Contents. 1. Introduction to Materials Processing Starting Materials 21. Acknowledgements

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1 Preface Acknowledgements xiii xv 1. Introduction to Materials Processing Materials Processing: Definition and Scope Three Approaches to Materials Processing Materials Processing Steps Processing of Metals Processing of Ceramics Processing of Polymers Summary 19 Bibliography and Recommended Reading 19 Cited References Starting Materials What is a Starting Material? Metals Introduction Bulk Metal Starting Materials Metal Powder Starting Materials Ceramics Introduction Ceramic Powder Starting Materials Glass Starting Materials Polymers Introduction Thermoplastic Polymer Starting Materials Thermoset Polymer Starting Materials Summary 95 Bibliography and Recommended Reading 97 Cited References 98 Questions and Problems 98 Questions 98 Problems 100 vii

2 viii Contents 3. Melt Processes Introduction Fundamentals Melt Structure and Surface Tension Melt Rheology Flow Fundamentals Heat Transfer Fundamentals Solidification Shape Casting Process Overview Metal Melt Preparation Sand Casting Permanent Mold Casting Die Casting Post-Processing of Cast Metal Parts Casting of Flat Sheets Process Overview Glass Melt Preparation Float Glass Process Fusion Downdraw Process Post-Processing Operations for Glass Sheets Extrusion Process Overview Melting and Flow in a Single Screw Extruder Die Flow Single Screw Extruder Operating Diagram Twin Screw Extrusion Die Exit Effects Extruded Products and Solidification Injection Molding Process Overview The Injection Molding Machine and Cycle Mold Flow Packing and Solidification Reaction Injection Molding Blow Molding Process Overview Blow Molding of Glass Blow Molding of Polymers Melt-Based Additive Processes Process Overview Fused Deposition Modeling (FDM) Inkjet Printing of Melts Summary 238 Bibliography and Recommended Reading 240 Cited References 242 Questions and Problems 244

3 ix Questions 244 Problems Solid Processes Introduction Fundamentals Deformation and Plastic Flow under Uniaxial Tension Effects of Temperature and Strain Rate on Deformation Deformation and Yielding under Triaxial Stresses Friction Efficiency and Temperature Rise Solid Processes Process Overview Wire Drawing Extrusion Forging Rolling Bending Thermoforming Superplastic Forming Summary 333 Bibliography and Recommended Reading 335 Cited References 336 Questions and Problems 337 Questions 337 Problems 338 Appendix: Stress in a Spherical Pressure Vessel Powder Processes Introduction Fundamentals Powder Characteristics and Flow Sintering and Microstructure Development Dimensional Changes during Densification Pressing Process Overview Powder Preparation Uniaxial Pressing Isostatic Pressing Post-Forming Processes for Green Parts Hot Pressing and Hot Isostatic Pressing Rotational Molding Process Overview Powder Preparation Rotational Molding Process Steps 398

4 x Contents 5.5 Powder-Based Additive Processes Process Overview Selective Laser Sintering (Melting) Inkjet Binder Printing ( 3D Printing ) Summary 407 Bibliography and Recommended Reading 409 Cited References 410 Questions and Problems 411 Questions 411 Problems Dispersion and Solution Processes 415 Lorraine F. Francis and Christine C. Roberts 6.1 Introduction Fundamentals Colloidal Dispersions Polymer Solutions Rheology of Dispersions and Solutions Characteristics of Volatile Liquids for Dispersions and Solutions Drying Curing of Liquid Monomers Shape Casting Process Overview Capillary Action Predicting Cast Layer Thickness Slip Casting Process Considerations Post-Processing Operations Coating and Tape Casting Process Overview Coating Methods Polymer Coatings Tape Casting of Ceramics Extrusion and Injection Molding Process Overview Extrusion of Concentrated Dispersions Powder Injection Molding Liquid Monomer-Based Additive Processes Process Overview Stereolithography (SLA) Inkjet Printing with Liquid Monomers Summary 504 Bibliography and Recommended Reading 505 Cited References 507 Questions and Problems 508 Questions 508 Problems 509

5 xi 7. Vapor Processes 513 Bethanie Joyce Hills Stadler 7.1 Introduction Fundamentals Kinetic Theory of Gases and Its Relationship to Vapor Processes Thin Film Microstructures Epitaxial Growth of Single Crystal Films Evaporation Process Overview Thermodynamics of Evaporation Evaporation of Alloys and Compounds Transport Phenomenon and Film Uniformity Sputtering Process Overview Plasma Physics Magnetron Sputtering Radio Frequency (RF) Sputtering Reactive Sputtering Optimizing Sputtered Rates Chemical Vapor Deposition Process Overview Thermodynamics of Formation Reactions Types of Reactions Kinetics of CVD Deposition Rate and Uniformity Post-Processing of Films after Deposition Annealing Patterning Summary 580 Bibliography and Recommended Reading 582 Cited References 583 Questions and Problems 583 Questions 583 Problems 585 Appendix A 589 Index 591

Metal Matrix Composite (MMC)

Matrix Metal Matrix Composite (MMC) The matrix is the monolithic material into which the reinforcement is embedded, and is completely continuous. This means thatt there is apath throughh the matrix ti