which improve x-ray visibility but are expensive.
We identified a number of alloying elements that will make these devices as visible as those
where platinum has been added to enhance the visibility, but at a significantly reduced cost.
Tests on a prototype wire of the new alloy show potential for use in a number of products.
For more information: Syed Tofail, +353/61-234132, tofail.syed@ul.ie, www.ul.ie.
Royal DSM, the Netherlands, is reducing the weight of the Peugeot 508 with the use of
oil sumps injection molded in Akulon Ultraflow polyamide 6. The grade used for the application is Akulon Ultraflow K-FHG7, a 35% glass reinforced, heat stabilized polyamide 6
with good flow properties. It offers significant processing advantages compared to standard polyamide 6 products, while maintaining the required mechanical properties.
The French Tier One supplier Steep Plastique, Saint-Maurice-de-Beynost, developed a
sump that is 60% lighter than the metal version it
replaces. Due to the use of sophisticated computer
simulation software developed by Steep, the sump
passes demanding application tests, including a
severe curb impact test, stone impact test, and engine drop test. www.dsm.com/automotive, www.
akulon.com, www.steep-plastique.com.
DSMs Akulon Ultraflow used by Steep for oil sumps
of the new Peugeot 508 engine. Courtesy of
DSM Engineering Plastics.
A team of researchers from the University of Rostock, Germany, developed a new way
to rapidly produce high strength metallic alloys, at a lower cost and using less energy than
before. The research reports on the first spark plasma sintering (SPS) system with an integrated gas quenching mechanism, capable of alternating phase compositions and retaining
the smallest grain features inside structured metallic alloys.
Led by Eberhard Burkel, professor of physics of new materials, researchers demonstrated that rapidly cooling a material directly after SPS fabrication can produce enhanced
hardness, strength, and ductility. The new rapid
Abakan Inc., Miami, received the Steel
cooling SPS system is based on a commercially availExcellence Award from American Metal
able design, modified to include a series of gas inlet
Market (AMM) under the Best Process
nozzles. Nitrogen gas is then blasted into the chamInnovation category for its CermaClad highber at high speeds, rapidly cooling the material.
speed large-area metal cladding technology.
Grade 5 Titanium (Ti-6Al-4V) was produced at difThe technology uses a high intensity plasma
arc lamp to rapidly melt, fuse, and
ferent cooling rates. The most-rapidly cooled alloy
metallurgically bond corrosion-resistant and
was found to be up to 12% harder than the naturallywear-resistant materials to metal substrates,
cooled alloy, and with an improved ductility up to
including pipes. The technology addresses an
343%. For more information: Eberhard Burkel,
increasing demand for corrosion resistant
+49-0-381-498/6860, eberhard.burkel@uni-rosalloy (CRA) clad pipes. www.abakaninc.com.
tock.de, www.uni-rostock.de/en.
Contract to produce
composite aft fan cases
ATK, Arlington, Va., received a contract valued at more than $50 million
from Rolls-Royce plc, UK, to produce aft
fan composite cases for the new Trent
XWB-97, the sole engine available to
power the Airbus A350-1000 aircraft
variant. ATKs automated composites
processing technology reduces fabrication costs and improves quality compared
to other methods, according to company
sources. The first ATK-fabricated Trent
XWB-97 aft fan case is scheduled for delivery in late 2013. Support of the RollsRoyce design effort and initial production
of the XWB-97 aft fan cases will begin
immediately at ATKs Aircraft Commercial Center of Excellence (ACCE) facility
in Clearfield, Utah. www.atk.com,
www.rolls-royce.com.
The Rolls-Royce
Trent XWB engine
aft fan cases to be
used on Airbus A3501000 aircraft are produced by ATK.
Courtesy of PRNewsFoto/ATK.
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
industry
news
briefs
The ZEISS
Xradia 810
Ultra,
introduced at
the 2013
Microscopy and
Microanalysis
conference,
held August 4-8
in Indianapolis.
10
TESTING CHARACTERIZATION
Neutron diffraction technique
could keep train wheels rolling longer
hydrogen diffuses through metals. On one side, the membrane is charged with hydrogen produced cathodically in an
aqueous solution. The electrochemical charging is simple
and efficient because a relatively low cathode current density, in the range of miliamperes per cm2, can correspond to
a pressure of gaseous hydrogen in the range of a few tens of
thousands of atmospheres.
Zakroczymskis team constructed a
membrane that allows it to electrochemically insert hydrogen into highly reactive
metals and also to electrochemically detect it. The membrane has a multilayer
structure. The main layer, a structural
basis of the membrane, is made of iron,
which was selected because hydrogen
atoms move exceptionally fast in iron
crystal lattices; their rate of diffusion at
room temperature is comparable to that of
hydrogen ions in aqueous solutions.
Therefore, the iron layer has a relatively
small effect on the hydrogen permeation
rate through the entire membrane.
Both sides of the iron membrane are
coated electrochemically with a thin palladium film and then with magnesium
and, for protection purposes, again with
palladium by using PVD methods. Both
elements were deposited in cooperation
with Wen-Ta Tsais laboratory from National Cheng Kung University in Tainan,
Taiwan.
The measured rate of hydrogen permeation through a multilayer membrane
depends on hydrogen diffusion in each
membrane layer. Because hydrogen diffusion in iron and palladium is a well known
process, the diffusion coefficient of hydrogen in the magnesium layer can be deduced if we know the thickness of each
layer, explains Zakroczymski. For more information: Tadeusz Zakroczymski, tzakroczymski@ichf.edu.pl, www.ichf.edu.pl.
11
industry
news
briefs
A research team at University of
California, Berkeley, led by Ali
Javey, associate professor of
electrical engineering and
computer sciences, reportedly
created the first user-interactive
sensor network on flexible plastic.
The new electronic skin, or e-skin,
responds to touch by instantly
lighting up. In addition to giving
robots a finer sense of touch,
researchers believe the new
technology could be used to create
things like wallpapers that double
as touchscreen displays and
dashboard laminates that allow
drivers to adjust electronic controls
with the wave of a hand.
www.berkeley.edu.
EMERGING TECHNOLOGY
Shock waves could lead to new materials
A team of researchers from the National Institute of Standards and Technology (NIST),
Gaithersburg, Md., and Argonne National Laboratory, Lemont, Ill., reports possible evidence
for a new category of solids, things that are not pure glasses, crystals, or even quasicrystals.
The team analyzed a solid alloy discovered in small discrete patches of a rapidly cooled
mixture of aluminum, iron, and silicon. The material appears to have none of the extended
ordering of atoms found in crystals, which would make it a glass, except that it has a very
defined composition and grows outward from seeds.
The new material, which the research team has provisionally dubbed a q-glass, can be
shown by x-ray diffraction to have neither rotational nor translational symmetry, just like
a glass, says Lyle Levine at NIST. However, the atomic arrangement apparently is not random. The q-glass seems to have a strict chemical composition, according to Levine. Seen
under a microscope, it is clear that, like a crystal, the spherical q-glass regions grow outward from a seed during cooling and exclude atoms that dont fit. Everything behaves like
a crystal, except it isnt, says Levine.
The team used a variety of techniques at Argonnes Advanced Photon Source to rule
out other possibilities. The material might, for example, be a mass of randomly arrayed
crystals so small they dont show up individually under the x-ray probes. But if such crystals were there, they would grow slowly as annealing takes place and that
does not happen.
One exciting possibility is that the q-glass is the first example of a 3Dordered configuration of atoms that possesses neither translational nor rotational symmetry, explains Levine. Such structures have been theorized
by mathematicians, but never before observed in nature. For more information: Lyle Levine, 301/975-6032, lyle.levine@nist.gov, www.nist.gov.
Microstructure of aluminum-iron-silicon mixture. The round nodules are the
q-glass, not crystalline, but with a well-defined chemical composition.
Courtesy of Bendersky/NIST.
12
PROCESS TECHNOLOGY
industry
news
Scientists from the Fraunhofer Institute for Mechanics of Materials IWM, Freiburg, Germany, together with colleagues from the Australian
Commonwealth Scientific and Industrial Research
Organization (CSIRO) are developing a saw wire that
will lead to dramatic reductions in kerf loss. In place
of diamond-impregnated steel wires, researchers use
ultrathin and extremely stable threads made of carbon nanotubes coated with diamond. To solve one of
the problems with the new process, IWM scientist
Manuel Mee found a solution to protect the delicate
nanotubes used to grow diamonds.
New ultrathin saw wire for cutting
silicon wafers: Diamond on top of
During our first experiments, fused silica from
carbon nanotubes. Courtesy of
the reaction chamber accidentally came into contact
Fraunhofer IWM.
with the coating plasma. It settled on the substrate
and protected it against the aggressive hydrogen, explains Mee. To his surprise, diamonds
actually grew on this layer. We then had to study the silicon oxide layer, which was deposited in an undefined manner, and find a method of controlling the deposition and optimizing the process.
Tests with a transmission electron microscope at CSIROs lab revealed that the nanotubes survived under their protective layer. If they found a way to use diamond to coat the
nanothreads that the CSIRO specialists make from nanotubes, these diamond-coated
threads could be used to manufacture ultra-thin saws capable of cutting through silicon
wafers. The process requires special carbon nanotube forests, which can be extracted as an
ultrathin felt and twisted into a yarn 10-20 m in diameter. In principle, this diamondcoated yarn is the ideal material on which to base a new generation of saws, which could
be used in the solar industry, for example. Due to their high tensile strength, they can be
manufactured much thinner than steel wires and that means significantly less kerf loss.
www.fraunhofer.de.
A new method from Brigham Young Universitys (BYU) School of Technology, Provo,
Utah, may help achieve the 54.5 mpg average mandated by the EPA for U.S. fleets by 2025.
Manufacturing engineering technology professor Michael Miles found a way to create an
extremely strong bond between lightweight aluminum and ultrahigh-strength steel. Called
friction bit joining, researchers claim it may be the breakthrough the automotive industry
is looking for. The process uses a small, consumable bit to create a solid-state joint between
different metals.
The process successfully bonds lightweight aluminum with cast iron by inserting a thin
layer of steel between the two metals to facilitate bonding. Currently, the automotive industry uses resistance
spot welding to join steel stampings together into a completed body. In recent years, aluminum parts were introduced into vehicle structures using a mechanical
fastening method called self-piercing riveting. While this
approach works to join lower strength steels with aluminum, it is not suitable for joining aluminum to ultrahigh-strength steel. Friction bit joining offers a new
approach. For more information: Michael Miles, 801/4221858, mmiles@byu.edu, www.byu.edu.
Manufacturing systems grad student Lile Squires
bonds metals together with friction bit joining.
Courtesy of BYU.
briefs
13
industry
news
briefs
Ametek Process Instruments,
Pittsburgh, received a contract to
supply ultraviolet process gas
analyzers for the sulfur recovery
units and tail gas treating units at
the Abu Dhabi Gas Development
Companys (Al Hosn Gas) Shah
Gas Field project in the United Arab
Emirates. Ametek was selected
based on its experience in sulfur
recovery operations worldwide and
the field-proven performance of its
analyzers on similar projects in the
region. The project is among the
largest greenfield gas development
endeavors ever undertaken and is
expected to process approximately
one billion bcf/d of sour gas into
0.5 bcf/d of usable gas.
www.ametekpi.com,
www.alhosngas.com.
Corrosion Solutions Conference
2013 (CSC13), hosted by
Allegheny Technologies Inc.
(ATI), Pittsburgh, takes place Sept.
15-18 in San Diego. The
conference features technical
sessions and panel discussions
geared toward materials selection,
fabrication issues, and innovations
in the chemical processing, oil and
gas, and energy industries. CSC13
provides the latest information on
working with various construction
materials, such as stainless steels,
nickel-based and specialty alloys,
titanium, niobium, tantalum, and
zirconium, and will cover a broad
spectrum of corrosive applications
and environments.
www.atimetals.com/
news/corrosion-conference.
