Proceedings

of the

1978 ASM MATERIALS & PROCESSING CONGRESS

7-9 November 1978

Philadelphia Civic Center

Programmed by

Cleaning, Finishing and Coating Division

Energy Division

Heat Treating Division

Joining Division

Materials Science Division

Materials Systems and Design Division

Materials Testing and Quality Control Division

Mechanical Working and Forming Division

of the American Society for Metals

METAL PROGRESS .Magazine

American Welding Society

The Metal Properties Council

Conference Chairman

Donald R. Muzyka

Carpenter Technology Corporation

AMERICAN SOCIETY FOR METALS

Metals Park, Ohio 44073

UNIVERSITATSBIBL10THEKHANNOVER

TCCr'iV-'.Sr.WFINFOSMATiGi lb-'iVi.-QTHEK

J

CONTENTS *

PART ONE: ABSTRACTS

WELDMENTS IN ELECTRIC POWER GENERATION

Welding - The Nucleus of All Production, ParticularlyElectric Power Production for the Twentieth Century 1

George J. Schnabel

Fabrication of Primary Loop Components for Nuclear Steam

Supply Systems 2E. S. Proctor

Field Welding in Electric Power Generation Facilities 3B. D. Hackney

Concepts for Stress Corrosion Cracking in Steel PipeWeldments 4

R. E. Hanneman

Repair Welding of Heavy Section Steel Nozzles 5Paul S. Ayres

ADVANCES IN VACUUM HEAT TREATING

Gas/Fan Oil Quenching in Vacuum Compared to Processingin Salt Pots and Box Furnaces Abstract Not Available

James F. Grochmal

Practical Aspects of Vacuum Carburizing.Abstract Not AvailableThomas Becker

Commercial Vacuum Heat Treating and Brazing - HighQuality and Flexibility Abstract Not Available

George C. Carter

Advances in Vacuum Brazing Abstract Not AvailableSam J. Whalen

*See microfiche index (in microfiche envelope in back inside cover) fordetailed contents of this volume and microfiche respectively.

v

MATERIALS/ENERGY SAVINGS IN RECLAMATION AND RECYCLING

An Introduction to Recycling 6Michael B. Bever

Resources and Energy From Municipal Solid Waste , . .7S. L, Blum

Recycling and Applications of

Secondary Aluminum Abstract Not Available

Les Armstrong

Recovery and Recycling in the Copper Industry 8

John E. Fay

Recovery and Recycling of Transition Metals 9

M. M. Fine and L. A. Neumeier

Metals Recycling: An Energy/Environmental Overview 10Charles Lembit Kusik

IMPACTS OF THE COBALT PRICE-SUPPLY SITUATION ON MATERIALS

Since this is a Panel Discussion, abstracts are not available.

RELIABILITY PROBLEMS IN TURBINES FOR POWER GENERATION: STEAM

TURBINE ROTORS

Turbine Rotor Inspection - A Status Report 11

Matthew J. Golis

A Lifetime Prediction Analysis System for Steam

Turbine Rotors 12

C. H. Wells

Controlled Reluctance Eddy Current Inspection of

Turbine Rotor Components. 13

Duane P. Johnson and S. Sarian

Contributions of the ESR Technology to the Manufacture

of Large Rotors for the Electrical Industry 14

G. K. Bhat

HIGH TEMPERATURE FATIGUE IN ENGINEERING ALLOYS - I

High Temperature Fatigue in Power Generation Systems 15

L. F. Coffin

VI

High Temperature Fatigue in the Solar Energy Systems 16

G. D. Gupta and T. V. Narayanan

Microstructural Features Associated with a Low Cycle

Fatigue-Creep Mechanism in a Cr-Mo-V Rotor Steel 17

L. D. Kramer

Characterization of High Temperature Fatigue Behavior 18

A. E. Carden

The Application of Fatigue Data in Engineering Designat High Temperatures 19

M. J. Manjoine

LIQUID BATH HEAT TREATING

Automated Neutral Salt Bath Hardening 20

Donald R. Wensing

Surface Cleaning With Salt Abstract Not Available

William G. Wood

Austenitizing Phase of Powder Particles HSS Vs.

