Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page i 6.2008 6:02pm Compositor Name: VBalamugundan Handbook of Thermal Process Modeling of Steels Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page ii 6.2008 6:02pm Compositor Name: VBalamugundan Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page iii 6.2008 6:02pm Compositor Name: VBalamugundan Handbook of Thermal Process Modeling of Steels Edited by Cemil Hakan Gür Jiansheng Pan Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page iv 6.2008 6:02pm Compositor Name: VBalamugundan CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2009 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U. Government works Printed in the United States of America on acid-free paper 10 9 8 7 6 5 4 3 2 1 International Standard Book Number-13: 978-0-8493-5019-1 (Hardcover) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained.
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Visit the Taylor & Francis Web site at http://www.com and the CRC Press Web site at http://www.com Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page v 6.2008 6:02pm Compositor Name: VBalamugundan Contents Preface. xi Chapter 1 Mathematical Fundamentals of Thermal Process Modeling of Steels. 1 Jiansheng Pan and Jianfeng Gu Chapter 2 Thermodynamics of Thermal Processing. 63 Sivaraman Guruswamy Chapter 3 Physical Metallurgy of Thermal Processing.
89 Wei Shi Chapter 4 Mechanical Metallurgy of Thermal Processing. 121 Božo Smoljan Chapter 5 Modeling Approaches and Fundamental Considerations. 185 Bernardo Hernandez-Morales Chapter 6 Modeling of Hot and Warm Working of Steels. 225 Peter Hodgson, John J.
Jonas, and Chris H. Davies Chapter 7 Modeling of Casting. 265 Mario Rosso Chapter 8 Modeling of Industrial Heat Treatment Operations. 313 Satyam Suraj Sahay Chapter 9 Simulation of Quenching.
341 Caner ¸Sims ¸ir and C. Hakan Gür Chapter 10 Modeling of Induction Hardening Processes. 427 Valentin Nemkov v Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page vi 6.2008 6:02pm Compositor Name: VBalamugundan vi Chapter 11 Modeling of Laser Surface Hardening. 499 Janez Grum Chapter 12 Modeling of Case Hardening.
627 Gustavo Sánchez Sarmiento and María Victoria Bongiovanni Chapter 13 Industrial Applications of Computer Simulation of Heat Treatment and Chemical Heat Treatment. 673 Jiansheng Pan, Jianfeng Gu, and Weimin Zhang Chapter 14 Prospects of Thermal Process Modeling of Steels. 703 Jiansheng Pan and Jianfeng Gu Index. 727 Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page vii 6.2008 6:02pm Compositor Name: VBalamugundan Preface The whole range of steel thermal processing technology, from casting and plastic forming to welding and heat treatment, not only produces workpieces of the required shape but also optimizes the end-product microstructure.
Thermal processing thus plays a central role in quality control, service life, and the ultimate reliability of engineering components, and now represents a funda- mental element of any company’s competitive capability. Substantial advances in research, toward increasingly accurate prediction of the microstructure and properties of workpieces produced by thermal processing, were based on solutions of partial differential equations (PDEs) for temperature, concentration, electromagnetic properties, and stress and strain phenomena. Until the widespread use of high-performance computers, analytical solution of PDEs was the only approach to describe these parameters, and this placed severe limitations in terms of prediction for engineering applications so that thermal process developments themselves relied on empiricism and traditional practice. The level of inaccuracy inherent in computational predictions hindered both materials performance improvements and process cost reduction.
Since the 1970s, the pace of development of computer technology has made possible effective solution of PDEs in complicated calculations for boundary and initial conditions, as well as non- linear and multiple variables. Mathematical models and computer simulation technology have developed rapidly; currently well-established mathematical models integrate fundamental theories of materials science and engineering including heat transfer, thermoelastoplastic mechanics, fluid mechanics, and chemistry to describe physical phenomena occurring during thermal processing. Further, evolution of transient temperature, stress–strain, concentration, microstructure, and flow can now be vividly displayed through the latest visual technology, which can show the effects of individual process parameters. Computation=simulation thus provides an additional decision- making tool for both the process optimization and the design of plant and equipment; it accelerates thermal processing technology development on a scientifically sound computational basis.
The basic mathematical models for thermal processing simulation gradually introduced to date have yielded enormous advantages for some engineering applications. Continued research in this direction attracts increasing attention now that the cutting-edge potential of future developments is evident. Increasingly profound investigations are now in train globally. The number of important research papers in the field has risen sharply over the last three decades.
Even so, the existing models are regarded as highly simplified by comparison with real commercial thermal processes. This has meant that the application of computer simulation has thus far been relatively limited precisely because of these simplifying assumptions, and their consequent limited computational accuracy. Extensive and continuing research is still needed. This book is now offered as both a contribution to work on the limitations described above and as an encouragement to increase the understanding and use of thermal process models and simulation techniques.