ENERGY TRENDS
Super filter cleans up carbon dioxide emissions
Wake Forest University, Ill., along with collaborators at the University of Texas at Dallas were awarded a new Department of Energy grant worth more than $1 million to design
a novel material that could help revolutionize green engineering using a metal organic
framework (MOF)a material scientists can engineer down to the molecular and atomic
scale. Because they are inexpensive and can easily be grown overnight, MOFs hold enormous potential for a new generation of clean engineering, from super-efficient CO2 filters
to helping make hydrogen vehicles a reality.
One challenge with current MOF filters is that while they can trap carbon dioxide emitted when burning a fossil fuel such as coal, they also hold on to water molecules. Once the
water builds up, the filter wont hold on to CO2 anyEngineers at the University of Calimore, according to Timo Thonhauser, physicist at Wake
fornia, Berkeley, developed an inexForest. However, swapping different metals like magnepensive new way to grow thin films
sium, iron, gold, and platinum into a computer simulaof a material prized in the semicontion helps to explore which types of metals work best in
ductor and photovoltaic industries, an
a MOF carbon dioxide filter. In the future, we envision
achievement that could bring highcars that run on hydrogen instead of gas, says Thonend solar cells within reach of consumer pocketbooks. Researchers
hauser. One of the big questions that remains is where
demonstrated that indium phosphide,
to get the hydrogen. Preliminary studies suggest the posa III-V compound, could be grown on
sibility of MOF materials being used to split water into
thin sheets of metal foil in a process
its separate components. For more information: Timo
that is faster and cheaper than tradiThonhauser, 336/758-3991, thonhauser@wfu.edu,
tional methods, yet still comparable
www.wfu.edu.
in opto-electronic characteristics.
www.berkeley.edu.
UCLA researchers developed a two-layer, see-through solar film that could be placed
on windows, sunroofs, smartphone displays, and other surfaces to harvest energy from the
sun. The new device is composed of two thin polymer solar cells that collect sunlight and
convert it to power. It is more efficient than previous devices because its two cells absorb
more light than single-layer solar devices. It uses light from a wider portion of the solar
spectrum and also incorporates a layer of novel materials between the two cells to reduce
energy loss, according to researchers.
While a tandem-structure transparent organic photovoltaic (TOPV) device developed
at UCLA in 2012 converts about 4% of the energy it receives from the sun into electric
power, the new tandem devicewhich uses a combination of transparent and semi-transparent cellsachieves a conversion rate of 7.3%.
The tandem polymer solar cells are made of a photoactive plastic. A single-cell device absorbs only about 40% of the infrared light that passes through. The
tandem devicewhich includes a cell
composed of a new infrared-sensitive
polymer developed by the researchers
absorbs up to 80% of infrared light plus
a small amount of visible light. For more
information: Yang Yang, 310/825-4052,
yangy@ucla.edu, http://yylab.seas.ucla.edu.
Photovoltaic cells with energy harvesting
capacity can be processed to be transparent
or in shades ranging from light green to
brown. They could be used to turn building
windows, smartphone screens, car sunroofs,
and other surfaces into sources of
sustainable energy.
14
SURFACE ENGINEERING
industry
news
Carmen Scholz of the University of Alabama, Huntsville, has been working on the
customized synthesis of biocompatible polymers that can coat sensors that are then implanted into the body to cloak them from the immune system, referred to as a stealth
character. Recent research proves the in-vitro stability and nontoxicity of thin layers of
customized block copolymers that coat tiny sensors, which were produced by a collaborator group at the University of Technology in Dresden, Germany. After further testing,
coated sensors could be implanted in patients to sense blood glucose, carbon dioxide,
and serum pH levels. The coating uses a multilayer concept that includes a hermetic sealing layer, a chemically inert innermost diffusion barrier for ions and humidity, and a surface layer of amphiphilic block copolymers.
Implanted into a patient beneath the skin, coated sensor data could be monitored wirelessly to control an insulin pump or monitor bodily functions to provide greater information to physicians treating patients with respiratory problems. Because the coatings make
the implants invisible to the immune system, the body does not react to them as invaders
and allows them to function. For more information: Carmen Scholz, 256/824-6188,
scholzc@uah.edu, www.uah.edu.
Researchers at Massachusetts Institute of Technology, Cambridge, developed an approach to improving heat transfer in power plants and cooling systems that they say could
provide a 100% boost in efficiency of heat transfer over conventional systems. The new
system modifies the traditional condensers used to turn steam back into water: A copper
pipe coated with a combination of oil and a hydrophobic material with local hydrophilic
sites exhibits a dense concentration of droplet formation, and quick release of those
droplets before they have a chance to grow large. This leads to greatly enhanced heat transfer and could improve the overall efficiency of power plants.
The innovation combines two properties: A nanopatterned surface, etched with tiny
pillars, reduces contact between droplets and the surface; and a layer of oil coats the surface, helping droplets to form abundantly on the surface and also making it easy for them
to slide off. Because droplets condense right through the thin coating of oil, and end up
being immersed in oil, researchers coined the term immersion condensation to describe
their new system. For more information: Evelyn Wang, 617/324-3311, enwang@mit.edu,
http://drl.mit.edu.
The FasterBlaster from RBW Enterprises Inc., Newnan, Ga., is said to be the only machine on the market that can blast clean both vertical and horizontal surfaces and pipes. It
is now available in models that can cover either 16- or 32-in. blast patterns, reportedly saving time, labor, cleanup, wastes, and costs. Both
units are available with a choice of 30 or 60 hp
electric motors. Because the machine is a fully
contained system, no environmental protection
measures are needed at job sites. The system features a flat mat seal that creates a suction cup affect against the wall, roof, or floor surface. The
seal vacuums tightly over weld seals. In addition,
there are zero emissions, making it possible for
paint to be applied simultaneously near the operating machine. www.rbwe.com.
The new FasterBlaster: Shot blasting is now
available in models that can cover 16- or 32-in.
blast patterns. Courtesy of PRNewsFoto/
RBW Enterprises.
briefs
Titan Spine, Mequon, Wis., was
awarded four new patents in 2013
relating to the companys implant
surface technology, as well as the
design of the Endoskeleton
interbody device and specialized
system instrumentation. A
proprietary treatment is applied to
titanium devices producing a
textured surface that creates
optimal surface energy for
enhanced bone production at
fusion sites. Additional aspects of
the Endoskeleton platform
protected by these new patents
include the devices unique shape,
designed to rest on the apophyseal
ring of the vertebral endplate for
strength and stability, and large
windows for increased bone graft
volumes and improved
radiographic visualization and
fusion evaluation.
www.titanspine.com.
NASA Langley Research Center,
Hampton, Va., joined the
Commonwealth Center for
Advanced Manufacturing
(CCAM), Richmond, Va., as a
government member. The move
creates opportunities for joint
participation in research and
development of new surface
engineering technologies and
manufacturing systems. NASAs
expertise, combined with the
manufacturing capabilities of
CCAM members, will speed the
process of bringing novel
technologies to market sooner.
www.ccam-va.com,
www.nasa.gov/centers/langley.
Chemetall, New Providence, R.I.,
announced the approval of Oxsilan
9810/2 for Federal Specification
TT-C-490, Type IV on abrasive
blasted steel. According to
company sources, this means that
for the first time, there is a viable
replacement for zinc phosphate in
military applications. Oxsilan
9810/2 is phosphorous-free and
does not contain any regulated
heavy metals. The technology is
available in a ready-to-use
formula. www.chemetallus.com.
15
Integrated Computational
Materials Engineering Helps Successfully
Develop Aerospace Alloys
Jeff Grabowski*
Jason Sebastian*
Greg Olson, FASM*
Aziz Asphahani,
FASM*
Raymond Genellie,
Jr.
QuesTek Innovations
LLC
Evanston, Ill.
ICME methods
prove effective
in shrinking
materials
development
timelines and
accelerating
implementation
of high
performance
alloys in
real-world
applications.
*Member of
ASM International
17
Fig. 1 T-38 main landing gear piston, produced from Ferrium S53.
Bell Helicopters Army-Funded Future Advanced Rotorcraft Drive System (FARDS) program is currently evaluating C64 in transmission
gear boxes to replace Pyrowear 53. Material performance requirements for strength, toughness,
surface hardness, and other parameters that
drove the design of C64 were defined by Bell
several years ago.
QuesTek was also a leading contributor to
the Accelerated Insertion of Materials program, a strategic initiative spearheaded by the
U.S. Defense Advanced Research Projects
Agency and the Office of Naval Research.
Among the programs many accomplishments
is the ability to predict the minimum design
strength for production scale usage, based solely on three
10-ton heats of Ferrium S53.
Future prospects for ICME
Historically, QuesTek has received roughly 75% of its
research funding from government project work, with the
remainder coming from private industry. Recently, alloy
design and modeling projects for private industry have increased, as companies see the value of ICME methodology,
but lack ICME-experienced personnel, time, and capital to
build an in-house ICME-based team.
Although the early focus was on
aerospace steel, successful alloy development projects for Al, Ti, Ni, Co, Cu,
Nb, Mo, W, and even ceramics and
polymers have also proved useful.
Government projects will be pursued
across all alloy systems, with a focus on
continuous growth in energy, oil and
gas, transportation, healthcare, and
other industries.
Accurate and powerful design
toolsets can now predict strength,
toughness, oxidation resistance, fatigue
life, and fatigue nucleation. Additional
tools are under development to predict
corrosion resistance, weldability, and
other key design concerns.
The past 15 years of integrated computational materials design produced
several novel materials that will impact
industry for decades to come, as both
demand and successful implementation
of innovative, advanced ICME-designed
alloys grows. There is much anticipation
about what the next 15 years of ICME
methodologies could bring.
19
Performance Advances in
Copper-Nickel-Tin Spinodal Alloys
W. Raymond
Cribb, FASM*
Michael J. Gedeon*
Fritz C. Grensing
Materion Brush Inc.
Mayfield Heights, Ohio
The unique
metallurgy and
microstructure
of Cu-Ni-Sn
alloys offer a
beneficial
combination
of strength,
tribology,
corrosion
resistance,
toughness,
and reliability
for diverse
applications in
the oil and gas,
aerospace,
mechanical
systems, and
electronics
industries.
Cast/wrought alloy
inventions
(Bell Laboratories)
1980s
Early 1990s
Casting scale-up
(rod, tube)
(Materion Brush Inc.)
Late 1990s
Early 2000s
Cast shapes
Late 2000s
2010s
*Member of ASM
International
Near-net-shape
castings
Expanded size
ranges
CX tempers
AT tempers
TS tempers
This article updates the current state of the art regarding Cu-15Ni-8Sn alloy manufactured under the tradename
ToughMet 3, which uses vertical continuous casting and molten metal stirring to produce the so-called EquaCast
microstructure. This casting technology enables hot working processes, extending the property combination options
that meet demanding application needs in aerospace bearings, oil and gas exploration components, tribologic parts
for mechanical systems and machinery, and electronic connectors. An article in the June 2006 edition of Advanced
Materials & Processes provides more detail about the metallurgy and utility of ToughMet 3. Selected references
further detail the alloy system.
20
further developing and verifying process reliability. Using production material, engineers were able to verify property sets.
Production lots were separated by both time
and dimension to measure within and between variation in the system. These results
were valuable for developing manufacturing
control plans as alloy tempers were commercialized. In addition, this approach helped
significantly when introducing the alloy into
the materials community.
Spinodal alloy metallurgy
Most copper-base alloys derive strength
from solid solution hardening, cold working,
precipitation hardening, or a combination of
these. In the ternary copper-nickel-tin alloys
that include Cu-9Ni-6Sn (ToughMet 2) and
Cu-15Ni-8Sn (ToughMet 3), the high mechanical strength options shown in Table 2 are produced by controlled thermal treatment that
causes spinodal decomposition.