Conventional HSS Abstract Not Available

Norman E. Robinson

The Economics of Commercial

Austempering Abstract Not Available

Joseph A. Lincoln

Non-Cyanide Liquid Carburizing Abstract Not Available

Brian L. Radford

Commercial Economics of Salt Bath

Heat Treating Abstract Not Available

Dick Harvey

HEAVY SECTION EB WELDING METALLURGY

Some Electron Beam Welding Developments for Welding

of 8" Thick 2-1/4 Cr-1 Mo Steel 21

Charles M. Weber

Investigations of EB Welding of Heavy Sections 22

W. Dietrich

Some Metallurgical Aspects of EB-Welding of Heavy

Sections 23-24

Walther Hiller

vii

Welding Process and Metallurgical Effects in HeavySection EB Welding , 25

J. D. Russell

INFLUENCE OF STEEL MAKING TECHNOLOGY ON SHEET METAL PROPERTIES

Keynote Address Abstract Not Available

D. M. Ross

Surface Characteristics Controlling Paint Adhesion on

Cold-Rolled Steel Abstract Not Available

Robert A. Iezzi

Vacuum Degassing at Weirton Steel for Sheet Product .26

R. S. Miltenberger

Continuous Annealing and Finishing Line for

Cold Rolled Strip 27

Hiroshi Naemura and Sinobu Osaka

CASE HISTORIES AND OPPORTUNITIES FOR ENERGY SAVINGS IN THE

PRODUCTION, PROCESSING, AND FABRICATION OF METALLURGICAL PRODUCTS

Total Energy Management in General Motors 28

Neil DeKoker

Ford Casting Division's Energy Conservation Program 29

R. Mrdjenovich, R. Lipka and T. Burt

Energy Management at Deere & Company . 30

P. Michael Boyd

Examples of Energy Conservation in the Metals

Producing Industry 31

John S. Huntington

AEROSPACE: NEW CONCEPTS FOR ADVANCED STRUCTURES

Design Applications of SPF/DB Titanium 32Michael L. Griffith

Lower-Cost Structure by Substituting AF1410 Steelfor Titanium 33

Guy V. Bennett

Materials Selection Criteria for Supersonic Cruise

Missile Structures Abstract Not Available

Ramon A. Mayor

viii

Short Term Elevated Temperature Tests

Harold Anson and Robert H. Ault

34

NEEDS AND POSSIBILITIES FOR PROCESS MODELING RESEARCH - I:

FUNDAMENTALS

The Role of Process Modeling in the Future of MaterialsScience and Technology , 35

H. M. Burte and H. L. Gegel

Material Constitutive Relations in the Modeling of

Mechanical Processing 36E. W. Hart and J. F. Thomas, Jr.

Computer Simulation of Heat Transfer During Metals

Processing. .Abstract Not Available

Robert D. Pehlke

Simulation of Solidification Processes..Abstract Not Available

H. D. Brody

Economic Models for Process Development, Planning,

Optimization, and Control 37-38V. A. Tipnis

HIGH TEMPERATURE FATIGUE IN ENGINEERING ALLOYS - II

Strain-Rate and Hold-Time Effects in Austenitic Stain¬

less Steels 39

S. Majumdar and P. S. Maiya

Fatigue Behavior of 2 1/4 Cr-1 Mo Steel in Support of

Steam Generator Development 40

C. R. Brinkman

Mechanisms of Intergranular Fracture in High TemperatureFat igue 41

R. Raj and B. K. Min

High Temperature Crack Growth in Thermostructural Alloys....42

K. Sadananda

The Effects of Environment on High Temperature Fatigue

Crack Growth in a Superalloy 43

S. Floreen and R. H. Kane

Effects of Irradiation on Fatigue Crack Propagation at

High Temperatures in Austenitic Stainless Steels 44

D. J. Michel

IX

HEAT TREATMENT OF GEARS, BEARINGS AND FASTENERS

An Analytical Approach for Establishing Case Depth

Requirements in Carburized Gears 45

V. K. Sharma, G. H. Walter and D. H. Breen

Bearings - Heat Treated Abstract Not Available

Phil Pearson

Induct ion Hardening Axles - Growing Pains 46

Dick W. Hemphill

Determination of Heat Treatment Condition Using Controlled

Reluctance Eddy Current Generator (CREG) Probes 47S. Sarian and Duane P. Johnson

High Volume Heat Treatment of Fasteners .Abstract Not Available

Noble C. York

SOME APPLICATIONS OF HEAVY SECTION WELDING PROCESSES

Welding Procedures for Thick-Section

Pressure Vessels Abstract Not Available

Domenic A. Canonico

Heavy Section Fabrication with Narrow

Gap Welding Abstract Not Available

Ronald P. Simpson

Application of New Processes for Welding Thick Aluminum

Plate 48

W. R. Reichelt, J. W. Evancho and E. T. Wanderer

Recent Experience with Electroslag Welds .49

Alan W. Pense

STRENGTHENING MECHANISMS AND THEIR INFLUENCE ON FORMING BEHAVIOR

Introduction,

Abstract Not Available

John L. Duncan

Combining Strength and Bend Formability in

Aluminum Alloys 50

E. Shapiro and F. N. Mandigo

Effects of Precipitation Strengthening on an Al-Si-Mg

Sheet Alloy in Biaxial Stretching....Abstract Not Available

J. E. Bird

x

Relationship Between Alloying, Strain Rate Sensitivity,and the Forming of Aluminum Sheet 51

