MSE 3207 MATERIALS PROCESSING

2 LECTURE 18

Can this process be continuous?

Conservation of Volume:
m3
(0.25)(1)(1.3) = (0.0005)(1)(Vout )
s
m m
Vout = 650 = 25
min hr
⇒ Such a high velocity is dangerous and requires an extremely long factory

Therefore: The only path to fully continuous strip production is to cast even thinner
⇒ strip casting
· How do you maintain throughput?
– parallelize ⇒ multi-strand casting (requires huge capital investment)
· New processes: mini-mills
– record thin casting ∼ 2mm
√
– s = 2γ αt
 3.044 MATERIALS PROCESSING 3

Solid State Shape Forming:

Hot solid material: must be high enough temperature to have viscous (fluid like)
flow, but not so high that it melts

Newtons law of viscosity Creep

δx ∂x
for small angles: γ ≈ δy
≈ ∂y
∂vx  
∂γ
τxy = −μ γ̇ = ∂t = ∂t ∂x
∂
∂y
= ∂
∂y
(vx )
∂y
∂vx
γ̇ =
∂y

In conclusion: Newton’s law of viscosity for fluids is same as the creep law
for solids except for a factor of μ and the negative sign difference between solid and
fluid mechanics
τxy = ± μγ̇
4 LECTURE 18

m is defined as strain rate sensitivity

when m = 1, Newtonian ∼ fluid like
when m < 1, non-Newtonian

Stability of Tensile Flow:

Will necking to failure occur? How far will it stretch?

σi Ai = σh Ah
⇓ ⇓
stress geometry
relates to strain
 3.044 MATERIALS PROCESSING 5

General Power-Law Equation:

σ = μΣ˙ m
˙m m
i Ai = ˙h Ah

Volume Conserved:
V0 = V
A0 L0 = AL
True Strain:
 
L
 = ln
L0
 
A0
 = ln
A
A = A0 exp(−)
˙m m
i A0,i exp(−) = ˙h A0,h exp(−)
 1  i   1   
h
˙i A0,i exp −
m
= ˙h A0,h exp −
m

m m
di  m1    d  1
i h
  
h
A0,i exp − = m
A0,h exp −
dt m dt m
1 i 1 h
m
di A0,i e− m = di A0,h
m
e− m