Classic spinodal decomposition takes place
spontaneously and does not require an incubation period. Instead of the typical nucleationand-growth process, spinodal decomposition is
a continuous diffusion process in which the original alloy decomposes into two chemically different phases with identical crystal structures.
Each phase in the spinodally hardened alloy is
on the nanoscale and is continuous throughout
the grains up to the grain boundaries.
Spinodal decomposition in copper-nickeltin alloys triples the yield strength of the base
metal and results from the coherency strains
produced by the uniform and high-numberdensity dispersion of tin-rich perturbations in
the copper matrix. Cold working prior to the
spinodal hardening treatment adds additional
strength and ductility.
Spinodal decomposition hardening only
happens under certain conditionsthe solidstate phase diagram of a spinodal system must
contain a miscibility gap, a region in which the
single phase alloy separates into nanophases.
The alloying elements must also have sufficient
mobility in the parent matrix at the miscibility
gap to allow interdiffusion.
Spinodal heat treatment
Heat treatment steps for spinodal decomposition include:
ToughMet 2 CX
UNS C96900
Cast and
spinodally
hardened
ASTM B505
ToughMet 3 CX
UNS C72900
ToughMet 3 AT
Wrought and
spinodally
hardened
UNS 72900
ToughMet 3 TS
UNS C72900
BrushForm 158
UNS C72700
BrushForm 96
Wrought,
cold worked,
and
spinodally
hardened
HRC
27-30
Product
forms
K1c fracture
toughness
UNS C96970
Tensile
strength
Hardness
Description
0.2%
Offset
yield
strength
Tensile
elongation
Alloy
Specifications
and MMPDS handbook
appearances
CVN
impact
strength
rod, tube,
custom
shape
45-30
ksiin rod, tube,
49-33
plate
MPam
70-40
106-165 ksi
HRB
97ksiin rod, tube,
30-4
ft
lb
18-3%
730-1140
HRC 36 40-5 J 77-44
wire
MPa
MPam
95-205 ksi
strip
95-150 ksi
655-1035
MPa
ASTM B740
75-200 ksi
515-1380
MPa
ASTM B740
9-4 ft lb
12-5 J
strip
21
Desired attribute
Resistance to fracture
Fatigue resistance
Electronic connectors
Long life/reliability
Galling resistance
Wear resistance
Heat generation, power loss
Abrasion resistance
Low operating temperature
Temperature resistance
Cracking/spalling resistance
Interference fit stability
Weight/volume control
Resistance to permanent
deformation
22
ToughMet 3 in jet aircraft landing gear systems. Secondary property testing is a part of the MMPDS system, including basic tensile properties, pin bearing,
compression, shear, and selected physical properties, all
having a statistical basis recognized by the FAA.
Spherical bearings for aerospace use require significantly higher strength than those used in other applications due load concentration. To meet this need, a new
temper with 150 ksi yield strength and increased size capability was developed to enable use in landing gear, particularly when operating with gall-sensitive titanium and PH
stainless steels.
Mechanical systemsGround engaging machinery,
mining equipment, and internal combustion engines
are finding success in adapting cast and wrought versions of ToughMet 3 for bushing and bearing applications. As such, these applications are steadily growing.
The need to manage mechanical distortion during fabrication is being met by FEA methods and development of precision machining methods using designed
experiments, tooling engineering, and measurement
technology.
Plate and sheet forms are offered to service sliding
componentry or roll formed bushings and bearings,
along with rod, bar, and tube configurations in both
wrought and cast forms.
23
24
Current trends
Demand for more mechanically robust products continues in oil and gas exploration markets and the TS tempers are beginning to satisfy this demand.
Environmental pressure is driving producers of performance components away from alloys containing beryllium, in spite of their superior attributes. In response, the
Cu-15Ni-8Sn alloy and associated tempers are gaining
wider use.
Strip product forms are building the basis for passive
micro-mechanical products in the electronics industry.
Future prospects
Machining of finished parts in oil and gas, aerospace,
and mechanical systems necessitates a premium for the
components. Additional product forms will be available to
improve yields and minimize costs associated with machining, material handling, and related infrastructure.
Bearings manufactured from strip, rolled into shape,
and potentially welded will reduce the cost of machining
thin-walled bearings out of tube. Alternative additive
manufacturing or net shape processes might be able to
reduce cost and enhance overall competitiveness without sacrificing performance. New property combinationsgenerally higher strength with higher
ductilityare a challenge that will resolve by further de-
W.R. Cribb, Anti-Friction Behavior of Selected CopperBased Bearing Alloys, Brush Wellman, Cleveland,
AT0023/0502.
W.R. Cribb and F.C. Grensing, Mechanical Design Limits for a Wrought Cu-15Ni-8Sn Spinodal Alloy, SAE
AeroTech Congress, Paper 2009-01-3255, Seattle, November 2009.
W.A. Glaeser, Wear Properties of Heavy Loaded Copper-Base Bearing Alloys, JOM, Vol 35, No. 10, p 50-55.
D. Krus and W.R. Cribb, ToughMet Alloy: Improving
Thrust Bearing Performance Through Enhanced Material
Properties, SAE Commercial Vehicle Engineering Congress and Exhibition, Paper 2004-01-2675, Chicago, October 2004.
S. Para, Spinodal Transformation Structures, ASM
Handbook, Vol. 9, p 140-43, 2004.
Metallic Materials Properties Database and Standardization (MMPDS) Handbook, Chapter 7, MMPDS-07, Federal Aviation Administration, 2012.
J.T. Plewes, Method for Treating Copper-Nickel-Tin
Alloy Compositions and Products Therefrom, U.S. Patent,
No. 3,937,638, February 1976.
J.-C. Zhao and M.R. Notis, Spinodal Decomposition Ordering Transformation and Discontinuous Precipitation in
a Cu-15Ni-8Sn Alloy, Acta Metall., Vol 46, No. 12, p 42034218.
25
An industry
pioneer shares
a historical
overview of
the early days
of single
crystal
superalloy
development.
*Fellow of ASM
International
blades, as in a pinwheel. The fan and the various compressor stages get their power from the
turbines via the shafts. Discs and shafts are
mounted in a bearing structure. Temperatures
and pressures increase inside the compressor
and decrease throughout the turbine as energy
is extracted.
Recall that the overall efficiency of a thermodynamic cycle increases as the maximum
temperature increases. This leads to one of the
primary problems in engine development
how to cope with increased temperature. Generally, the fan is composed of aluminum, the
compressor is titanium based, and the turbine
is nickel based. Nickel alloys are referred to as
superalloys due to their excellent combination
of mechanical properties and environmental
resistance[1]. The combustor exhaust temperature is near or above the melting point of the
nickel alloys as well as the cobalt-based alloys,
which have been used in the combustor or as
first-stage turbine vanes. Early turbines used
alloys such as IN718 and parts were made
from forgings or castings. However, component life was limited by oxidation, corrosion,
strength, creep, and cyclic properties. As engine temperatures continued to rise, three
things had to evolve:
Alloys for high strength and improved
creep resistance
Interior cooling passages
Better coatings
Path to progress
All of these improvements came to pass, especially throughout the 1970s. Alloys were upgraded to IN792, U700, B1900, and Mar-M200.
See Table 1. Phase stability considerations became commonplace, to guard against topolog-
Cr
Co
Ti
Al
Zr
Nb
Hf
Mo
Ta
Other
Udimet-700
15.0 15.3
3.4
4.30
0.070
0.016
4.4
IN-718
19.0
0.9
0.60
0.060
3.0
18.0 Fe
IN-792+Hf
12.2
9.0
3.8
4.1
3.50
0.120
0.015
0.100
0.5
1.9
3.9
IN-100
9.5
15.0
4.8
5.50
0.180
0.015
0.060
3.0
1.0 V
B-1900+Hf
8.0
10.0
1.0
6.00
0.110
0.015
0.080
1.2
6.0
4.3
Mar-M200+Hf
9.0
10.0
12.5
2.0
5.00
0.150
0.015
0.050
1.0
2.0
PWA 1480
10.0
5.0
4.0
1.5
5.00
12.0
PWA 1484
5.0
10.0
5.9
5.65
0.1
1.9
8.7
3.0 Re
opportunity to improve
processes such as directional
solidification (DS) used to
make columnar grained superalloys and possibly single crystals. Columnar grained alloys
seemed ideal for turbine blades, as the primary stress was
axial due to centrifugal stress from high speed rotation. And
single crystals would address more complex states of stress
associated with ever increasing shape complexity.
Changing course
It was soon discovered that one thorny issue was
freckles, narrow chains of equiaxed grains within an otherwise aligned grain structure. The exact formation mechanism was not understood, although the most credible
theory centered on something changing in the inner mold
surface as the ceramic shell mold was being dewaxed. This
lead to the following action plan:
Check the chemistry and microstructure of the
freckle trails
Determine the thermal conditions during solidification
Look for correlations between mold design variables
and the incidence of freckling
It was discovered that after carefully machining out
freckle trails as shown in Fig. 3, freckles were loaded with
eutectic and all the elements with a distribution coefficient
less than 1, such as Al and Ti. They also exhibited signifiADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
27
cant shrinkage. Next, the processing group needed to instrument a few molds to get cooling curves at known positions. This involved writing a computer program to
reduce the data into thermal gradients, growth rates, cooling rates, mushy zone height, and other variables. Conditions were marginal at best, with the worst part orientation
300
Equiaxed
growth
zone
Unidirectional
dendritic growth
zone
Liquid
tin
cooling
200
100
Withdrawal
Power Down
50
Crystal
grower
7-in. coil
150
Pancake coil
250
Conventional Modified
10
20
30
40
Thermal gradient (C/cm)
50
60
Conventional
casting
Columnar grain
Single crystal
Grain
nucleation
Competitive
grain growth
Grain
selection/growth
The team continued to try to improve thermal conditions. Progress was remarkable, as shown in Fig. 5. Freckles were disappearing. Results were published in two
papers[4,5] and designers now had three choices in grain
structure, as shown in Fig. 6. We worked with casting vendors to improve the process and DS yields were soon above
90%. The vendors also continuously improved and developed better core formulations to create the cooling passages. By the next scientific conference, Dr. Fred Weinberg
of the University of British Columbia, Canada, had added
small particles of W to a metallic dendrite field and showed
by radiography that they were indeed moving about. The
results were now accepted by the scientific community.
Superalloys continue making strides
With regard to single crystals, physicists argued that
materials formed from dendrites (rather that planar front
growth) were not true single crystals. This is a fine point.
Superalloy single crystals were actually ideally imperfect crystals, which is to say that the slight substructure
eliminated double diffraction or extinction. In fact, Copley was very interested in elastic anisotropy and wanted to
make a single crystal spring. In analyzing these attempts,
a nearly complete lack of asterism in Laue patterns was
evident. This led to the belief that a helix would make
an ideal single crystal grain selector, as shown in Fig. 7.
29
T = 815C
(m)
0.25
0.20
0.15
4Re
0Re
2Re
0.10
0.05
2000
6Re
2
4
6
8
10
Aging time 1/3, hrs 1/2
Metal temperature
capability, F
0.30
1950
Single crystal
1900
1850
PWA 1480
Columnar grain
MM 200 (Hf)
Conventionally
cast
MM 247
MM 247
1800
IN 100 B 1900
1960
1970
1980
1990
Engine incorporation date
Fig. 9 Relationship between materials and
temperature capability.
Future considerations
Despite the advances briefly outlined
here, there is much more work to be done
to further develop this field. Here is a
glimpse of what may lie ahead:
Faster computers will enable faster
model building; widespread use of
computer simulation will include
pour dynamics, improved
microstructural predictors, as well
as stress state and strain fields
More accurate multicomponent
phase diagrams
Better life prediction
Improved inspection methods
Better molds and cores
Improved repair methods
More complete recycling for Ta, Re,
Cr, Hf, and others
Right-sized automated casting
facilities
In addition, as Integrated Computational Materials Engineering tools become more widespread, they could have
a noticeable impact on alloy development
timelines.
