DeGarmo's Materials and Processes in Manufacturing, Global Edition

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Newly revised, DeGarmo's Materials and Processes in Manufacturing has been the market-leading text on manufacturing and manufacturing processes courses for over fifty years. Authors J T. Black and Ron Kohser have continued this book's long and distinguished tradition of exceedingly clear presentation and highly practical approach to materials and processes, presenting mathematical models and analytical equations only when they enhance the basic understanding of the material. Updated to reflect all current practices, standards, and materials, this edition has new coverage of additive manufacturing, lean engineering, and processes related to ceramics, polymers, and plastics.

Inhalt

Preface iii

1 Introduction to DeGarmo's Materials and Processes in Manufacturing 1

1.1 Materials, Manufacturing, and the Standard of Living 1

1.2 Manufacturing and Production Systems 3

Review Questions 24

Problems 25

2 Properties of Materials 26

2.1 Introduction 26

2.2 Static Properties 28

2.3 Dynamic Properties 38

2.4 Temperature Effects (Both High and Low) 43

2.5 Machinability, Formability, and Weldability 46

2.6 Fracture Toughness and the Fracture Mechanics Approach 46

2.7 Physical Properties 48

2.8 Testing Standards and Testing Concerns 48

Review Questions 48

Problems 50

3 Nature of Materials 51

3.1 Structure-Property-Processing-Performance Relationships 51

3.2 The Structure of Atoms 52

3.3 Atomic Bonding 52

3.4 Secondary Bonds 53

3.5 Atom Arrangements in Materials 54

3.6 Crystal Structures 54

3.7 Development of a Grain Structure 56

3.8 Elastic Deformation 56

3.9 Plastic Deformation 57

3.10 Dislocation Theory of Slippage 58

3.11 Strain Hardening or Work Hardening 59

3.12 Plastic Deformation in Polycrystalline Material 60

3.13 Grain Shape and Anisotropic Properties 60

3.14 Fracture 61

3.15 Cold Working, Recrystallization, and Hot Working 61

3.16 Grain Growth 62

3.17 Alloys and Alloy Types 62

3.18 Atomic Structure and Electrical Properties 62

Review Questions 63

Problems 64

4 Equilibrium Phase Diagrams and the Iron-Carbon System 65

4.1 Introduction 65

4.2 Phases 65

4.3 Equilibrium Phase Diagrams 65

4.4 Iron-Carbon Equilibrium Diagram 71

4.5 Steels and the Simplified Iron-Carbon Diagram 72

4.6 Cast Irons 74

Review Questions 75

Problems 76

5 Heat Treatment 77

5.1 Introduction 77

5.2 Processing Heat Treatments 77

5.3 Heat Treatments Used to Increase Strength 80

5.4 Strengthening Heat Treatments for Nonferrous Metals 80

5.5 Strengthening Heat Treatments for Steel 83

5.6 Surface Hardening of Steel 94

5.7 Furnaces 96

5.8 Heat Treatment and Energy 97

Review Questions 98

Problems 99

6 Ferrous Metals and Alloys 101

6.1 Introduction to History-Dependent Materials 101

6.2 Ferrous Metals 101

6.3 Iron 102

6.4 Steel 102

6.5 Stainless Steels 113

6.6 Tool Steels 115

6.7 Cast Irons 117

6.8 Cast Steels 120

6.9 The Role of Processing on Cast Properties 120

Review Questions 121

Problems 122

7 Nonferrous Metals and Alloys 123

7.1 Introduction 123

7.2 Copper and Copper Alloys 123

7.3 Aluminum and Aluminum Alloys 128

7.4 Magnesium and Magnesium Alloys 134

7.5 Zinc and Zinc Alloys 136

7.6 Titanium and Titanium Alloys 137

7.7 Nickel-Based Alloys 138

7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 138

7.9 Lead and Tin and Their Alloys 141

7.10 Some Lesser-Known Metals and Alloys 141

7.11 Metallic Glasses 141

7.12 Graphite 142

7.13 Materials for Specific Applications 142

7.14 High Entropy Alloys 142

Review Questions 143

Problems 144

8 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 145

8.1 Introduction 145

8.2 Plastics 145

8.3 Elastomers 156

8.4 Ceramics 159

8.5 Composite Materials 166

