Hot forming processes

E. Parteder, H. Riedel Simulating of hot forming processes of refractory metals using porous metal plasticicty models, Proc. 15th Plansee Seminar, Vol. 3 (Plansee AG, Reutte 2001) p. 60... 

Total 1991 world production of sulfur in all forms was 55.6 x 10 t. The largest proportion of this production (41.7%) was obtained by removal of sulfur compounds from petroleum and natural gas (see Sulfurremoval and recovery). Deep mining of elemental sulfur deposits by the Frasch hot water process accounted for 16.9% of world production mining of elemental deposits by other methods accounted for 5.0%. Sulfur was also produced by roasting iron pyrites (17.6%) and as a by-product of the smelting of nonferrous ores (14.0%). The remaining 4.8% was produced from unspecified sources. 

Metal Cleaning. About 204 thousand metric tons of HCl (100% basis) was consumed in 1993 for steel pickling, wherein the hydrochloric acid readily dissolves all of the various oxides present in the scale formed during the hot rolling process. Using suitable inhibitors such as alkyl pyridines, HCl reacts very slowly with the base metal rendering the surface so clean that it must be passivated with a mild alkaline rinse. 

Eabrication techniques must take into account the metallurgical properties of the metals to be joined and the possibiUty of undesirable diffusion at the interface during hot forming, heat treating, and welding. Compatible alloys, ie, those that do not form intermetaUic compounds upon alloying, eg, nickel and nickel alloys (qv), copper and copper alloys (qv), and stainless steel alloys clad to steel, may be treated by the traditional techniques developed for clads produced by other processes. On the other hand, incompatible combinations, eg, titanium, zirconium, or aluminum to steel, require special techniques designed to limit the production at the interface of undesirable intermetaUics which would jeopardize bond ductihty. 

Vessel heads can be made from explosion-bonded clads, either by conventional cold- or by hot-forming techniques. The latter involves thermal exposure and is equivalent in effect to a heat treatment. The backing metal properties, bond continuity, and bond strength are guaranteed to the same specifications as the composite from which the head is formed. AppHcations such as chemical-process vessels and transition joints represent approximately 90% of the industrial use of explosion cladding. 

Metal-Matrix Composites. A metal-matrix composite (MMC) is comprised of a metal ahoy, less than 50% by volume that is reinforced by one or more constituents with a significantly higher elastic modulus. Reinforcement materials include carbides, oxides, graphite, borides, intermetahics or even polymeric products. These materials can be used in the form of whiskers, continuous or discontinuous fibers, or particles. Matrices can be made from metal ahoys of Mg, Al, Ti, Cu, Ni or Fe. In addition, intermetahic compounds such as titanium and nickel aluminides, Ti Al and Ni Al, respectively, are also used as a matrix material (58,59). P/M MMC can be formed by a variety of full-density hot consolidation processes, including hot pressing, hot isostatic pressing, extmsion, or forging. 

Both cold- and warm-coating processes employ solutions of phenoHc resins. The principal process used for foundry resins is the hot-coating process. It is the fastest, least expensive, and safest process, and it requires no volatile removal. The sand is heated to 135—170°C in a muller, and soHd novolak resin in flake form is added, which melts quickly and coats the sand. A lubricant may be added at this point. After one minute of mulling, the batch is cooled by adding water, which evaporates rapidly. 

A crystalline form of free silica, extremely hard and inert chemically very resistant to heat. Quartz in refractory bricks and amorphous silica in diatomaceous earth are altered to cristobalite when exposed to high temperatures (calcined). Cristobalite is extensively used in precision casting by the hot wax process, dental laboratory work, and certain speciality ceramics. 

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