For more information: Anthony F. Giamei, (retired) principal scientist, United
Technologies Research Center, agiamei@
comcast.net.
References
1. Superalloys II, C.T. Sims, N.S. Stoloff, and
W.C. Hagel (eds.), John Wiley & Sons, N.J.,
1987.
2. W.J. Boesch and J.S. Slaney, Metal
Progress, 86:109-111, 1964.
3. J.E. Doherty, B.H. Kear, and A.F. Giamei,
J. of Metals, 23:59-62, 1971.
4. A.F. Giamei and B.H. Kear, Met. Trans.,
1:2185-2192, 1970.
5. S.M. Copley, A.F. Giamei, S.M. Johnson,
and M.R. Hornbecker, Met. Trans., 1:21932204, 1970.
6. T.K. Pratt, F. Landis, and A.F. Giamei,
ASME Publication No. 80-HT-34, 1980.
7. Superalloys, J.K. Tien (ed.), ASM International, p 205-214, 1980.
8. A.F. Giamei and D.L. Anton, Met. Trans.
A, 16A:1997-2005, 1985.
PLENARY SESSION
The MS&T Plenary Session will be held on October 28 from 8:00 to 10:20 a.m. in
room 517. A Q&A session will be held immediately after the presentations.
Hypersonic Flight: The Final Frontier of Aeronautics
Kevin G. Bowcutt, senior technical fellow, chief scientist of hypersonics, The Boeing Co.
This presentation addresses key technical aspects and challenges of hypersonic vehicle design, and summarizes progress made in maturing technologies critical to the
successful development of practical hypersonic systems. The successful X-51A and Hypersonic International Flight Research and Experimentation (HIFiRE) flight test programs will be highlighted. The presentation concludes with a vision for a hypersonic
space and global transportation system.
Materials in Turbine Engine Environments
Tresa M. Pollock, ALCOA Professor, University of California, Santa Barbara
The design and performance of new aircraft engines, power generation plants, and
rocket propulsion systems are often limited by turbine materials. For individual components, a spectrum of failure modes may occur and challenges in developing monolithic materials as well as hybrid combinations of materials that satisfy a wide range of
property constraints will be discussed. Computational and experimental tools that enhance the discovery, design, and deployment of new materials for turbine environments
will be discussed.
The Co-Design of Experiment and Theory at the Mesoscale:
A MaRIE Perspective
John Sarrao, associate director for theory, simulation, and computation,
Los Alamos National Laboratory
MaRIE (Matter-Radiation Interactions in Extremes) is Los Alamos National Laboratorys facility concept for addressing decadal challenges in materials, especially in
extreme environments, through a focus on predicting and controlling materials microstructure. MaRIE will be an international user facility and enable unprecedented
in-situ, transient measurements of real mesoscale materials in relevant extremes,
especially dynamic loading and irradiation extremes. Recent experience in attempting to pursue this vision of prediction and control will form a central element of the
presentation.
32
LECTURES
AND SPECIAL EVENTS
Sunday, October 27
ACerS Frontiers of Science and Society:
Rustum Roy Lecture 5:00 6:00 p.m.
Larry Hench, Florida Institute of
Technology, Affordable Healthcare? Role of
Bio-Ceramic Technology, Socio-Economic,
and Ethical Issues
Welcome reception: 6:00 7:30 p.m.
100th Anniversary Gala
5:00 9:30 p.m.
The celebration features a cocktail
reception, gala jubilee dinner, Presidents
Reception (by invitation only), distinguished
awards ceremony, historical tributes,
keynote speaker, live entertainment,
mementos, and much more.
Monday, October 28
ASM/TMS Distinguished Lecture
1:00 2:00 p.m.
Tresa M. Pollock, University of California,
Santa Barbara, Flight in the 21st Century:
The Role of Materials and ICME
ASM Alpha Sigma Mu Lecture
2:30 4:00 p.m.
David B. Williams, The Ohio State
University, Reflections on Microscopy &
Analysis: From Viewing the Small World to
Leading on a Larger Stage
ASM Leadership Awards Luncheon
11:30 a.m. 1:00 p.m.
ASMs organizational unit awards as well as
awards and scholarships of the ASM
Materials Education Foundation will be
presented. ASMs incoming Committee/
Council chairs will also be recognized for
their leadership. ASM Committee and
Council members meeting during MS&T,
and awardees, will receive an invitation to
attend.
ASM 100th Annual Business Meeting
4:00 5:00 p.m.
Officers will be elected for the 2013-2014
term and other ASM business will be
transacted. ASM members and guests are
welcome.
Women in Materials Science and
Engineering Reception 5:30 6:30 p.m.
Enjoy the chance to network with
professionals and peers in a relaxed
environment.
Continued
EXHIBITOR LIST
Booth
1504
800
1117
1307
1000
1006
1007
1100
1115
1104
1105
1116
1311
1510
1419
1312
911
1304
1001
T13
1407
1411
1406
904
1214
701
1205
T16
1418
1024
T18
1013
1211
801
1119
906
1022
1316
1414
1303
1305
1701
1011
923
1026
1400
Company
Accutek Testing Laboratory
Across International LLC
Activation Laboratories Ltd.
(ACT Labs)
AdValue Technology LLC
Agilent Technologies
Air Liquide Canada
Aldrich Materials Science
Alfa Aesar, a Johnson Mathey
Co.
Alfred University
Allied High Tech Products Inc.
American Stress Technologies
Inc.
Angstrom Scientific Inc.
Applied Test Systems Inc.
Ashland Inc.
Blasch Precision Ceramics
Brim G&H Fluid Handling
Products Inc.
Buehler
Carbolite
Carl Zeiss Microscopy LLC
Carpenter Technology Corp.
Centorr Vacuum Industries Inc.
Clemex Technologies
CM Furnaces Inc.
CMD Network
CompuTherm LLC
CSM Instruments Inc.
Delong America Inc.
Dispersion Technology Inc.
Edax Inc.
EDFAS Society
Euraxess Links North America
Evans Analytical Group
FEI Company
GEA Westfalia Separator
Goodfellow Cambridge Limited
Granta Design
Heat Treating Society
Hitachi High Technologies
America Inc.
Hockmeyer Equipment Corp.
Horiba Scientific
Hoskin Scientifique LTEE
Hunan Premco Ltd.
Hysitron Inc.
IMS Metallographic Contest
Display
International Metallographic
Society
IMR Test Labs
Booth
1317
1101
1507
1201
917
900
1207
1319
1500
919
1118
1110
807
1200
1210
1219
1217
1511
1310
1005
T12
1301
1107
707
1313
1410
903
1506
1501
1206
1023
700
T17
901
1111
1018
1517
1102
1019
1300
1025
1204
907
1122
1114
1401
1016
806
1202
1701
Company
INNOVNANO S.A.
JEOL USA Inc.
Keyence Canada Inc.
LECO Corp.
Maney Publishing
Metal Samples Co.
Metcut Research Inc.
Micro Materials
Micromeritics Instrument
Corp.
Momentum Press
MTI Corp.
MTS Systems Corp.
NANOVEA
Netzsch Instruments North
America LLC
NIST
Ocean Optics
Olympus Canada Inc.
OSIsoft Canada ULC
Oxford Instruments
PANalytical
Photon Etc.
Proto Manufacturing
PTX-Pentronix/Simac Ltd.
Pultrusion Technique Inc.
Quinn Process Equipment Co.
Rigaku Americas Corp.
Romquest Technologies
RPS Composites Inc.
Saudi Aramco
Sente Software Ltd.
Shape Memory & Superelastic
Tech. Society
Springer
SSAB
Strem Chemicals Inc.
Struers Inc.
Surface Combustion Inc.
Swiss Pavilion
TA Instruments
TEC
Tescan USA
Thermal Spray Society
Thermcraft Inc.
Thermo-Calc Software
TSI Inc.
UES Inc.
Union Process Inc.
University of California, Davis
Watson Valve Services Inc.
Wiley
Zhuzhou Kori Convertors Ltd.
Tuesday, October 29
Show hours: 11 a.m. 6 p.m.
Lunch: 12:00 2:00 p.m.
Poster session: 2:00 6:00 p.m.
Happy hour reception:
4:00 6:00 p.m.
*Times are subject to change
Wednesday, October 30
Show hours: 9 a.m. 2 p.m.
Poster session: 9:30 10:30 a.m.
Lunch: 12:00 2:00 p.m.
33
LECTURES
AND SPECIAL EVENTS
Tuesday, October 29
ASM Edward DeMille Campbell
Memorial Lecture 12:45 1:45 p.m.
Enrique J. Lavernia, FASM, University of
California, Davis, Stress-induced Grain
Growth in Ultra-fine Grained Materials
MS&T Young Professionals Reception
4:30 6:00 p.m.
Attend this reception to meet and network
with fellow young professionals.
MS&T13 Exhibit Happy Hour Reception
4:00 6:00 p.m.
Network with colleagues and build
relationships with qualified attendees,
buyers, and prospects.
ASM Awards Dinner and Presidents
Reception 7:15 11:30 p.m.
Come celebrate the wonderful
accomplishments of this years award
recipients and the 2013 Class of Fellows.
Tickets, which include the Presidents
Reception following the dinner, can be
purchased via the registration form.
Montral
Convention
Centre (Palais
des congrs de
Montral).
Courtesy of
Marc Cramer.
34
*Thermal Spray for Oil and Gas Industries 8:00 a.m. 4:00 p.m.
Instructor: Andre McDonald, University of Alberta
Given the special needs of the oil and gas sector for wear and corrosion
resistant coatings with high longevity, the certification process and validation
of the coatings produced by those examining them needs to be different from
other industries. Therefore, this course will include training and testing
information that applies specifically to the oil and gas sector.
Corrosion Prevention and Maintenance Reliability in Hydrometallurgical
Plants 8:00 a.m. 4:00 p.m.
Organizer: Wilson Pascheto, Xstrata
This course provides an overview of corrosion issues in hydrometallurgical
operations. Expert speakers from academia and industry will cover the
following topics: Corrosion fundamentals, corrosion prevention methods, case
histories of failures of hydrometallurgical plant equipment, and failure
prevention through engineering specifications and maintenance practices.
Managing Technical and Financial Risk in a New Technology Project
Environment 8:00 a.m. 5:00 p.m.
Organizer: Mark Kennedy, ProVal Partners S.A.
This course reviews the past performance of major mining and metallurgical
projects. Students will learn to identify root causes of risk in mining and
metallurgical projects, particularly those with a high component of new
technologies. Standard project management techniques will be reviewed and
specific methods to identify and manage risks in new technology projects will
be introduced.
35
s we celebrate the 100-year anniversary of ASM International (1913-2013), we look at the many notable advancements in materials and
processes technology that occurred along the way. ASM has played a significant role in this by providing a forum for bringing together
engineers, scientists, and practitioners to exchange information on these advancements, and by disseminating information about them to
the engineering community in general. The society, which began in 1913 as the Steel Treaters Club, also went through several changes over
the years to its present ASM International. In each issue of AM&P in 2013, we are highlighting in 10-year increments significant advancements
in technology, as well as advancements in the society.
1994
The ASM Heat Treating
Society is formed, making its
debut at the Heat Treating
Conference in October.
36
Cobalt-Chromium-Iron ternary
phase diagram, one of thousands
published in the 10-volume
Handbook of Ternary Alloy Phase
Diagrams. The project is the
culmination of a massive six-year
effort by editors Alan Prince (left),
Pierre Villars, and Hiroaki Okamoto.
1995
1996
1997
ASM enters
the Internet
age with
AccessASM
online at
www.
asm-intl.org.