Review Questions 174

Problems 175

9 Material Selection 177

9.1 Introduction 177

9.2 Material Selection and Manufacturing Processes 179

9.3 The Design Process 179

9.4 Approaches to Material Selection 180

9.5 Additional Factors to Consider 183

9.6 Consideration of the Manufacturing Process 183

9.7 Ultimate Objective 184

9.8 Materials Substitution 185

9.9 Effect of Product Liability on Materials Selection 186

9.10 Aids to Material Selection 186

Review Questions 187

Problems 188

10 Fundamentals of Casting 191

10.1 Introduction to Materials Processing 191

10.2 Introduction to Casting 192

10.3 Casting Terminology 193

10.4 The Solidification Process 194

10.5 Patterns 202

10.6 Design Considerations in Castings 203

10.7 The Casting Industry 206

Review Questions 206

Problems 208

11 Expendable-Mold Casting Processes 209

11.1 Introduction 209

11.2 Sand Casting 209

11.3 Cores and Core Making 222

11.4 Other Expendable-Mold Processes with Multiple-Use Patterns 225

11.5 Expendable-Mold Processes Using Single-Use Patterns 226

11.6 Shakeout, Cleaning, and Finishing 232

11.7 Summary 232

Review Questions 232

Problems 234

12 Multiple-Use-Mold Casting Processes 235

12.1 Introduction 235

12.2 Permanent-Mold Casting 235

12.3 Die Casting 238

12.4 Squeeze Casting and Semisolid Casting 241

12.5 Centrifugal Casting 242

12.6 Continuous Casting 244

12.7 Melting 244

12.8 Pouring Practice 247

12.9 Cleaning, Finishing, Heat Treating, and Inspection 247

12.10 Automation in Foundry Operations 248

12.11 Process Selection 248

Review Questions 250

Problems 251

13 Fabrication of Plastics, Ceramics, and Composites 252

13.1 Introduction 252

13.2 Fabrication of Plastics 252

13.3 Processing of Rubber and Elastomers 262

13.4 Processing of Ceramics 263

13.5 Fabrication of Composite Materials 267

Review Questions 275

Problems 277

14 Fundamentals of Metal Forming 279

14.1 Introduction 279

14.2 Forming Processes: Independent Variables 280

14.3 Dependent Variables 281

14.4 Independent-Dependent Relationships 281

14.5 Process Modeling 282

14.6 General Parameters 282

14.7 Friction, Lubrication, and Wear under Metalworking Conditions 283

14.8 Temperature Concerns 284

14.9 Formability 290

Review Questions 290

Problems 292

15 Bulk Forming Processes 293

15.1 Introduction 293

15.2 Classification of Deformation Processes 293

15.3 Bulk Deformation Processes 294

15.4 Rolling 294

15.5 Forging 298

15.6 Extrusion 308

15.7 Wire, Rod, and Tube Drawing 312

15.8 Cold Forming, Cold Forging, and Impact Extrusion 314

15.9 Piercing 317

15.10 Other Squeezing Processes 318

15.11 Surface Improvement by Deformation Processing 320

Review Questions 321

Problems 322

16 Sheet-Forming Processes 325

16.1 Introduction 325

16.2 Shearing Operations 325

16.3 Bending 331

16.4 Drawing and Stretching Processes 338

16.5 Alternative Methods of Producing Sheet-Type Products 349

16.6 Seamed Pipe Manufacture 349

16.7 Presses 350

Review Questions 354

Problems 356

17 Powder Metallurgy (Particulate Processing) 357

17.1 Introduction 357

17.2 The Basic Process 357

17.3 Powder Manufacture 358

17.4 Powder Testing and Evaluation 359

17.5 Powder Mixing and Blending 360

17.6 Compacting 360

17.7 Sintering 363

17.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 364

17.9 Hot-Isostatic Pressing 365

17.10 Other Techniques to Produce High-Density P/M Products 366

17.11 Metal Injection Molding (MIM) 366

17.12 Secondary Operations 368

17.13 Properties of P/M Products 369

17.14 Design of Powder Metallurgy Parts 371

17.15 Powder Metallurgy Products 371

17.16 Advantages and Disadvantages of Powder Metallurgy 373

17.17 Process Summary 374

Review Questions 375

Problems 376

18 Additive Processes-Including 3-D Printing 377

18.1 Introduction 377

18.2 Layerwi…