Advanced Materials Processing and Manufacturing (eBook)

Dr. Yogesh Jaluria is Board of Governors Professor and Distinguished Professor at Rutgers University, New Jersey. He is the author/co-author of eight books and editor/coeditor of thirteen conference proceedings, eight books, and seven special issues of archival journals. He has contributed over 500 technical articles, including over 210 in archival journals and 20 book chapters. He has received the prestigious 2007 Kern Award from AIChE, the 2003 Robert Henry Thurston Lecture Award from ASME, and the 2002 Max Jakob Memorial Award, the highest international recognition in heat transfer, from ASME and the AIChE. He received the 2000 Freeman Scholar Award, the 1999 Worcester Reed Warner Medal and the 1995 Heat Transfer Memorial Award all from ASME. He was the Editor of the Journal of Heat Transfer (2005-2010), and Computational Mechanics (2003-2005). He is an Honorary Member of ASME, a Fellow of AAAS and APS, and an Associate Fellow of AIAA. He is currently the President of the American Society of Thermal and Fluids Engineers.

Preface 6
Contents 9
Part I: Basic Considerations 14
Chapter 1: Introduction 15
1.1 Materials Processing and Manufacturing 15
1.2 Different Materials and Products 18
1.3 Underlying Transport Phenomena 20
1.4 Important Manufacturing and Materials Processing Techniques 21
1.4.1 Traditional Manufacturing Processes 22
1.4.2 Recent and Advanced Materials Processing Methods 25
1.5 Practical Aspects 28
1.6 Basic Thrust and Scope of the Book 28
References 29
Chapter 2: Mathematical Modeling of Manufacturing Processes 31
2.1 Basic Aspects 31
2.2 Governing Equations 34
2.3 Common Challenges in Mathematical Modeling 35
2.3.1 Variable Properties 35
2.3.2 Viscous Dissipation 38
2.3.3 Buoyancy Effects 39
2.4 Additional Transport Mechanisms and Considerations 42
2.4.1 Non-Newtonian Fluids 42
2.4.2 Surface Tension Effects 43
2.4.3 Particulates and Powdery Materials 44
2.4.4 Phase Change 45
2.4.5 Chemically Reactive Materials 46
2.4.6 Complicated Geometry 48
2.4.7 Combined Mechanisms 49
2.4.8 Complex Boundary Conditions 49
2.5 Other Challenges 50
References 50
Chapter 3: Numerical Modeling and Experimentation 52
3.1 Analytical Solution 52
3.2 Numerical Modeling 55
3.2.1 Accurate Imposition of Appropriate Boundary Conditions 56
3.2.2 Numerical Modeling of Complicated Regions 58
3.2.3 Modeling of Combined Mechanisms and Complex Transport Phenomena 60
3.2.4 Multiscale Modeling 63
3.3 Numerical Solution 64
3.4 Verification and Validation of the Model 66
3.5 Modeling of Manufacturing Systems 67
3.6 Numerical Simulation 68
3.7 Experimentation 70
3.8 Link Between Transport Processes and Product Characteristics 74
References 75
Part II: Different Manufacturing Processes 77
Chapter 4: Manufacturing Processes with Phase Change 78
4.1 Analysis 79
4.1.1 Interface Tracking 79
4.1.2 Enthalpy Method 82
4.2 Simple Conduction Models 83
4.3 One-Dimensional Solidification 88
4.4 Results for Multidimensional Problems 91
4.4.1 Interface Tracking: Transformed Grid Method 91
4.4.2 Enthalpy Formulation 92
4.4.3 Conjugate Transport 94
4.4.4 Experimental Studies 96
4.5 Continuous Casting 97
4.6 Alloys 102