1998
The Electronic Device
Failure Analysis Society
becomes an Affiliate
Society of ASM.
Induction
heating of a
test gear for a
Gear
Research
Institute
project to
characterize
the results of
nine induction
heating
approaches.
An article in
the August
issue of Heat
Treating
Progress
reports the
findings.
1999
2000
2001
2002
2003
SR-71 Blackbird
ASM celebrates the Centennial of Flight by presenting
the 2003 AeroMat Conference in Dayton, Ohio, home
of the Wright Brothers. Advanced Materials &
Processes features a significant aircraft each month.
The SR-71 Blackbird, whose structural weight was
93% titanium, first flew in 1964. It was a long-range
strategic reconnaissance aircraft that could fly more
than 2200 mph at an altitude of 85,000 ft.
McIntyre Louthan
becomes editor
of ASMs new
publication,
Practical Failure
Analysis. After
two years, the
name is changed
to Journal of
Failure Analysis
and Prevention.
Mac remains
editor for 11
years, during
which time the
journal becomes
an international
success.
37
INDUCTION
HARDENING OF
CRANK/CAMSHAFTS
PAGE 17
ACTIVE SCREEN
PLASMA NITRIDING
PAGE 24
hts.asminternational.org
TABLE OF CONTENTS
10 HEAT TREAT 2013 EXHIBITOR SHOWCASE
The exhibit hall at the 27th ASM Heat Treating Society Conference and
Exposition in Indianapolis will be packed with quality company displays.
A few exhibitors are highlighted.
17 LOW-DISTORTION, HIGH-QUALITY
INDUCTION HARDENING OF CRANKSHAFTS
AND CAMSHAFTS
Gary Doyon, Valery Rudnev, and John Maher
20 MODELING DISTORTION
AND RESIDUAL STRESSES OF
AN INDUCTION HARDENED TRUCK AXLE
DEPARTMENTS
4 EDITORIAL
4 HEAT TREATING SOCIETY NEWS
8 CHTE UPDATE
45
HTPRO
46
Our continued focus on generating quality technical content and the demand for print advertising with HTS, combined with an opportunity to join
our efforts with ASMs Advanced Materials & Processes magazine, resulted
in the launch of the HTPro print publication, a quarterly supplement to
AM&P, and the hard copy cousin of our HTPro eNewsletter. By putting ourselves in the ASM flagship print vehicle, we are expanding our audience
within the ASM family and adding to the overall content growth strategy of
ASMs position as Everything Material.
As I come to the end of my term as HTS President, I want to thank all the
committed men and women of our organization who devote their time and
talents to the development of their professional society. You are the heart of
HTS and your efforts are appreciated. To those of you who have not volunteered with HTS or ASM, I encourage you to consider doing so. Volunteering makes you a better professional; it broadens your understanding of our
industry and enhances your professional and personal networks, improving
you in ways you never dreamed of.
I look forward to seeing you at the HTS Conference and Exposition in
Indianapolis.
Thomas E. Clements
President, Heat Treating Society
The ASM HTS/Surface Combustion Emerging Leader Award was established in 2013 to recognize an outstanding early-to-midcareer heat treating professional whose accomplishments exhibit exceptional achievements in the heat treating industry. The award was created in
recognition of Surface Combustions 100-year anniversary in 2015. The award acknowledges
an individual who sets the highest standards for HTS participation and inspires others around
him/her to dedicate themselves to the advancement and promotion of vacuum and atmosphere heat treating technologies. Rules for submitting nominations:
Candidates must be submitted by an ASM International member.
Nominations should clearly state the nominees impact on the industry and/or service and
dedication to the future of the HTS. Three support letters should be included with the
nomination.
Nominees must be 40 years of age or younger, and employed full time in the heat treating
industry for a minimum of five (5) years.
The award shall be presented to one (1) recipient every two (2) years at the General Membership Meeting at the HTS Conference and Exposition. Winner receives a plaque and $4000 cash
award funded by Surface Combustion.
For rules and nomination form for the ASM HTS/Surface Combustion Emerging Leader Award, visit
the Heat Treating Society Community Web site at http://hts.asminternational.org and click on Membership & Networking and HT Awards. For additional information or to submit a nomination, contact Sarina Pastoric at 440/338-5151, ext. 5513, or sarina.pastoric@asminternational.org.
Roger A. Jones is corporate president of Solar Atmospheres Inc., Souderton, Pa. After graduating
from Hocking Technical College, he joined ABAR
Corp. in 1975. In 1978, he joined Vacuum Furnace
Systems Corp., founded by his father William R.
Jones, FASM. In 1983, he helped found Solar Atmospheres Inc., serving as vice president, became president in 1993, and became corporate president in
2001. He has been a member of the Metal Treating
Institute since 1983, serving on the Board of Trustees
(19982004, and 2009present), and as president
(20042005). Roger has been a member of ASM
Philadelphia Liberty Bell Chapter since 1983, and
chapter president (19931994). He was chair of the
ASM Heat Treating Society (HTS) Immediate Needs
Committee and the HTS Education Committee,
served on the Nominating Committee for two separate terms, and is a member of the HTS Technology
& Programming Committee. He was elected to the
HTS Board in 2005.
Steven G. Kowalski is president of Kowalski Heat
Treating Co., Cleveland, assuming the position in1997
for the second-generation family business. He earned
his B.S. degree in business administration from Miami
University in 1984. Kowalski is a member of the Metal
Treating Institute and was a founding member of the
ASM Heat Treating Society. He served on the Heat
Treating Society Board from 20032010, served as
chair of the HTS Membership Committee from
20062013, and also served as chair of the ASM
Membership Committee from 20122013. Kowalski
served on many non-profit boards working to enhance private and public partnerships. He has also
worked with local, state, and national employment organizations to develop and implement training programs to enhance worker retention rates. Steve has
published several papers on furnace systems controls,
HTPRO
5
Mashl
Oakes
Xia
Birt
Sigelko
The new
board will
begin its
term on
September 1,
2013.
HTS/Bodycote
Student Paper
Contest
47
HTPRO
6
5th International
Conference on
Thermal Process
Modeling and
Computer
Simulation
(co-located with
AeroMat)
June 1618, 2013
Gaylord Palms Resort
& Convention Center
Orlando, Fla.
Abstract submission
deadline is November
11, 2013. To submit
an abstract, or for
conference details,
visit www.
asminternational.
org/modeling.
ence and engineering in 1999. During his undergraduate years, Jeff had several papers published on leadfree soldering research conducted under the
direction of Prof. K.N. Subramanian, including one
published in Advanced Materials & Processes in
March 2000. Jeff joined American Axle & Manufacturing (AAM), Detroit, in 2000, working in the Corporate Materials Lab, and as a process metallurgist
for induction hardening and conventional gas carburizing in the driveline division. While at the company, he received his M.S. degree in materials science
and engineering from Wayne State University, Detroit, in 2003. Jeff currently is metallurgy leader for
MSP Industries Corp. (an AAM owned company),
Leonard, Mich.
Continuing board members include Timothy De
Hennis, William Disler, Bill Flower, Robert Goldstein, Richard Howell, and Christopher Klaren.
Mr. John D. Hubbard, CEO (retired), Bodycote plc, headquartered in Macclesfield, Cheshire, UK, is the recipient of the 2013 George H. Bodeen Heat Treating Achievement Award.
Established in 1996, this award recognizes distinguished and significant contributions to the field of heat
treating through leadership, management, or engineering development of substantial commercial impact.
Hubbard is recognized for a lifetime of devotion to and advancement of heat treating by transforming
numerous small localized commercial heat treat providers into a network of knowledgeable and technologically strong heat treating facilities to meet the needs of the worldwide manufacturing community.
Hubbard worked nights at Warner & Swasey while earning a B.S. degree in metallurgical engineering at
Cleveland State University. After graduating in 1970, he was appointed metallurgical engineer and promoted
to manager of heat treating departments for six facilities. He received his MBA from Cleveland State in 1973 and
was a part-time adjunct professor for Business Ethics and Statistics at the university. He and a partner founded
Furnace Services and Furnace Controls in Cleveland in 1973, and sold the companies in 1976. He joined Hinderliter Heat Treating Inc., North American Heat Treating Group in 1976 as general manager, and became
2013 HTS/Bodycote Best Paper
president in 1983. Bodycote plc acquired the company
in Heat Treating Award
in 1996 and Hubbard became president of Bodycotes
The winner of the 2013 HTS/Bodycote Best Paper in Heat
North American Thermal Processing Div. In 2002, he
Treating Award is entitled, Localized Surface Modificabecame CEO of Bodycote plc, growing the company
tion on 1018 Low Carbon Steel by Electrolytic Plasma
from 479m (~$745m) and 5700 employees to 730m
Process and its Impact on Corrosion Behavior, by (pri(~$1.1b)and 11,000 employees in more than 300 facilmary author) Dr. Jiandong Liang, who recently received
ities in 32 countries when he retired.
his Ph.D. in mechanical engineering from Louisiana
State University, Baton Rouge. The award will be preHubbard was on the Board of Trustees for the Metal
sented at the HTS General Membership Meeting on
Treating Institute (19831986 and 19942002), and
Tuesday, September 17, at the ASM Heat Treating Soci- Winner of the
HTS/Bodycote
was MTI president (20002001). He was a founding
ety Conference and Exposition in Indianapolis.
2013 Best
member of CHTE, was on the Heat Treating Society
Paper in Heat
Board
of Directors (19942000) and HTS president
The ASM Heat Treating Society established the Best Treating
(20002001), and received the ASM Distinguished
Award, Dr.
Paper in Heat Treating Award in 1997 to recognize a Jiandong
Life Member Award in 2005.
paper that represents advancement in heat treating Liang.
technology, promotes heat treating in a substantial
The award will be presented at the HTS General
way, or represents a clear advancement in managing the business of
Membership Meeting on Tuesday, September 17, at
heat treating. The award includes a plaque and $2500 cash prize enthe ASM Heat Treating Society Conference and Exdowed by Bodycote Thermal Process-North America.
position in Indianapolis.
48
HTPRO
Induction Tempering
CHTE collaborators are developing a fundamental understanding of the induction tempering process, including the effects of
induction process parameters of power (kW)
and frequency (kHz) on the microstructure
and properties of the induction tempered
part. A comparison of the microstructures,
residual stress distribution, and mechanical
properties (hardness, impact toughness, and
torsional properties) of induction tempered
steels with furnace tempered steels is also
underway.
CHTE makes it easy to tap into a pipeline of invaluable knowledge and a far-reaching network of excellent
people with countless years of heat treating experience. Alexander Brune, Sikorsky Aircraft
For more information about CHTE and its member services, visit www.wpi.edu/+chte.
50
HTPRO
2013
EXHIBITOR SHOWCASE
10
AFC-Holcroft
Offering thermal processing solutions to meet the increasing demand for flexible, scalable heat treatment systems with consistent,
repeatable metallurgical results.
Our featured UBQ (Universal Batch Quench) system is capable of running a variety of metallurgical processes; whether a single unit or as a
complete, fully-automated cell integrated with
companion equipment. With its compact, modular design, additional cells can be added for maximum production flexibility.
When high volume production is needed, our
classic pusher-style furnace offers continuous
throughput under protective gas atmosphere. Many of
the largest manufacturers worldwide rely exclusively on AFC-Holcroft pusher furnaces for maximum control and economy.
With offices on 3 continents
and partners worldwide, AFC-Holcroft stands ready to help you meet your specific heat treatment
needs. ISO 9001:2008 certified. www.AFC-Holcroft.com
Booth 1817
Booth 1723
BeaverMatic Inc.
Jack Beavers began a determined journey toward furnace innovation with simplified yet sophisticated equipment designs 50
years ago. From our past successes and solid installation base,
BeaverMatic remains steadfastly focused
on its core competency to build simplified
yet dependable performance-proven
equipment. Today, BeaverMatic is a
family-owned manufacturer of custom,
standard, batch and continuous
atmosphere heat-treating equipment.