Larry R, Morris and Harry Sang

Strain Hardening and the Forming of Aluminum RigidContainer Sheet 52

W. A. Anderson, H. C. Stumpf and J. K. McBride

Warm Forming of Strain Hardened Aluminum Alloys 53

E. Shapiro and F. N. Mandigo

CASE HISTORIES AND OPPORTUNITIES FOR ENERGY SAVINGS IN THE

PRODUCTION, PROCESSING AND FABRICATION OF METALLURGICAL

PRODUCTS - II

Energy Management of Utilities: Electrical Energyfor the Future Abstract Not Available

William B. Morlok

Natural Gas for Industry Through 1990 54

K. G. Darrow, Jr.

Carpenter Technology's Fuels Conservation Program Report....55

William E. Bennis

Energy Conservation Using Recouperation

Systems Abstract Not Available

Gordon Hansen

Energy Conservation Using Substitute

Atmospheres .Abstract Not Available

Wilfred G. Shedd

Energy Accounting and Analysis - The Carborundum System....56

Edward D. Howell

AEROSPACE: TITANIUM ALUMINIDES

The Titanium Aluminides: A Family of High Temperature

Alloys 57

Harry A. Lipsitt

Primary Processing of Titanium Aluminide Alloys 58

James A. Hall

Superplastic Forming and Diffusion Bonding of Titanium

Aluminide Materials 59

C. H. Hamilton and N. E. Paton

xi

The Potential for Titanium Aluminides in Advanced

Aircraft Gas Turbines 60-61

J. Holowach, T. K. Reddin and P. Copp

Titanium Aluminides and the Gas Turbine Engine 62

T. E. O'Connell

NEEDS AND POSSIBILITIES FOR PROCESS MODELING RESEARCH - II:

APPLICATIONS

Application of Process Modeling in Bulk Metal Forming 63

Taylan Altan and Alan T. Male

A Review of Analytical Modeling in Sheet Metal Forming 64

A. K. Ghosh

Cost and Process Analysis in Machining

Operations Abstract Not Available

C. F. Barth

Process Model ing in the Foundry 65

T. S. Piwonka

Simulation Methods for Heat Treatment Process Development... 66

P. V. Dembowski

COATINGS FOR CORROSION PREVENTION - I

Zinc-Rich Precoated Steel 67

Griff W. Froman

Zinc Coatings for Chemical Plants and Refineries:

Three Studies in Decision Making 68

Glen S. Nishimura

One-Side Electro-Galvanizing - The Simple Approach 69Charles L. Faust, Thomas A. Sellitto and Allen W. White

Mechanical Plating 70

E. A. Davis

Hot Dip 55% Al-Zn Alloy Coated Sheet Steel - Properties,Performance and Applications 71

A. R. Borzillo, H. E. Townsend and J. B. Horton

xii

METALLURGICAL APPLICATIONS OF MODERN ANALYTICAL TECHNIQUES - I:SPECTROSCOPY AND MICROSCOPY

Metallurgical Applications of Auger ElectronSpectroscopy (AES) . 72

William C. Johnson

Metallurgical Applications of X-Ray Photoelectron

Spectroscopy (XPS) .Abstract Not AvailableA. Joshi

Applications of S. T. E. M. X-Ray Microanalysis 73David R. Clarke

TEM-SEM Applications to Materials Problems 74J. M. Rigsbee

ADVANCES IN FURNACE ATMOSPHERE AND ATM3SPHERE CONTROL

Furnace Protective Atmospheres Can Be IndependentFrom Natural Gas

,

Sidney Dressier

Economic New Heat Treating Processes Using Nitrogenand UCAR-HTF

Jack Solomon

Effect of Sulfur on Carburizing in an Endothermic

AtmosphereFred Mahler

Control of Carburizing Processes with Newly DevelopedFurnace Atmosphere Analyzer

B. Gupta and D. Appel

FULLY DENSE P/M MATERIALS - I: COMPETING PROCESSES

Methods for the Consolidation of Powders to Full Density 79

Alan Lawley

Properties of Extruded Metal Powders 80

Gerald Friedman

Vacuum Hot pressing of Fully Dense Shapes 81

K. E. Meiners

P/M Forging Increases Heavy Duty Part Performance 82

Douglas Glover

xiii

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.76

.77

.78

MATERIALS FOR NEAR-TERM ENERGY SYSTEMS

Keynote Address...Near-Term Future Supply Of and Demand For

Corrosion-Resistant Materials for Energy Applications....83John D. Morgan, Jr.