4.7 Crystal Growing 108
4.8 Other Processes and Materials 110
4.9 Summary 110
References 112
Chapter 5: Continuous Materials Processing 115
5.1 Basic Process 116
5.2 Heat Transfer Within the Moving Material 118
5.2.1 Analysis 119
5.2.2 Analytical and Numerical Results 121
5.3 Convective Transport Due to a Moving Surface 125
5.4 Conjugate Transport 128
5.4.1 Boundary-Layer Formulation 128
5.4.2 Solution of the Full Equations (Elliptic Formulation) 131
5.5 Buoyancy and Forced Flow Effects 134
5.6 Transient Effects 141
5.7 Experimental Work 144
5.8 Additional Aspects 145
5.9 Summary 149
References 149
Chapter 6: Polymer Processing 152
6.1 Material Properties 153
6.2 Single Screw Extrusion 156
6.2.1 Two-Dimensional Model 157
6.2.2 Fully Developed Flow 160
6.2.3 Developing Flow 162
6.2.4 Three-Dimensional Transport 164
6.2.5 Axial Formulation 167
6.2.6 Tapered Screw 167
6.3 Residence Time 170
6.4 Mixing 172
6.5 Experimentation 172
6.6 Twin Screw Extrusion 176
6.7 Combined Heat and Mass Transfer and Chemical Reactions 179
6.7.1 Moisture Transport 180
6.7.2 Chemical Reactions 182
6.8 Die Flows 187
6.8.1 Coupling of Extruder with Die 187
6.8.2 Transport in Complex Dies 188
6.9 Additional Aspects in Extrusion 192
6.10 Injection Molding 193
6.11 Thermoforming 196
6.12 Summary 199
References 200
Chapter 7: Thin Film Deposition: Micro-/Nanoscale Fabrication 203
7.1 Introduction 203
7.2 Basic Aspects 207
7.3 Characteristic Results 209
7.4 Metal-Organic Chemical Vapor Deposition (MOCVD) 215
7.4.1 Basic Process 217
7.4.2 Gallium Nitride 217
7.4.3 Chemistry for GaN Deposition 218
7.5 Validation 220
7.6 Flow and Temperature Distributions 223
7.7 GaN Deposition 230
7.8 Transient Effects 233
7.9 Characteristics of Deposited Thin Films 238
7.10 Summary 240
References 241
Chapter 8: Manufacture of Optical Fibers: Drawing and Coating Processes 244
8.1 Optical Fiber Systems 244
8.2 Optical Fiber Manufacturing 247
8.3 Preform Fabrication 248
8.4 Drawing of Optical Fibers 249
8.4.1 Basic Equations 251
8.4.2 Characteristic Results 253
8.4.3 Multilayer Fibers and Dopants 257
8.4.4 Hollow Fibers 264
8.4.5 Furnace Wall Temperature Distribution 269
8.5 Process Feasibility 270
8.6 Thermally Induced Defects 273
8.7 Fiber Cooling 277
8.8 Fiber Coating 279
8.9 Multiscale Modeling 287
8.10 Summary 288
References 289
Chapter 9: Other Manufacturing Processes 292
9.1 Heat Treatment 293
9.1.1 Basic Aspects 294
9.1.2 A Batch Annealing Furnace 297
9.1.3 Surface Heat Treatment 302
9.1.4 Case Hardening 305
9.2 Joining and Bonding Processes 305
9.2.1 Soldering 306
9.2.2 Welding 312
9.3 Fabrication of Microchannels and Microdevices 318
9.4 Additional Manufacturing Processes 322
9.5 Summary 325
References 325
Part III: System Considerations 327
Chapter 10: Simulation, Design, and Optimization of Manufacturing Systems 328
10.1 Modeling and Simulation 330
10.2 Inverse Problem and Process Feasibility 333
10.2.1 Inverse Problem 333
10.2.2 Feasible Domain 334
10.3 Design Optimization 334
10.4 Uncertainties 342
10.5 Additional Design Aspects and Strategies 345
10.5.1 Knowledge-Based Design 345
10.5.2 Concurrent Experimentation and Simulation 349
10.6 Summary 350
References 350
Index 352