Best known for the Internal Quench
Furnace with Beaver Ram transfer
system, BeaverMatics product line
includes temper furnaces, washers,
endothermic gas generators, box
furnaces, pit furnaces, continuous
pushers, carbottom furnaces, and tip up
furnaces. Come visit us in booth 2016 where we will feature the
various Internal Quench Furnace configurations that we have available. www.beavermatic.com
Booth 2016
52
Booth 1710
GeoCorp Inc.
GeoCorp Inc. is a manufacturer of thermocouples and thermocouple wire. GeoCorp keeps an extensive inventory so thermocouple and thermocouple wire lead-times are DAYS NOT WEEKS to ship.
We can even inventory your products at our plant through our blanket order system so the product is ready to ship the same day. All
thermocouples and thermocouple wire meets Boeing BAC 5621 K,
AMS 2750 Rev.E, CQI-9 and P10TF3 requirements. GeoCorp can offer
thermocouples and thermocouple wire with a maximum temperature tolerance of +/- 2F or 0.2%, whichever is greater. We have an
on-site ISO 17025:2005 accredited calibration lab that provides temperature certification for thermocouples and thermocouple wire.
www.geocorpinc.com
Booth 1706
Booth 1728
Inductoheat Inc.
HTPRO
11
Booth 1744
Booth 1701
Ipsen Inc.
Booth 1529
Booth 1601
Booth 1823
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
53
HTPRO
13
eral boost intervals, because its decomposition is catalyzed by iron atoms at the
gear surface, providing high carbon potentials for diffusion into the austenitic
structure[5]. After achieving the desired
0.31.0 mm carburized case depth, the
workload is transported into the
quenching chamber where controlled
cooling using high pressure, turbulent
nitrogen gas flow produces the desired
microstructure[6]. Surface and core hardness, as well as properties such as fatigue
strength, wear resistance, and pitting
corrosion resistance are determined by
the microstructural constituents resulting from different cooling rates and carbon profile[6].
For example, a straight quench at constant pressure and velocity leads to a
large temperature difference between
the gear surface and core, introducing
nonuniform thermal and martensitetransformation stresses, which can
cause distortion as shown in Fig. 1b.
Stop quench, dynamic quenching, and
reversing quenching are recent developments[1-5] used to control cooling rate
(and thus phase transformation) in three
steps: (1) high quench severity prior to
martensite phase transformation to
27C
Temperature
C2H2 2C + H2
N2 flow
Heating
Austenite
Carburizing
Diffusion
N2 + acetylene
boost
N2 flow
High pressure
120 bar
~870C
Pearlite
~400C
Bainite
Ms
Quenching
Pearlite
T
Step quench
P, v constant
Tcore
Bainite
Ms
Tsurface
Time
(c)
Straight quench
P, v = constant
Tcore
Temperature
Time
Temperature
(a)
Pearlite
Tsurf.
Bainite
Ms
T 0
Time
Fig. 1 (a) LPC and HPGQ heat treating process and schematics of (b) straight quench and (c) step quench.
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
55
HTPRO
14
Mechanical properties:
f (phase, T, )
E (phase, C,)
CTE (phase, C,)
transformation (phase)
Mechanical
analysis
Thermodynamics:
(phase, C, T)
Ms (C,)
CP (phase, C, T)
(phase, C, T)
TTT (C,)
N2 (T)
Hardness
Temperature
L (dT(x, y, z)/dt) distribution
Displacement 100
distribution
Fig. 2 ICME-GearHT is a suite of integrated computational materials engineering (ICME)
tools to predict quantitative processing-structure-property relationships for gear heat
treatment.
avoid pearlite formation, (2) temperature equalization in each part, and (3)
fast cooling to generate martensite for
surface and core hardening (Fig. 1c).
The prediction of heat transfer in combination with the phase-transformation
process during HPGQ has become increasingly important as more attention
is paid to optimizing the quenching
process to minimize distortion[8-10]. The
need for CAE tools that can predict the
conjugate heat transfer during high
pressure gas quenching and couple it
with phase transformation distortion
analysis led to the development of
ICME-GearHT.
Computational tool development
The ICME-GearHT tool enables accurate simulation of the transmission gear
heat-treatment process, predicts phase
transformation kinetics and distortion,
and provides cost-effective, time-efficient evaluation of new equipment designs. These will ensure high quality
product launch and help achieve a firsttime-through manufacturing vision
(Fig. 2). This was accomplished by gaining a clear understanding of the fundamentals of carburizing, conjugate heat
transfer, phase transformation, and micromechanics during the gear heat
treatment process; and integration with
the most advanced models in different
disciplines[8-10] and related leading industrial experimental validations.
ICME-GearHT analysis is broken down
into four parts: carburization, CFD,
phase transformation, and mechanical
analysis. Figure 2 shows the data requirements and how the analyses are coupled.
Each analysis starts from diffusion-based
carburization at high temperature using
56
during quenching[12]. However, commercial CFD codes are intrinsically unable to accurately predict the thermal
history of the gear quenching process
due to the lack of a phase-transformation model. We implemented a subroutine in the commercial Fluent CFD code
to take the latent heat effect due to
phase transformation into account.
Model validation is accomplished using
experimentally measured temperature
data (Fig. 3 I-a) at 40 and 100% fan
speeds. Figure 3 I-b shows that higher
cooling velocity results in higher heattransfer coefficient. The predicted thermal profile captures the effect of latent
heat release, agreeing well with experiments for different gear orientations (Fig.
3 I-c). Temperature uniformity during
HPGQ is critical for improving process
performance to minimize distortion and
maximize gear service life. Therefore, the
ICME-GearHT model was used to evaluate properties of furnace-fixture materials, chamber configurations, and parts
loading in the furnace.
Experimental validations
New kinetic parameters were developed
for 5130 alloy steel, which is widely used
for transmission gears. Kinetic parameters in the phase transformation models
were determined using an optimization
approach that matches model predictions
with experimental measurements. The
parameters were implemented into the
DANTE materials database, allowing accurate prediction of phase transformation and seamless integration with the
micromechanical model for calculating
both thermal and transformation plasticity during the gear quenching process.
Distortion analysis using ICME-GearHT
is validated by mapping the distortion at
various locations of the load and at three
different quenching conditions including
step quench, 40% fan speed, and 100%
fan speed. The experimental setup is
shown in Fig. 3 II-a. Experimentally
measured distortion at three different
conditions (Fig. 3 II-b) agrees well with
previous studies[7]. Step quenching produces less distortion and better product
quality. Distortion calculations determined using the ICME-GearHT approach are compared with experimental
results to provide efficient, effective solutions for process design and optimization. Figure 3 II-c shows predicted gear
(l-b)
1000 (l-c)
100% fan speed
40% fan speed
1400
1000
200
200
0 1 2 3 4 5
400
Circularity
(II-a)
300
200
100
0
600
400
600
500
800
6 7 8 9
700
After straight After
600
straight
quench at
500
quench
40%
fan
Max
at 100%
speed
fan speed 400
Min
300
200
After
stop
Before
quench
heat
100
treatment
0
0
0
(lI-b)
TC #08
TC #09
TC #07
10
20
30
40
Time, s
50
60
100%
fan
speed,
straight
quench
Circularity from major (Sim.)
Gear #07
Exaggerated
distortion 100
8
9
10
Gear Number
(lI-c)
Fig. 3
(I-a) experimental
setup for measuring
the temperature field,
(I-b) heat transfer
coefficients
calculated from
experiments,
(I-c) predicted
temperature
compared with
experimental results,
(II-a) experimental
setup for distortion
analysis,
(II-b) distribution of
measured distortion
values, and (II-c)
predicted distortion
for 100% straight
quench
(exaggerated/
magnified by 100).
HTPRO
HTC, W/m2 K
1800
TemperatureC
(I-a)
15
57
HTPRO
Summary
The ICME-GearHT model incorporating latent heat release due to phase
transformation was validated using experimental data. The entire workload is
a complex thermal body subjected to
large temperature variations during
quenching. ICME-GearHT captures
those variations. It was used to investigate and validate a new gas quenching
process, propose cost-effective, time-efficient recommendations for new transmission-product development, and
accelerate new process development. It
was also used to evaluate the benefits of
using different heat treating furnace-fixture materials and different quenching
furnace stator and fan designs to improve temperature distribution uniformity for reduced distortion.
16
58
Treat Process and Alloy on the Surface Microstructure and Fatigue Strength of Carburized Alloy Steel, SAE Tech. Paper
1999-01-0600, 1999.
7. A. Goldsteinas, High Pressure Gas
Quench Technologies: Distortion Control &
Mechanical Properties Improvement, SAE
Tech. Paper 2008-01-0433, 2008.
8. W.E. Dowling, et al., Development of a
Carburizing and Quenching Simulation
Tool: Program Overview, Proc., 2nd Intl.
Conf. on Quenching and Control of Distortion, ASM Intl., 1996.
9. B. Ferguson and W.E. Dowling, Predictive
Model and Methodology for Heat Treatment Distortion, Natl. Ctr. for Mfg. Sci. Report #0383RE97, 1997.
10. B. Ferguson, Z. Li, and A. Freborg, Modeling Heat Treatment of Steel Parts, Comput.
Matl. Sci., 34, p 274281, 2005.
11. R.H. Leal, Transformation toughening of
metastable austenitic steels, Ph.D. thesis,
MIT, Cambridge, Mass., 1984.
12. S.J. Lee and Y.K. Lee, Finite element simulation of quench distortion in a low-alloy
steel incorporating transformation kinetics,
Acta Mater., 56, p 14821490, 2008.
For more information: Junsheng Wang is
research scientist, Ford Research and Advanced Engineering Lab, 2101 Village Rd.,
Ford Motor Co., Dearborn, MI 48124,
313/390-5503, jwang134@ford.com.
HTPRO
LOW-DISTORTION, HIGH-QUALITY
INDUCTION HARDENING
OF CRANKSHAFTS AND CAMSHAFTS
17
59
HTPRO
18
60
The inductor for the nonrotational hardening process consists of two sections
(Fig. 2, bottom) machined from a copper
block: a top (passive) inductor and bottom (active) inductor. The
bottom inductor is
connected to a medium-frequency power supply,
and the top inductor
represents (electrically) a short circuit
(closed loop). The bottom coil is stationary, while
the top coil can be opened and closed.
Each inductor has two semi-circular
areas to locate journals to be heat
treated, while the top inductor is in the
open position.
A robot loads the crankshaft into the
heating position, the top coil pivots
into a closed position, and power is
applied to the bottom coil. Electrical
current flows in the bottom coil, and
with a lamination pack that serves as
a magnetic flux coupler, both top and
bottom coils are tightly electromagnetically coupled. Current flowing in
the bottom coil instantly induces
eddy currents that begin to flow in
the top coil. According to Faradays
law of electromagnetic induction,
the induced currents are oriented in
a direction opposite that of the
source current, similar to a transformer effect.
The heated crankshaft journal sees the
nonrotational inductor as a fully encircling, highly electrically efficient induc-
HTPRO
Scan inductors offer the greatest flexibility by enabling lobes of various lengths to
be heat treated using minimum power,
because only a portion of the lobe is
heated. Low production rates, due to single-lobe processing, are the main limitation of using a scanning technique to
surface harden automotive camshafts.
Trying to produce the required range of
minimum-maximum hardness case
depths is also a challenge. In addition,
heating lobes that have an appreciably
different ratio of cam-nose diameter-tobase-circle diameter is difficult unless
lobes are stationary during processing
and properly oriented with respect to the
profiled inductor. Scan hardening is also
difficult when lobes are in close proximity to each other (i.e., triple-lobe cams).