The main objectives of this book are, therefore, to provide a useful resource for thermal processing of steels by drawing together. An approach to a fundamental understanding of thermal process modeling. A guide to process optimization. An aid to understand real-time process control.
Some insights into the physical origin of some aspects of materials behavior. What is involved in predicting material response under real industrial conditions not easily reproduced in the laboratory vii Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page viii 6.2008 6:02pm Compositor Name: VBalamugundan viii Linked objectives are to provide. A summary of the current state of the art by introducing mathematical modeling method- ology actually used in thermal processing. A practical reference (industrial examples and necessary precautionary measures are included) It is hoped that this book will.
Increase the potential use of computer simulation by engineers and technicians engaged in thermal processing currently and in the future. Highlight problems requiring further research and be helpful in promoting thermal process research and applications This project was realized due to the hard work of many people. We express our warm appreciation to the authors of the respective chapters for their diligence and contribution. The editors are truly indebted to everyone for their contribution, assistance, encouragement, and constructive criticism throughout the preparation of this book.
Here, we also extend our sincere gratitude to Dr. Totten (Totten Associates and a former president of the International Federation for Heat Treatment and Surface Engineering [IFHTSE]) and Robert Wood (secretary general, IFHTSE), whose initial encouragement made this book possible, and to the staff of CRC Press and Taylor & Francis for their patience and assistance throughout the production process. Hakan Gür Middle East Technical University Jiansheng Pan Shanghai, Jiao Tong University Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page ix 6.2008 6:02pm Compositor Name: VBalamugundan Editors C. Hakan Gür is a professor in the Department of Metallurgical and Materials Engineering at Middle East Technical University, Ankara, Turkey.
He is also the director of the Welding Tech- nology and Nondestructive Testing Research and Application Center at the same university. Professor Gür has published numerous papers on a wide range of topics in materials science and engineering and serves on the editorial boards of national and international journals. His current research includes simula- tion of tempering and severe plastic deformation processes, nondestructive evaluation of residual stresses, and microstruc- tures obtained by various manufacturing processes. Jiansheng Pan is a professor in the School of Materials Science and Engineering at Shanghai Jiao Tong University, Shanghai, China.
He was an elected member of the Chinese Academy of Engineering in 2001. Professor Pan’s expertise is in chemical and thermal processing of steels (including nitriding, carburiz- ing, and quenching) and their computer modeling and simula- tion. He has established mathematical models of these processes integrating heat and mass transfer, continuum mechanics, fluid mechanics, numerical analysis, and software engineering. These models have been used for computational simulation to design and optimize thermal processes for parts with complicated shape.
Pan and his coworkers have published extensively in these areas and have been awarded over 40 Chinese patents. In addition to a number of awards for scientific and technological achievements, Professor Pan was the president of the Chinese Heat Treatment Society (2003–2007) and is the chairman of the Mathematical Modeling and Computer Simulation Activity Group of the Inter- national Federation for Heat Treatment and Surface Engineering. ix Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page x 6.2008 6:02pm Compositor Name: VBalamugundan Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page xi 6.2008 6:02pm Compositor Name: VBalamugundan Contributors María Victoria Bongiovanni Peter Hodgson Facultad de Ingeniería Centre for Material and Fibre Innovation Universidad Austral Institute for Technology Research and Buenos Aires, Argentina Innovation Deakin University and Geelong, Victoria, Australia John J. Jonas Facultad de Ciencias Exactas y Naturales Department of Materials Engineering Universidad de Buenos Aires McGill University Buenos Aires, Argentina Montreal, Quebec, Canada Chris H.
Davies Valentin Nemkov Department of Materials Engineering Fluxtrol, Inc. Monash University Auburn Hills, Michigan Melbourne, Victoria, Australia and Janez Grum Faculty of Mechanical Engineering Centre for Induction Technology University of Ljubljana Auburn Hills, Michigan Ljubljana, Slovenia Jiansheng Pan Jianfeng Gu School of Materials Science and Engineering School of Materials Science and Engineering Shanghai Jiao Tong University Shanghai Jiao Tong University Shanghai, China Shanghai, China Mario Rosso C. Hakan Gür R&D Materials and Technologies Department of Metallurgical and Materials Politecnico di Torino Engineering Dipartimento di Scienza dei Materiali e Middle East Technical University Ingegneria Chimica Ankara, Turkey Torino, Italy and Sivaraman Guruswamy Department of Metallurgical Engineering Politecnico di Torino University of Utah Sede di Alessandria Salt Lake City, Utah Alessandria, Italy Bernardo Hernandez-Morales Satyam Suraj Sahay Departamento de Ingeniería Metalúrgica Tata Research Development and Design Centre Universidad Nacional Autónoma de México Tata Consultancy Services Limited Mexico Pune, Maharashtra, India xi Gur/Handbook of Thermal Process Modeling of Steels 190X_C000 Final Proof page xii 6.