Sagamore Army Materials Research Conference Proceedings – serie

The Army Materials and Mechanics Research Center in coop­ eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. These proceedings entitled, FATIGUE - ENVIRONMENT AND TEMPER­ ATURE EFFECT, address the overview of temperature and environmental effects of fatigue, room temperature environmental effects, high temperature and environmental effect - mechanisms, high tempera­ ture and environmental effect - mechanisms, materials and design-engineering applications. We wish to acknowledge the assistance of Messrs. Joseph Bernier and Dan McNaught of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of the book. The continued active interest and support of these conferences by Dr. E. Wright, Director of the Army Materials and Mechanics Research Center, is appreciated.

The Army Materials and Mechanics Research Center in coop­ eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. These proceedings, entitled RESIDUAL STRESS AND STRESS RELAXATION, address the nature of residual stresses and their measurements, the sources of residual stress, stress relaxation, sub-critical crack growth in the presence of residual stress, residual stresses and properties, and research in progress. We wish to acknowledge the assistance of Mr. Dan McNaught of the Army Materials and Mechanics Research Center and Mr. Robert J. Sell and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of the book. The continued active interest and support of these conferences by Dr. E. Wright, Director of the Army Materials and Mechanics Research Center, is appreciated.

The Army Materials and Mechanics Research Center in cooperation with the Office of Sponsored Programs of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conferences since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry and government to explore in depth a subject of importance to the Department of Defense, the Army, and the scientific community. This 30th Sagamore Conference, entitled Innovations in Materials Processing, has attempted to focus on the inter­ disciplinary nature of materials processing, looking at recent advancements in the development of unit processes from a range of standpoints from the understanding and control of the under­ lying mechanisms through their application as part of a manufactur­ ing sequence. In between, the classic link between processing and materials properties is firmly established. A broad range of materials are treated in this manner: metals, ceramics, plastics, and composites. The interdisciplinary nature of materials processing exists through its involvement with the basic sciences, with, process and product design, with process control, and ultimately with manufacturing engineering. Materials processing is interdisciplinary in another sense, through its application within all materials disciplines. The industrial community (and the Army as its customer) is becoming increasingly concerned with producibility/reliability/ affordability issues in advanced product development. These concerns will be adequately addressed only by employing the full range of disciplines encompassed within the field of materials processing.

The Army Materials and Mechanics Research Center of Water­ town, Massachusetts in cooperation with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has conducted the Sagamore Army Materials Research Conference since 1954. The main purpose of these conferences has been to gather together over 150 scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. This volume NONDESTRUCTIVE EVALUATION OF MATERIALS, addresses the areas of x-ray, ultrasonics and other methods of nondestructive testing. We wish to acknowledge the dedicated assistance of Joseph M. Bernier of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of this book. Their help is deeply appreciated. Syracuse University Syracuse, New York The Editors Contents SESSION I X-RAY S. Heissman, Moderator H. K. Herglotz, Moderator 1. Overview of X-Ray Diffraction Methods for Nondestructive Testing • • • • • • • ••• 1 L. V. Azaroff 2. Detection of Fatigue Damage by X-Rays 21 S. Taira and K. Kamachi 3. A Historical Example of Fatigue Damage • • • • • • • 55 H. K. Herglotz 4. The Application of X-Ray Topography to Materials Science . . . . . . . . . . . . . . . . . . . . 69 S. Weissman 5.

The Army Materials and Mechanics Research Center in coopera­ tion with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry, and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army, and the scientific community. The proceedings of this conference, entitled MATERIAL BEHAVIOR UNDER HIGH STRESS AND ULTRAHIGH LOADING RATES, will be published in two parts. The topics covered in the present volume include dynamic plasticity, adiabatic shear/localized deformation, and dynamic fracture mechanics. Papers dealing with ordnance applica­ tions, projectile launch environment, and recent work-in-progress will appear as an AMMRC Technical Report and will have more limited distribution in accordance with recent Army guidelines. The Conference Chairmen are particularly grateful to the members of the Program Committee. We wish also to acknowledge the assistance of Mr. Charles Polley of the Army Materials and Mechanics Research Center, Mr. Robert Sell, Ms. Helen Brown DeMascio, and Ms. Mary Ann Holmquist of Syracuse University throughout the con­ ference planning stages and the publication of the text. The continued active interest in and support of these confer­ ences by Dr. E. Wright and Col. George Sibert, Direct and Deputy Director/Commander, respectively, of the Army Materials and Mechan­ ics Research Center, is appreciated.