19
61
HTPRO
20
MODELING DISTORTION
AND RESIDUAL STRESSES OF
AN INDUCTION HARDENED TRUCK AXLE
ELECTROMAGNETIC AND THERMAL-STRESS MODELING OF INDUCTION SCAN HARDENING
HOLD PROMISE FOR OPTIMIZING PART DESIGN, PREVENTING IN-PROCESS FAILURE,
AND PREDICTING SERVICE PROPERTIES.
Zhichao (Charlie) Li*
B. Lynn Ferguson, FASM*
DANTE Software, Cleveland
Valentin Nemkov*, Robert Goldstein*,
and John Jackowski
Fluxtrol Inc., Auburn Hills, Mich.
Greg Fett*
Dana Corp., Maumee, Ohio
(b)
stresses, which are further used to analyze the mode and location of fatigue
failures[2]. Component geometry and
process can also be optimized to reduce
part weight, trim manufacturing costs,
and improve performance.
Induction hardening of steel components is a common processing method
due to fast heating times, high efficiency,
and ability to heat locally. However, predicting final properties of a hardened
component adds another layer of complexity. Temperature and structure must
be considered, as well as electromagnetism. When hardening steel, magnetic
properties change throughout the
process, affecting thermal distribution
and structure. Coupling these phenomena to achieve end properties after treatment is a state-of-the-art technology. In
a simple case, stress and distortion modeling of ID and OD hardening of a tubular product was investigated[3]. To study
a component common in industry with a
more complex geometry and subjected
to external stresses in service, a full-float
truck axle with dimensions typical to
those manufactured by Dana Corp. was
selected. Using an axle (a common automotive component) enables comparing
simulation results to desired axle properties. Results are compared to typical
performance criteria for the selected
axle. The goal is to produce results representative of actual part performance.
Part geometry and model for
thermal/stress analysis
Axles must be surface hardened for
durability to prevent failure in service.
Hardening is commonly performed
using induction scanning. Induced
stresses and distortion are affected by
the method in which the induction scan
process is performed. Bowing distortion
and change in length are the main con-
HTPRO
21
63
HTPRO
22
Fig. 3 From left to right: temperature, austenite phase, hoop stress, radial displacement,
and axial displacement distributions at the end of 16.5 s in the induction heating process:
Heat transfer coefficient = 25 kW/m2 C.
64
Gas inlet
Gas inlet
(a)
(b)
Gas outlet
Bias
generator
Pulse
generator
(anode)
24
Furnace wall
Pulse
generator
HTPRO
Gas outlet
Plasma nitriding and plasma nitrocarburizing are used to improve wear and
corrosion resistance, as well as fatigue
strength of steel components. Compared
with conventional gas and salt-bath nitriding methods, plasma nitriding offers
advantages of lower energy and gas consumption and the ability to be integrated
into in-line manufacturing processes.
The process is environmentally friendly
as well. Additionally, partial nitriding is
possible by masking areas where nitriding is not required; surface enrichment
with nitrogen and carbon occurs only at
areas exposed to the plasma glow discharge. Glow-seam thickness is highly
dependent on process parameters, especially gas pressure. Adjusting working
pressure improves the plasma seam for
true shape coverage of components with
a complex geometry.
Limitations of plasma nitriding stem from
applying the plasma discharge energy directly onto the surface of parts to be
treated, resulting in a nonhomogeneous
temperature distribution through the
workload, especially for components with
different surface-to-volume ratios. Therefore, only parts with similar geometries
can be treated together in the same batch.
Furthermore, parts must be arranged in
the chamber in a specific manner.
Plasma nitriding equipment can be improved by placing resistance heating elements in the furnace wall and
implementing pulsed mode plasma discharge with controlled pulse frequency
66
Varying the N2-to-H2 gas ratio in the N2H2 plasma has a strong influence on compound-layer growth rate and structure up
to the point of suppressing layer growth.
Figure 3 shows the microstructure of the
nitrided layer and the x-ray diffraction
(XRD) spectrum of the compound layer
of active screen plasma nitrided 1045 carbon steel, which has a single-phase
layer thickness of about 5 m.
Bias activation can also be used to control nitrogen concentration near the
component surface. The role of bias
power in the ASPN process is shown in
Fig. 4. An increase in bias power leads to
a significant improvement of compound-layer thickness. Surface hardness, hardness profile, and hardness
depth are not dependent on compound
layer thickness.
Nitriding with or without a very thin
phase compound layer typically results
in decarburization of the nitrided layer,
which prevents precipitation of carbides
along grain boundaries up to 70 to 100
Intensity/Imp.s-1
400
200
0
20
(a)
25
30 40 50 60 70 80
Diffraction angle 2/grad
(b)
10 m
Fig. 3 XRD-pattern (a) and metallographic cross section (b) of the active screen plasma
nitrided sample of 1045 carbon steel with compound layer: TN = 580C, tN = 4 h.
16
CL thickness, m
600
12
8
4
0
(a)
600
Hardness, HV0.1
Figure 2 shows a dense workload consisting of about 22,000 Type AISI 304
stainless steel piston rings that were
treated in a single batch using the ASPN
process. Treating a similar workload in a
conventional plasma nitriding unit is not
possible. Even using gas nitriding, surface activation of the high-alloy steel
would present severe problems due to
the influence of various uncontrollable
parameters in the pretreatment step.
800
HTPRO
500
0.13
0.26
0.39
Bias, W/in.2
Bias
0.13 W/in.2
0.45 W/in.2
4142 alloy steel
400
300
(b)
4
8
12
16
20
Distance from surface, mm
67
(a)
00
C
5 10 15 20 25 30
Distance from surface, m
60
40
Fe
20
0 Fe C
3
20
30
40
50
60
(b)
Diffraction angle 2/grad
Fig. 6 Carbon- and nitrogenconcentration profiles of active screen
plasma nitrocarburized 4142 alloy steel
(a) and XRD pattern of active screen
plasma nitrocarburized 1045 carbon steel
(b): TN = 580C, tN = 8 h.
68
CO2:H2
0.19
1.0
2
6
4
2
0
3
Carbon conc., wt%
10
Nitrogen conc., wt%
80
Intensity/Imp.s-1
HTPRO
26
0
5
10
15
20
Distance from surface, m
ASMnews
www.asminternational.org/ASMnews
Official Notice:
ASM Annual Business Meeting
The Annual Business Meeting of members of ASM International
will be held in conjunction with MS&T13 on:
Monday, October 28, 2013
4:00 5:00 p.m.
Palais des congre`s de Montral, Canada
The purpose of the ASM Annual Business Meeting is the
election of officers for the 2013-14 term and transaction of
other society business.
78 Chapter News
79 Emerging Professionals
Submit news of ASM and its members, chapters, and affiliate societies to
Joanne Miller, editor, ASM News ASM International, 9639 Kinsman Road, Materials Park, OH 44073
tel: 440/338-5151, ext. 5662 fax: 440/338-4634 e-mail: joanne.miller@asminternational.org
Contact ASM International at 9639 Kinsman Road, Materials Park, OH 44073 tel: 440/338-5151, ext. 0, or 800/336-5152, ext. 0
(toll free in U.S. and Canada) fax: 440/338-4634 e-mail: MemberServiceCenter@asminternational.org website: www.asminternational.org
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
71
ASMnews
ASMnews
Nomination Deadline
for the 2014 Class of Fellows
is Fast Approaching!
The honor of Fellow of the Society was established to provide recognition to members for distinguished contributions in
the field of materials science and engineering, and to develop
a broadly based forum for technical and professional leaders
to serve as advisors to the Society.
Criteria for the Fellow award are:
Outstanding accomplishments in materials science or
engineering
Broad and productive achievement in production,
manufacturing, management, design, development,
research, or education
Five years of current, continuous membership in ASM
International
Deadline for nominations for the class of 2014 is November
30, 2013.
Complete information including the rules, interpretive comments, and online nomination forms are available on the ASM
website at www.asminternational.org/awards, or by contacting Christine Hoover, ASM International, 440/338-5151, ext.
5509, christine.hoover@asminternational.org.
Seeking Nominations
for Thermal Spray Hall of Fame
73
ASMnews
ASMnews
75
ASMnews
IN MEMORIAM
In July, just short of his 95th birthday, James
M. Taub, FASM, of Tucson, Ariz., passed
away. He was born and raised in Cleveland and
earned his B.S. from Case School of Applied
Sciences and returned to Case for night school
to earn his M.S. in metallurgical engineering.
For two years he worked for Republic Steel
Corp., and then returned to Case to work in a
research and development program. In 1944, he was invited to
Los Alamos, N.M., for a top-secret government program, which
turned out to be the Manhattan Project. He became group leader
of CMB-6 for the Los Alamos Scientific Laboratory (now LANL)
and held that position for 29 years. He retired in 1981 after nearly
37 years with the lab. In 1963, he received a letter from President
Kennedy authorizing the Atomic Energy Commissions recommendation that he be awarded the prestigious Ernest Orlando
Lawrence Award. He was the first metallurgical engineer to receive that recognition.
Prof. Samuel Stanford Mansons name survives in decadesold formulas still in use to predict metal fatigue on Earth and in
space. The NASA Lewis Research Center (Cleveland) retiree
died July 7 in Santa Barbara, Calif., at age 93. Stan Manson
earned a masters degree at the University of Michigan. In 1942,
Manson joined the Langley Research Center, a Virginia facility
of the National Advisory Committee for Aeronautics, later
NASA. A year later, he transferred to Clevelands Lewis Laboratory. He helped discover the Manson-Coffin Law and the
Manson-Hirschberg Method of Universal Slopesfindings
crucial to space engines and heat shields. He later became chief
of Lewis new Materials and Structures Division. Manson retired from NASA in 1974 and began teaching at Case Western
Reserve University (Cleveland). Prof. Manson was coauthor,
with Gary Halford (also now deceased), of two ASM books: Fatigue and Durability of Structural Materials and Fatigue and
Durability of Metals at High Temperatures. He was also past
president of the Society for Experimental Stress Analysis.
Mr. David J. Chellman passed away on July
15 at the age of 66. He was a long time Senior
Technical Fellow at Lockheed Martin Aeronautics (LM Aero) in the Advanced Development Program organization (aka Skunk
Works) with more than 36 years of experience
in the aerospace industry. In addition to 21
years as an LM Technical Fellow, Chellman
was also an AIAA Associate Fellow. He was recognized for outstanding work in the development, evaluation, and application
of advanced metallic materials, ranging from low density and
high temperature aluminum alloys to creep resistant titanium
alloys. He served as technical consultant on numerous LM
committees and was an executive committee member for AeroMat and ASM annual technical meetings. He was a co-recipient of both the 2003 Defense Manufacturing Technology
Achievement Award for Laser Additive Manufacturing Technologies and the 2001 R&D 100 Award for High Temperature
Supersonic Aluminum Alloy Development. He received his
M.S. in metallurgy and materials science from the University
of California at Los Angeles.
76
inaugural recipient of the Dresselhaus Award is Polina Anikeeva, the AMAX Career Development Assistant Professor
in Materials Science and Engineering. Anikeeva's research
focuses on materials and devices for neural prosthetics.
ASTM Honors Brandt
Michael Brandt, senior staff manager,
quality systems, at Alcoa Inc., Alcoa Center, Pa., received the ASTM International
Award for Merit for exceptional and sustained leadership and technical contributions within Committee B07 on Light
Metals and Alloys. The Award of Merit,
which also includes the honorary title of
Fellow, is ASTMs highest organizational recognition for individual contributions to standards activities.
A member of ASTM International since 2004, Brandt currently serves as Committee B07 recording secretary. He is also
secretary of Subcommittee B07.01 on Aluminum Alloy Ingots
and Castings and chairs the U.S. Technical Advisory Group
National Committee for ISO/TC 79 on Light Metals and Alloys (B07.09). Brandt is a member of ASM International, the
American Society for Quality, and SAE International.
