Contents. Preface. Lightweight Materials Understanding the Basics F.C. Campbell, editor

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2 Lightweight Materials Understanding the Basics F.C. Campbell, editor Copyright 2012 ASM International All rights reserved Contents Preface ix CHAPTER 1 Introduction and Uses of Lightweight Materials Today s Lightweight Materials Aluminum Alloys Magnesium Alloys Beryllium Titanium Alloys Titanium Aluminide Intermetallics Engineering Plastics Polymer-Matrix Composites Metal-Matrix Composites Structural Ceramics Ceramic-Matrix Composites CHAPTER 2 Aluminum Alloys Applications Aluminum Metallurgy Aluminum Alloy Designation Aluminum Alloys Wrought Non-Heat-Treatable Alloys Wrought Heat Treatable Alloys Melting and Primary Fabrication Rolling Plate and Sheet Extrusion Forging Heat Treating Annealing

3 iv / Contents 2.13 Forming Casting Casting Alloys Machining Chemical Milling Joining Corrosion of Aluminum and Aluminum Alloys CHAPTER 3 Magnesium Alloys Magnesium Metallurgy Magnesium Applications Magnesium Alloy Designation Magnesium Casting Alloys Die Casting Alloys Sand and Permanent Mold Casting Alloys Wrought Magnesium Alloys Sheet and Plate Extrusions Forgings Forming Magnesium Heat Treating Joining Methods Machinability Magnesium Corrosion Corrosion Protection of Magnesium Protective Coating Systems CHAPTER 4 Beryllium Beryllium Properties and Applications Beryllium Powder Production Operations Powder Consolidation Methods Beryllium Grades and Their Designations Wrought Products and Fabrication Forming Beryllium Beryllium Machining Beryllium Joining Aluminum-Beryllium Alloys Beryllium Corrosion Corrosion-Protection Surface Treatments and Coatings Health and Safety

4 Contents / v CHAPTER 5 Titanium Alloys Titanium Applications Titanium Physical Metallurgy Titanium Properties Processing of Titanium and Titanium Alloys Titanium Primary Fabrication Titanium Secondary Fabrication Titanium Powder Metallurgy Directed Metal Deposition Titanium Forming Superplastic Forming Heat Treating Titanium Casting Machining Titanium Joining Corrosion Resistance of Titanium and Titanium Alloys CHAPTER 6 Titanium Aluminide Intermetallics Titanium Aluminides Alpha-2 Alloys Orthorhombic Alloys Gamma Alloys Gamma Titanium Aluminide Applications Processing Near-Gamma Alloys CHAPTER 7 Engineering Plastics General Characteristics Thermosets and Thermoplastics Metals versus Plastics Effect of Fillers and Reinforcements Temperature and Molecular Structure Effect of Crystallinity Effect of Viscoelasticity Thermal Properties Electrical Properties Environmental Factors Categories of Engineering Plastics and Applications Plastic Fabrication Processes Joining Plastics

5 vi / Contents CHAPTER 8 Polymer-Matrix Composites Advantages and Disadvantages of Composite Materials Applications Laminates Fibers Product Forms Matrices Fabrication Processes Thermoplastic Consolidation Thermoforming Sandwich and Cocured Structure Integrally Cocured Unitized Structure Machining Mechanical Fastening Thermoplastic Joining CHAPTER 9 Metal-Matrix Composites Applications of Metal-Matrix Composites Discontinuously Reinforced Metal-Matrix Composites Discontinuously Reinforced Aluminum Processing of Discontinuously Reinforced Aluminum Processing of Discontinuously Reinforced Titanium Secondary Processing of Discontinuous Metal-Matrix Composites Continuous Fiber-Reinforced Metal-Matrix Composites Processing of Continuous Fiber-Reinforced Aluminum Composites Processing of Continuous Fiber-Reinforced Titanium Composites Secondary Fabrication of Titanium-Matrix Composites Processing of Other Metal-Matrix Composites Fiber-Metal Laminates CHAPTER 10 Structural Ceramics Structural Ceramics Applications for Structural Ceramics Properties of Structural Ceramics Toughened Ceramics Design and Selection Considerations Processing of Structural Ceramics Joining of Ceramics

6 Contents / vii CHAPTER 11 Ceramic-Matrix Composites Discontinuously Reinforced Ceramic-Matrix Composites Applications for Discontinuously Reinforced Ceramic- Matrix Composites Continuous Fiber Ceramic-Matrix Composites Applications for Continuous Fiber Ceramic-Matrix Composites Carbon-Carbon Composites Applications for Carbon-Carbon Composites Processing of Ceramic-Matrix Composites CHAPTER 12 Selection Guidelines for Lightweight Materials The Materials Selection Process Performance Characteristics of Materials Relation of Materials Selection to Manufacturing Costs and Related Aspects of Materials Selection Methods of Materials Selection Conclusions Lightweight Materials Selection Lightweight Materials in the Transportation (Automotive) Industry Summary Index 673