The Army Materials and Mechanics Research Center has con­ ducted the Sagamore Army Materials Research Conference in coop­ eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University since 1954. The purpose of the conference has been to gather to­ gether scientists and engineers from academic institutions, in­ dustry and government who are uniquely qualified to explore in depth a subject of importance to the Army, the Department of Defense and the scientific community. This volume, Advances in Deformation Processing, addresses the areas of Analytical Advances, Workability, Processing to Optimize Properties, Advanced Applications - Materials, and Advanced Applications - Processes. The dedicated assistance of Mr. Joseph Bernier of the Army Materials and Mechanics Research Center throughout the stages of the conference planning and finally the publication of the Sagamore Conference Proceedings is deeply appreciated. The support of Helen Brown DeMascio of Syracuse University in p- paring the final manuscript is acknowledged. The continued active interest and support of these conferences by Dr. A. E. Gorum, Director of the Army Materials and Mechanics Research Center, is appreciated. Syracuse University Syracuse, New York The Editors vii Contents SESSION I INTRODUCTION A. E. Gorum, Moderator Continuum Mechanics and Deformation Processing 1.

Syracuse University and the Army Materials and Mechanics Research Center of Watertown, Massachusetts have conducted the Sagamore Army Materials Research Conference since 1954. In ce1ebration of the 25th Anniversary of this conference, these proceedings are dedicated to the founding members of the Sagamore Conferences. They are Prof. Dr. George Sachs, Dr. James L. Martin, Colonel Benjamin S. Mesik, Dr. Reinier Beeuwkes, Mr. Norman L. Reed and Dr. J. D. Lubahn. This vo1ume, ADVANCES IN METAL PROCESSING, addresses Rapid Solidification Processing, Powder Processing and Conso1idation, We1ding and Joining, Thermal and. Mechanica1 Processing, Meta1 Removal and Process Mode1ing. The dedicated assistance of Mr. Joseph M. Bernier of the Army Materials and Mechanics Research Center and He1en Brown DeMascio of Syracuse University throughout the stages of the conference p1anning and fina11y the pub1ication of this book is deep1y appreciated. Syracuse University Syracuse, New York The Editors vii CONTENTS OVERVIEW Materials Processing - A Perspective of the Field 1 M.C. Flemings and R. Mehrabian SESSION I RAPID SOLIDIFICATION PROCESSING B.B.Rath, Moderator Heat Flow Limitations in Rapid Solidification Processing * ...* ...13 R. Mehrabian, S.C. Hsu, C.G. Levi, and S. Kou Laser Processing of Materials ...45 B.H. Kear, E.M. Breinan, and E.R. Thompson Electrohydrodynamic Techniques in Metals 79 Processing ...* . .

The Army Materials and Mechanics Research Center has conducted the Saga­ more Army Materials Research Conferences, in cooperation with the Metallurgi­ cal Research Laboratories of the Department of Chemical Engineering and Metallurgy of Syracuse University, since 1954. The purpose of the conferences has been to gather together scientists and engineers from academic institutions, industry, and government who are uniquely qualified to explore in depth a sub­ ject of importance to the Army, the Department of Defense and the scientific community. Grain size and its control is a major factor governing the behavior of materi­ als. Knowledge that one can obtain grain sizes in the 10 micron down to sub­ micron range has established the basis for a new technology. This volume, Ultrafine-Grain Ceramics, addresses itself to the broad areas of: realization of fine-grain ceramics; preparation of ultrafine particle size materials; characterization of ultrafine particles and ultrafine-grain ceramics; processing and behavior of ultra fine-grain ceramics. The technical advice provided by Dr. S. K. Dutta of the Army Materials and Mechanics Research Center during the editing of this book is acknowledged. The continued active interest and support of these conferences by Dr. E. Scala, Director, Lt. Col. Joseph B. Mason, Commanding Officer, and J. F. Sullivan, Deputy Technical Director, of the Army Materials and Mechanics Re­ search Center is appreciated.