Nanoengineering at NC State
North Carolina State University is launching a masters degree program in nanoengineering. There has long been a
tremendous focus on nanoscience, but for that science to
benefit society, we need nanoengineering, says Dr. Justin
Schwartz, Kobe Steel Distinguished Professor and head of
NC States Materials Science and Engineering Department,
which will house the new degree program. The program begins this fall and will hold classes on campus, but will also
be the first masters degree program in nanoengineering offered online. This is one of only a few comprehensive, engineering-specific
masters
degrees
focused
on
nanotechnology and nanomaterials, says Dr. Jay Narayan,
FASM, the John C. Fan Distinguished Chair Professor of
Materials Science and Engineering at NC State and senior
advisor to the degree program.
ASM Receives
Solar Atmospheres
Vacuum Furnace Donation
for 100th Anniversary
ASM International, Materials Park, Ohio, is proud to announce the donation of a new $250,000 lab-sized furnace,
designed specifically for use at Materials Park, by Solar Atmospheres Inc., Souderton, Pa. The gift commemorating the
ASM 100th Anniversary will better enable and further education efforts at ASM. The official dedication ceremony was
held July 20 with a ribbon cutting as part of the Annual
Chapter Leadership Days and the ASM Materials Education
Foundations Eisenman Materials Camp. The students attending the camp were excited to be the first users of the
new furnace.
77
ASMnews
HIGHLIGHTS...ASM/TMS Lectureship
ASMnews
Chapter News
Lehigh Valley Materials Camp in the News
Students who attended Materials Camp at Lehigh University, Bethlehem, Pa., held July 8-12, found themselves in the
news. The site www.azom.com
published the story, Teenagers
Fabricate Chocolate Composites, which described such fun
experiments as determining
which two candy types, when
combined with chocolate, will
form the strongest composite.
Its a lesson in bonding and fracture aimed at exciting students
in materials, engineering, and
science. The camp, hosted each
year by Lehighs department of
For their chocolate composite,
materials science and engineerKenny Gahler (left) of Boyertown
High School and Eric Scott of
ing and the ASM Lehigh Valley
Southern Lehigh High School chose Chapter, also received sponsorWhoppers for impact resistance and
ship from several local compaGummy Worms for their stretching
nies, including Carpenter
ability.
Technologies of Reading, Pa.
Lehigh is the first ASM Materials Camp to be taught by
graduate students. The camps faculty adviser, Wojciech Misiolek, and two former instructors, Ryan Deacon and Clifford Prescott, explained why in 2006 in the International
Journal of Engineering Education. The concept behind this
new format is simplethe young teaching the young, they
wrote. Teenagers relate better to slightly older students than
to faculty members, they said, and graduate students learn
how to teach and present engineering concepts.
VOLUNTEERISM COMMITTEE
Profile of a Volunteer
For a list of upcoming ASM Training Courses, see our ad on pages 38-39 of this issue.
78
EMERGING PROFESSIONALS
Materials Park, Ohio, was the site of the 14th annual ASM
Eisenman Materials Camp, sponsored by the ASM Materials
Education Foundation. Jaret J. Frafjord, technical director at
IMR KHA in Portland, Ore., served as curriculum leader. A
team of mentors assisted him in developing the weeks activities to excite high school juniors and seniors to explore careers
in materials, science, and engineering.
Dr. Daniel P. Dennies,
FASM, senior
managing engineer at
Exponent, shows a
microstructure to
campers microstructure
to campers Quentin
Chaillet (France) and
Isaac Luther (Ohio), and
mentor Philippe Maret
(France).
The cooperative Visiting Lecturer program of ASM International and the Indian
Institute of Metals (IIM) is pleased to announce the five distinguished individuals
named to participate in the 2013 Visiting
Lecturer program: Prof. Arun Gokhale,
FASM, Georgia Tech, Atlanta; Dr. Sandip
Harimkar, assistant professor, Oklahoma
Gokhale
Harimkar
Kumar
Singh, D
Singh, N.
State University, Stillwater; Dr. Prabhat
Kumar, FASM, H.C. Starck Inc., Framingham, Mass.; Dr. Dileep Singh, materials scientist, Argonne National Laboratories, Lemont,
Ill.; and Prof. Narsingh Singh, FASM, University of Maryland, Baltimore. The award includes an $800 honorarium to be used for
travel expenses within India during the lecturers visit and a certificate of recognition to be presented at the ASM Leadership Awards
Luncheon scheduled for October 28 in Montral, Canada during MS&T13.
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
79
ASMnews
products &
literature
80
classifieds
Apple Rubber Products, Lancaster, N.Y., offers two new silicone
compounds with UL 50 and UL 50E certifications for use with and
without environmental considerations. 14SL7ML and 35SL5ML provide an ultra-low compression set, even at elevated temperatures,
and offer quality and durability needed for safe operations. Included
in the UL listings are end uses for both atmospheric and generated
ozone. The compounds do not contain phthalate plasticizers, which
would craze plastic-based enclosures, or require any anti-corrosion
inhibitors for metal enclosures. www.applerubber.com.
Park Systems, Santa Clara, Calif., introduced Park NX-HDM, a
fully automated defect review and sub-angstrom surface roughness atomic force microscopy system for device substrates
and disk media. The system increases throughput up to 1000%
and offers a 30% higher success rate than the prior system, analyzing, identifying, and scanning media for all wafer sizes to 150
mm. The survey scan, zoom-in scan, and analysis of imaged defect types are automated with a wide range of optical inspection
tools. www.parkafm.com.
KLA-Tencor Corp., Milpitas, Calif., announced the 2910 Series
optical wafer defect inspection platform with NanoPoint technology and new eDR-7100 electron-beam wafer defect review
system. These tools combine increased speed with seamless
connectivity to quickly find and identify defects that inhibit yield
and reliability. The 2910 Series improved defect capture and the
eDR-7100s enhanced review resolution have been demonstrated
by detecting and imaging unique defects located at the bottom of
3D or vertical pattern structures such as FinFETs.
www.kla-tencor.com.
ad index
Advertiser
Page
AFC-Holcroft
49, 52
Allied High Tech Products Inc.
BC
Applied Test Systems Inc.
82
BeaverMatic Inc.
51, 52
Bose Corp.
3
Can-Eng Furnaces International Ltd.
52
Carl Zeiss MicroImaging Inc.
31
Carpenter Technology Corp.
24
Centorr Vacuum Industries Inc.
82
Clemex Technologies Inc.
19
Consarc Corp.
40
Dry Coolers Inc.
52
Epsilon Technology Corp.
81
GeoCorp Inc.
44, 52
Goodfellow Corp.
IBC
Harper International Corp.
25
Induction Tooling Inc.
53, 68
Inductoheat Inc.
53, 54
Instron
23
Ipsen Inc.
IFC, 4243, 53
JEOL USA Inc.
5, 7
Kureha America Inc.
53
Master Bond Inc.
80
Nitrex Metal Inc.
58
NSL Analytical Services Inc.
30
Portable Heat Treating Repairs, LLC
68
Proto Mfg. Ltd.
80
Shimadzu Scientific Instruments, subs. Shimadzu Corp.
11
Struers Inc.
16
Surface Combustion Inc.
53, 65
Thermo-Calc Software Inc.
29
Tinius Olsen Inc.
69
Ulbrich Stainless Steels & Special Metals Inc.
9
United Process Controls
53, 57
Westmoreland Mechanical Testing & Research Inc.
81
The ad index is published as a service. Every care is taken to make
it accurate, but Advanced Materials & Processes assumes no
responsibility for errors or omissions.
ADVANCED MATERIALS & PROCESSES SEPTEMBER 2013
81
editorial preview
OCTOBER
Nondestructive Testing
Highlighting:
Modeling NDE Processes
Advanced NDE Techniques
Integrated Computational Materials
Engineering (ICME)
Bonus Distribution:
International Symposium for Testing and Failure
Analysis (ISTFA) 2013,
November 3-7, San Jose, Calif.
Advertising closes September 4, 2013
NOVEMBER/DECEMBER
Materials Testing/Characterization
Highlighting:
Fracture Toughness Testing for Ductile
Materials
Robotic In-line Testing for Automotive
Applications
Critical Materials and Conflict Minerals
Special Supplements:
International Thermal Spray and Surface
Engineering newsletter covering emerging
technologies in the thermal spray industry.
HTPro newsletter covering heat treating
technology, processes, materials, and
equipment, along with Heat Treating Society
news and initiatives.
Advertising closes October 4, 2013
Contact us:
9639 Kinsman Road
Materials Park, OH 44073-0002
Tel: 440/338-5151
Fax: 440/338-4634
Web: www.asminternational.org/AMP
Subscriptions/Customer Service: 800/336-5152, ext. 0
E-mail: MemberServiceCenter@asminternational.org
Sales Staff:
Skip Wolfe, Director, Sales and Marketing
440/338-5151 (ext. 5226)
Fax: 440/338-8542
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National Sales Manager
440/338-5151 (ext. 5574)
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iTSSe/Affiliate Sponsorships
Kelly Thomas, CEM.CMP
National Account Manager
440/338-1733
Fax: 614/948-3090
kelly.thomas@asminternational.org
82
pastimes
Selected items from the pages of ASM Internationals monthly magazine: Metal Progress was published
from 1930 to 1986, after which Advanced Materials & Processes came into being.
Critical materials remain a timeless concern
From the article, Where Will We Get Our Future Metals?
Metal Progress, January 1950
The U.S. mining industry does not supply many necessary metals. For example, in recent years we have been
dependent on foreign sources for more than 90% of our beryllium, chromium, cobalt, columbium, nickel and tantalum.
Numerous problems of the domestic mining
industry were not solved satisfactorily in World
War II. These problems may be even more
important in a future emergency. Table source:
Special Study No. 30Import Policies and
Programs of the War Production Board and
Predecessor Agencies, May 1940 to November
1945, by David Horton. Washington, Civilian
Production Administration, May 1, 1947.
Micrographic rodent
From the Letters department,
Metal Progress, August 1980
A Mouse of Steel
I have been intrigued by the structural
animals (or animal structures) that occasionally
appear in Letters. To my great surprise, I
discovered a similar encroachment in the
microstructure of a carbon steel casting: An
energetic mouse! The 200 photomicrograph
shows microshrinkage with sulfide slag.
Yngve Bostrom, Dept. of Materials Testing,
AB Motala Verkstad, Motals, Sweden
83
At the University of California, Los Angeles (UCLA), 273 students in Neil Gargs
popular organic chemistry course, Chemistry 14D, created 98 music videos
detailing various chemical reactions they learnedthe most videos in the four
years Garg has offered the extra-credit assignment. Perhaps none is as creative
as Alkenes Are Used for These, an animated video made by Jessica Lee, Emily
Chuang, Christine Nguyen, and Maggi Lai. In the video, a student studying
chemistry falls asleep and is transported into a nightmarish world where she is
tormented by the Joker from Batman. Just as death appears inevitable,
professor Garg, in a cameo as the Caped Crusader, comes to the rescue and all
is right in the worlduntil the student wakes up and must find a rhyme for
ozonolysis.
Still from video by team Chem 14Dreamers (l-r):
What do the students learn from making these music videos? Nguyen
Laura Lorenzana, Michael Sianturi, Andy Truong,
learned a great deal about audio and video editing, and Chuang learned about
Sayda Hartoonian. Courtesy of the team.
animation. Lee values the teamwork with her fellow students. One student noted
We invite contributions for this page!
how it is impossible to get the reaction mechanisms out of my head. I literally
Please send cartoons, trivia, jokes, photomicrographs,
etc., to stressrelief@asminternational.org.
dreamt about organic chemistry three nights in a row. At this point, Im not
If we use your idea, we will send you
forgetting those organic reactions, because we made them rhyme. Visit
a cool mini multi-tool.
http://ucla.in/15Ur2uv and http://ucla.in/L38Gze to watch the videos.
84