GROZA: “3216_c000” — 2007/2/8 — 21:28 — page i — #1 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page ii — #2 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page iii — #3 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page iv — #4 Contents Preface. ix About the Editors. xv SECTION I Small-Scale (Atomic/Cluster/Nanoscale) Processes 1 Controlled Processes for Growth of Carbon Nanotube Structures Robert Vajtai and Pulickel M. 1-1 2 Controlled Self-Assembly Nathan W.
Moore and Tonya L. 2-1 3 Ion-Beam Processing Sergei O. 3-1 4 Spinodal Decomposition Subhash H. 4-1 5 Ostwald Ripening in Materials Processing K.
5-1 6 Crystallization of Amorphous Material Jürgen Eckert and Sergio Scudino. 6-1 7 Far-from-Equilibrium Processing of Nanostructured Ceramics Bernard H. Kear and Amiya K. 7-1 v GROZA: “3216_c000” — 2007/2/8 — 21:28 — page v — #5 vi Contents SECTION II Deposition Processes 8 Physical and Chemical Vapor Deposition Processes Chad Johns, M.
Saif Islam, and Joanna R. 8-1 9 Epitaxial Processes Peter Bjeletich. 9-1 10 Ion Beam Assisted Deposition Michael Nastasi, Amit Misra, and James W. 10-1 11 Spray Deposition and Coating Processes Jean-Pierre Delplanque, Samuel Johnson, Yizhang Zhou, and Leon Shaw.
11-1 SECTION III Dislocation-Based Processes 12 Metalworking C. 12-1 13 Mechanical Alloying and Severe Plastic Deformation A. 13-1 14 Superplasticity and Superplastic Forming Indrajit Charit and Rajiv S. 14-1 SECTION IV Microstructure Change Processes 15 Single Crystal Growth Roberto Fornari.
15-1 16 Casting and Solidification Rohit Trivedi and Wilfried Kurz. 16-1 17 Rapid Solidification and Bulk Metallic Glasses — Processing and Properties Jörg F. Kündig, and Florian H. 17-1 18 Diffusion-Based Processes A.
18-1 19 Basic Phase Transformations in Heat Treatment John Ågren. 20-1 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page vi — #6 Contents vii 21 Bonding Processes M. 21-1 22 Electrolytic Processes Uwe Erb. 22-1 SECTION V Macroprocesses 23 Glass Processing Alexis G.
24-1 25 Powder Processing Randall M. 25-1 26 Layer-Based Additive Manufacturing Technologies Brent E. 26-1 27 Solidification Macroprocesses (Thermal — Mechanical Modeling of Stress, Distorsion and Hot-Tearing) Michel Bellet and Brian G. 27-1 SECTION VI Multiscale Processes 28 Processing Nanoscale Structures to Macrocomposites Hans J.
28-1 29 Thermomechanical Processing John J. Barnett, and Peter D. 29-1 30 Multiscale Processing of Polymers and Nanocomposites Carol Barry, Julie Chen, Joey Mead, and Daniel Schmidt. 30-1 31 Multiscale Processes in Surface Deformation Leon L.
Shaw and Yuntian T. I-1 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page vii — #7 GROZA: “3216_c000” — 2007/2/8 — 21:28 — page viii — #8 Preface By the dawn of the 21st century, the field of materials science and engineering has evolved into a science of its own, embracing the well-established disciplines of physical metallurgy and ceramic/glass engineering, along with new and emerging developments in electronic, optical, and magnetic materials, as well as semiconductors, polymers, composites, bio- and nano-materials. Despite the enormous diversity in modern day advanced engineering materials, they are tied together by unifying concepts and first principles in areas such as thermodynamics of equilibria, statistical mechanics, phase transformations, matter and energy transport, as well as fundamental material structure from the atomic to macroscopic level. In the traditional representation of materials science as a tetrahedron, processing plays a central and critical role: processing generates the microstructure of a material, which in turn imparts the desired properties and performance.