Critical Corrosion Problems in Some Fossil-Fueled

Electricity Generating Systems 84

I. G. Wright, J. Stringer and D. P. Whittle

Refractories in Commercial Coal Gasifiers 85

R. A. Henrichsen and L. K. Stobbe

Materials Performance in Commercial Light Water Reactors. .. .86

John R. Weeks

WEAR: MATERIALS ASPECTS AND METHODS OF TESTING - I

Wear: Causes, Effects and Cures 87

K. C. Ludema

Wear of Metals 88

Kirit J. Bhansali

The Wear of Hard Materials in Material Removal

Processes 89-90-91

M. Lee and R. Komanduri

Wear of Polymers 92

Norman S. Eiss, Jr.

Wear of Composite Materials 93

M. F. Amateau and Z. Eliezer

COATINGS FOR CORROSION PREVENTION - II

Corrosion - Decorative Coatings for Aluminum 94

Robert J. Leipertz

A Diffused Nickel Bond With a Post Plate 95

James F. Braden

A New Concept in Aluminum Protection 96

Peg Gaul and Pete Didrichsons

Cathodic Electrodeposition: A New Painting Technologyfor the Automotive Industry 97

M. Moriondo and G. Bianchini

xxv

Nye-Carb(R) Coating — Wear Resistance Through SiliconCarbide and Electroless Nickel Codeposition .98

J. Michael Sale

METALLURGICAL APPLICATIONS OF MODERN ANALYTICAL TECHNIQUES -II:

METALLURGICAL APPLICATIONS

Metallurgical Evaluation by Acoustic Emission and

Sonic Resonance Abstract Not Available

B. V. Kovacs

Modern Analytical Techniques in Environmental Behavior 99

S. P. Clough and T. R. Pinchback

Application of Modern Microanalytical Techniques to

Materials Problems in the Nuclear Industry 100

R. E. Clausing, C. L. White and J. Bentley

Tribological Applications of Surface Techniques 101

Donald H. Buckley

INNOVATIONS IN HEAT TREATING EQUIPMENT/ALLOYS

Future Alloys for High-Temperature Heat-Treating

Equipment ? 102

R. W. Breitzig

Wear Properties of Sulfinuz and Tufftrided

Steels Abstract Not Available

J. M. Cullen and A. Cameron

Heat and Mass Transfer Characteristics of Fluidized Beds

and Effects on Energy Savings in the Heat Treating

Industry Abstract Not Available

Robert Staffin

High-Rate Carburizing in Glow-Discharge Plasmas 103

William L. Grube

FULLY DENSE P/M MATERIALS - II: HIP DEVELOPMENT

Superalloy Hot Isostatic Processing for Gas Turbine

Applications Abstract Not Available

P. S. Mathur

Overview of Superalloy P/M Gas Turbine Components —

A Manufacturer' s Viewpoint 104

Mark T. Podob

xv

HIP Powder Metallurgy Isothermal Forging Dies 105

Charles S. Kortovich

MATERIALS FOR ADVANCED ENERGY SYSTEMS

Materials Requirements for Primary Circuit Components of

Very High Temperature Gas Reactors 106

Orville F. Kimball

Materials Requirements for Fusion

Reactors Abstract Not Available

K. M. Zwilsky

Principal Materials Problems in Solar Dispersed Power

and Central Receiver Systems 107

J. J. Bartel, F. P. Gerstle, Jr., and R. B. Pettit

Material Needs for Energy Storage Flywheels 108

R. H. Toland

Materials Problems in Thermochemical Hydrogen Production... 109

J. H. DeVan

WEAR: MATERIALS ASPECTS AND METHODS OF TESTING - II

Effect of Lubrication on Component Wear 110Marshall B. Peterson

Wear Mechanisms Operating in Rolling Bearings Ill

H. Dalai

Dedendum Wear of Gears 112

A. Seireg

Wear of Seal Materials Used in the Aircraft PropulsionIndustry 113

Robert C. Bill and Lawrence P. Ludwig

Wear of Aut omot ive Brakes 114

S. K. Rhee

PART TWO: FULL PAPERS

(On microfiche enclosed in back inside cover of this volume)

xvi