Issues in the replacement of lead-bearing solders

The use of soft solders, particularly those containing lead, dates back nearly 5,000 years. Solders similar to the materials used to seal the aqueducts of ancient Rome are now an important building block in the manufacture of high-speed computer assemblies. This history attests to the technological versatility of soft solders and, in particular, the solder alloys that contain lead. However, the health effects of prolonged exposure to lead have also been documented; measures to limit human exposure—at the work place and indirectly through the environment—are being considered. The successful introduction of lead-free solders into future electronic products will rely heavily upon their solderability, which can be evaluated by test procedures such as the meniscometer/wetting balance technique and the capillary flow test.     

Debinding injection molded materials by melt wicking

For metal and ceramic injection molding procedures which use wax binders in the production of powder-based parts, melt wicking is commonly employed to debind the components prior to sintering. Because debinding is often a time-consuming procedure, the influence of such process variables as powder size, part height, green density and temperature have been investigated to reduce the amount of time required for debinding by melt wicking.     

Processing ceramic-matrix composites using electrophoretic deposition

A novel, cost-effective processing technique for manufacturing ceramic-matrix composites (CMCs) containing two-dimensional woven-fiber reinforcement has been developed. The technique relies on the electrophoretic deposition (EPD) of ceramic sols on/into the fiber preforms to achieve the required impregnation. The laboratory-scale results achieved thus far indicate that the processing approach offers great potential for the manufacture of high-quality, composite products with dual-component oxide matrices for high-temperature structural applications.     

The damping performance of aluminum-based composites

Metal-matrix composites may offer better damping properties than unreinforced alloys. Because damping properties (and metal-matrix composites) are becoming important in airframe design, the damping capabilities of a number of aluminum-matrix composites were measured over a wide range of frequencies at low strain amplitudes, using a new laser vibrometer technique. Silicon carbide and alumina reinforcements resulted in a material with damping properties similar to that of unreinforced aluminum 6061-T6, but unidirectional and planar-random graphite continuous-fiber reinforcements increased the damping by 5 and 14 times, respectively. The increased damping of the continuous fiber composites is attributed to the absence of interfacial reaction resulting from the high-pressure infiltration method used for their manufacture.     

Using Amorphous Phases in the Design of Structural Alloys

The recent discovery that amorphous alloy powders can be prepared by mechanically alloying a mixture of pure crystalline intermetallics is opening new windows to the synthesis of engineering materials. Amorphous powders synthesized by mechanical alloying may find application in the design of structural alloys, high thermal conductivity alloys, and metal-matrix composites.     

Computer modeling metal flow in forging

By simulating the flow of metal in forging, engineers can eliminate defects and undesirable flow patterns. Localized deformation heating of the forging can be predicted and avoided, with a resulting improvement of quality.     

Ordered intermetallic alloys,part I: Nickel and iron aluminides

This article summarizes recent progress in research and development on nickel and iron aluminide intermetallic alloys. Ordered intermetallics possess attractive properties for structural applications at elevated temperatures in hostile environments; however, brittle failure and poor fracture resistance limit their use as engineering materials. In recent years, efforts to understand this brittle fracture behavior have identified both intrinsic and extrinsic factors governing brittle fracture. Parallel work on alloy design using physical metallurgy principles has led to the development of aluminide alloys with improved mechanical and metallurgical properties for structural use.     

Applying MHD technology to the continuous casting of steel slab

The application of magnetohydrodynamics (MHD) in the continuous casting process started with the electromagnetic stirring of the stand pool with a traveling magnetic field. It has now advanced to the electromagnetic stirring of molten steel in the mold and the control of molten steel flow by an in-mold direct current magnetic field brake. These applied MHD techniques are designed to further improve the continuous casting process capability. They improve the surface quality of cast steel by homogenizing the meniscus temperature, stabilizing initial solidification, and cleaning the surface layer. They also improve the internal quality of cast steel by preventing inclusions from penetrating deep into the pool and promoting the flotation of argon bubbles. Applied MHD technology is still advancing in scope and methods in addition to the improvement of conventional continuously cast slab qualities. The continuous casting of bimetallic slab by suppressing mixing in the pool is one example of this progress.     

The in-line inspection of carbon anodes for aluminum production

In this paper, methods for measuring the quality of carbon anodes consumed in the commercial production of aluminum are discussed. The electrical and mechanical qualities of these anodes are important for the economic operation of the aluminum plant. While the investigation is ongoing, results from tests made at an aluminum reduction plant are included. The methods reviewed include direct resistivity measurement using core samples, ultrasonic measurement, the hammer method, analysis of the Hall effect, the four-probe method, and use of magnetic coils (various arrangements).     

Oxidation of Si-based ceramics in the presence of alkali halide vapors

Nonoxide silicon-based ceramics owe their oxidation resistance to the formation of a thin silica film that separates the ceramic from oxidizing environments. This silica film can be fluxed by alkali oxides to form low-melting alkali silicate corrosion products that do not provide protection. Alkali chlorides and other halides have sufficiently high vapor pressures that silica fluxing can occur without the formation of a condensed halide salt. The rates of oxidation of Si, SiC, and Si₃N₄ are influenced by the composition of gas mixtures containing these species.