With the impetus created by the rapid pace of contemporary technological innovation, the field of materials processing has grown exponentially in both popularity and importance. The explicit dependence of the ultimate properties of a material on the specific processing steps employed in its fabrication, places materials processing in a decisive position not only for the production and application of conventional engineering materials, but for the future of new and novel materials as well. Traditionally, materials processing has been considered part of materials technology or engineering and as such, was deemed the practical complement of materials science, with a high degree of associated empiricism. The evolution and complexity of new materials, such as cutting edge semiconductors, smart materials, high Tc superconductors, and materials based on spintronics, has enthused contemporary materials processing beyond this stage.
However, in contrast to the rigor and unity of materials prop- erty or structure treatments in the literature, materials processing has been somewhat neglected. First, few materials curricula provide in depth coverage of materials processing. Second, when processing is addressed in handbooks or textbooks, it is primarily from a technological or practical engineering point of view, with a conspicuous dearth of materials science fundamentals. Our intent is that the Materials Processing Handbook will fill these gaps.
This handbook is intended to provide broad coverage of a number of materials processes associated with a myriad of solid materials, including ceramics, polymers, metals, composites, and semiconductors. Our goal is to present the fundamentals of a particular materials process by emphasizing the integral processing– structure–property relationship. Principles of thermodynamics, phase transformations, mechanisms, and kinetics of energy and mass transport are defined for each process category. Simulation and modeling of materials processes are an important part of the chapter presentations.
Traditional, as well as novel processes are covered and the scale of the materials structures and associated processing spans from the nanometer level to macroscopic. Several challenges have been recognized with this approach. First, some materials processes have minimal or no associated microstructural change (e., the production of ix GROZA: “3216_c000” — 2007/2/8 — 21:28 — page ix — #9 x Preface raw materials, chemical synthesis, machining processes, etc.) and as such, will not be covered in this work. The mechanics and design aspects of process development have not been emphasized here.
Although some treatment of processing equipment is provided, it is done so only to enhance the understanding of a specific materials process. Since materials professionals and practitioners occasionally require quick insights or know-how to help them solve a demanding process problem, this handbook balances an emphasis on fundamentals with practical examples, case studies, and applications for each of the materials processes covered. The thirty-one chapters covered in this handbook are organized into six sections by the type of materials change (phase, structure, or shape), with the sections roughly corresponding to increasing lengths of scale. Each chapter within a section describes the principles, processing techniques, and means for controlling microstructural evolution to achieve the final desired properties and performance.
The first section, Small Scale Processes, addresses process events that occur at atomic or nanoscale dimensions. The second section deals specifically with deposition processes, while the third section focuses on processes that involve dislocations and plastic deformation. The fourth section is devoted to phase transitions, shape, and chemistry changes that modify the microstructure and hence, the properties of materials. The fifth section addresses processes that occur at the macroscopic scale.
Finally, the sixth section, Multiscale Processes, considers the basics of process integration, that is, combinations of any of the above processes occurring over a range of length scales. Since this handbook is intended to be a wide-ranging “one-stop” reference in materials processing for a variety of advanced engineering materials, it is our hoped that engineers, scientists, and students will be provided with an appreciation of the fundamental principles behind each of the processes presen- ted. World class experts in materials processing have been brought together to convey the principles and applications contained in this compilation. Their creative transfer of knowledge spans the gamut from traditional to emerging industries, from conventional to novel materials, across length scales, from sim- ulation and modeling to real materials processes.
It is our aspiration that this handbook will foster an understanding of the technical challenges associated with these processes, that it will help practitioners avoid processing inconsistencies, which may be counterproductive and costly, that it will aid in the selec- tion of a particular process for an intended application, and that it provides inspiration to researchers, designers, and inventors. GROZA: “3216_c000” — 2007/2/8 — 21:28 — page x — #10 About the Editors Joanna R. Groza is a professor at the University of California at Davis in the Department of Chemical Engineering and Materials Science. She holds a master of science with honors in metallurgical engineering, a Ph.
in physical metallurgy and is a registered professional engin- eer in California. She worked in industry in materials processing and powder metallurgy, gaining experience with traditional processing and nonconventional bonding and sintering techniques. Her research focuses on field assisted sintering of difficult to sinter powders, including nanocrystalline particles, simultaneous sintering and reactions, phase transformations, processing and microstructural characterization of various materials, net shape manufacturing. She is active in several professional organizations and is a Board of Review member for Metallurgical and Materials Transactions.