The Army Materials and Mechanics Research Center in coop­ eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together over 150 scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. These proceedings, entitled SURFACE TREATMENTS FOR IM­ PROVED PERFORMANCE AND PROPERTIES, address the Physical and Chemical Characteristics of Surfaces, Emerging Surface Modi­ fication Techniques, Surface Structure and Mechanical Proper­ ties, and Relationships between Properties and Processing for Non-metric Materials. We wish to acknowledge the dedicated assistance of JoseDh M. Bernier of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of this book. The continued active interest and support of these con­ ferences by Dr. E. Wright, Director of the Army Materials and Mechanics Research Center, is appreciated. Syracuse University Syracuse, New York The Editors vii CONTENTS SESSION I 1. Surface Modification for Improved Properties. . . . . . .. 3 P. A. Parrish SESSION II PHYSICAL AND CHEMICAL CHARACTERISTICS OF SURFACES P. Ficalora, Moderator 2. Characterization of Surfaces. 19 H. K. Herglotz 3. Reaction Kinetics 51 J. B. Hudson 4. Surfac e Treatments for Enhanced Bonding Between Inorganic Surfaces and Polymers ........ .

The U. S. Army Materials Research Agency has conducted the Saga­ more Army Materials Research Conferences, in cooperation with the Metallurgical Research Laboratories of the Department of Chemical En­ gineering and Metallurgy of Syracuse University, since 1954. The pur­ pose of the conferences has been to gather together scientists and engi­ neers from academic institutions, industry, and government who are uniquely qualified to explore in depth a subject of importance to the Army and the Department of Defenseo The subject of the Thirteenth Sagamore Army Materials Research Con­ ference, "Surfaces and Interfaces I: Chemical and Physical Characteris­ tics," was chosen from a substantial number of possible topics because scientists in the Army responsible for materials research, the conference committee, and the participants believed that much good would result from a detailed analysis of: the knowledge and role of surfaces, including their fundamental characteristics; the role of adsorption and adhesion; and the kinetics, both of exterior surfaces and interfaces. This informa­ tion should aid immeasurably in leading the way to vastly improved mate­ rials, vitally essential if progress is to be made in structures having improved performance. The wisdom of selecting a topic concerned with surfaces and inter­ faces is substantiated by the papers presented in this publication.

The Army Materials and Mechanics Research Center of Water­ town, Massachusetts in cooperation with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has conducted the Sagamore Army Materials Research Conference since 1954. The main purpose of these conferences has been to gather together over 150 scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. This volume, RISK AND FAILURE ANALYSIS FOR IMPROVED PERFORMANCE AND RELIABILITY, addresses the areas of Techniques of Failure Analysis, Risk and Failure Analysis for Design Against Fracture, Risk and Failure Analysis for Design Against Fatigue, Elevated Temperature Effects, Environmental Effects, Systems Approach to Production Reliability Integration and Outlook - Emerging Needs and Techniques. We wish to acknowledge the dedicated assistance of Joseph M. Bernier of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of this book is deeply appreciated.

The Army Materials and Mechanics Research Center has conducted the Sagamore Army Materials Research Conferences, in cooperation with the Metallurgical Research Laboratories of the Department of Chemical Engineering and Metallurgy of Syracuse University, since 1954. The purpose of the conferences has been to gather together scientists and engineers from academic institutions, industry, and government who are uniquely qualified to explore in depth a subject of importance to the Army, the Department of Defense and the scientific corr.munity. This volume, Surfaces and Interfaces ll: Physical and Mechanical Properties, can be considered a continuation, or perhaps an extension, of the information contained in Surfaces and Interfaces I: Chemical and Physical Characteristics. The emphasis in this volume is focused on: the technological significance of surfaces and interfaces; surface­ sensitive mechanical properties; environment-sensitive properties; control of grain structure; and composite materials. It is felt that the rather ambitious undertaking of the program committee to place the role of "surfaces and interfaces" in its proper context has been achieved. The balance between basic research findings and more applied research allows the reader a certain degree of latitude in the use of the two volumes. The continued active interest and support of these conferences by Col. C. T. Riordan, Commanding Officer, Dr. E. Scala, Technical Di­ rector, and J. F. Sullivan, Deputy Technical Director, of the Army Materials and Mechanics Research Center is appreciated.

The Army Materials and Mechanics Research Center in coop­ eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. These proceedings entitled, FATIGUE - ENVIRONMENT AND TEMPER­ ATURE EFFECT, address the overview of temperature and environmental effects of fatigue, room temperature environmental effects, high temperature and environmental effect - mechanisms, high tempera­ ture and environmental effect - mechanisms, materials and design-engineering applications. We wish to acknowledge the assistance of Messrs. Joseph Bernier and Dan McNaught of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of the book. The continued active interest and support of these conferences by Dr. E. Wright, Director of the Army Materials and Mechanics Research Center, is appreciated.