She authored (or coauthored) more than 100 technical papers, invited lectures, three book chapters on nanomaterials processing and properties, and a couple of chapters in the ASM Handbook, vol. She has served on numerous panels and grant reviews for NSF, ARO, LLNL, DOE, and has been involved in a number of NSF/NIST workshops on materials processing. Lavernia became the dean of the College of Engineering at UC Davis, on September 1, 2002. He came to UC Davis from the Depart- ment of Chemical Engineering and Materials Science at UC Irvine, where he was the chair of the department.
Dean Lavernia received his M. degrees from the Massachusetts Institute of Technology and his bachelor’s degree from Brown University. After completing a postdoctoral research program at MIT, he joined the faculty at UCI. He has held prestigious fellowships from the Ford Foundation; from the Alexander von Humboldt Found- ation, from the Iketani Science and Technology Foundation of Tokyo, and from Rockwell International.
Dean Lavernia has coauthored over 350 journal papers, over 190 conference papers, and one book, Spray Atomization and Deposition. He is currently the principal editor of the international journal, Materials Science and Engineering A and associate editor of the Journal of Metastable and Nanostructured Materials. xi GROZA: “3216_c000” — 2007/2/8 — 21:28 — page xi — #11 xii About the Editors Awards Received Dates Fellow, American Society of Mechanical Engineers (ASME) 2006 Best Paper Award, International Thermal Spray Conference Seattle, WA 2006 Elected as an Honorary Member of the Materials Research Society of India (MRSI) 2006 Brown University, Outstanding Engineering Alumnus Medal 2005 Named Highly Cited Researcher, ISI, Citation Impact for Research in Materials 2002 Chancellor’s Professor, UCI 2002 Fellow, American Association for the Advancement of Science 2000 1999 Marcus A. Grossmann Award for “Best Paper,” Metallurgical and Materials Transactions (with Weidong Cai — Ph.
Student) 1999 Chemical and Biochemical Engineering and Materials Science Teacher of the Year, UCI 1998 1998 Fellow, Board of Trustees of ASM International 1998 Marion Howe Medal for “Best Paper,” Metallurgical and Materials Transaction (with D. Students) 1998 Silver Medal of the Materials Science Division of ASM International 1996 Best Paper Award, Journal of Thermal Spray Technology with X. Wolfenstine (Faculty, Colleague) 1995 Fellowship, Ford Foundation 1995 Alexander Von Humboldt Fellowship from Germany 1995 Fellowship from the Iketani Science and Technology Foundation, Tokyo, Japan 1993 ASM International 1993 Bradley Stoughton Award for Young Teachers 1993 Ranked 21st in the World by Science Watch, ISI, Citation Impact for Research in Materials [1] 1990–1994 Young Investigator Award, Office of Naval Research (ONR) 1990–1993 Presidential Young Investigator, National Science Foundation (NSF) 1989–1994 Some of Dean Lavernia’s research accomplishments include the study and development of spray atomization and coinjection for the manufacture of metal matrix composites (MMCs); the analysis of fundamentals of microstructure evolution during spray deposition; the modeling and analysis of ceramic particle-molten droplet interactions; the development of elevated temperature spray facilities for reactive materials processing; the development of physical models to explain microstructure phenomena in spray processes; and the study and development of the spray atomization, reaction, and deposition technique. His more recent work has been in the area of nanostructured materials (NMs), which have the poten- tial of using atomic-level structural control to revolutionize traditional material, since their engineering properties can be tailored to specific requirements.