<p><strong> Preface xxiii </strong> <br> <strong> About the Authors xxvi </strong> <br> <strong> General Introduction </strong> <br> I.1 What is Manufacturing? <br> I.2 Product Design and Concurrent Engineering <br> I.3 Design for Manufacture, Assembly, Disassembly, and Service <br> I.4 Environmentally Conscious Design, Sustainable Manufacturing, and Product Life Cycle <br> I.5 Selection of Materials <br> I.6 Selection of Manufacturing Processes <br> I.7 Computer-integrated Manufacturing <br> I.8 Quality Assurance and Total Quality Management <br> I.9 Lean Production and Agile Manufacturing <br> I.10 Manufacturing Costs and Global Competition <br> I.11 Trends in Manufacturing<br> <br> <strong> PART I: FUNDAMENTALS OF MATERIALS: BEHAVIOR AND MANUFACTURING PROPERTIES </strong> <br> 1. The Structure of Metals <br> 1.1 Introduction <br> 1.2 Types of Atomic Bonds <br> 1.3 The Crystal Structure of Metals <br> 1.4 Deformation and Strength of Single Crystals <br> 1.5 Grains and Grain Boundaries <br> 1.6 Plastic Deformation of Polycrystalline Metals <br> 1.7 Recovery, Recrystallization, and Grain Growth <br> 1.8 Cold, Warm, and Hot Working <br> 2. Mechanical Behavior, Testing, and Manufacturing Properties of Materials <br> 2.1 Introduction <br> 2.2 Tension <br> 2.3 Compression <br> 2.4 Torsion <br> 2.5 Bending (Flexure) <br> 2.6 Hardness <br> 2.7 Fatigue <br> 2.8 Creep <br> 2.9 Impact <br> 2.10 Failure and Fracture of Materials <br> 2.11 Residual Stresses <br> 2.12 Work, Heat, and Temperature <br> 3. Physical Properties of Materials <br> 3.1 Introduction <br> 3.2 Density <br> 3.3 Melting Point <br> 3.4 Specific Heat <br> 3.5 Thermal Conductivity <br> 3.6 Thermal Expansion <br> 3.7 Electrical, Magnetic, and Optical Properties <br> 3.8 Corrosion Resistance <br> 4. Metal Alloys: Their Structure and Strengthening by Heat Treatment <br> 4.1 Introduction <br> 4.2 Structure of Alloys <br> 4.3 Phase Diagrams <br> 4.4 The Iron-Carbon System <br> 4.5 The Iron -- Iron-carbide Phase Diagram and the Development of Microstructures in Steels <br> 4.6 Cast Irons <br> 4.7 Heat Treatment of Ferrous Alloys <br> 4.8 Hardenability of Ferrous Alloys <br> 4.9 Heat Treatment of Nonferrous Alloys and Stainless Steels <br> 4.10 Case Hardening <br> 4.11 Annealing <br> 4.12 Heat-treating Furnaces and Equipment <br> 4.13 Design Considerations for Heat Treating <br> 5. Ferrous Metals and Alloys: Production, General Properties, and Applications <br> 5.1 Introduction <br> 5.2 Production of Iron and Steel <br> 5.3 Casting of Ingots <br> 5.4 Continuous Casting <br> 5.5 Carbon and Alloy Steels <br> 5.6 Stainless Steels <br> 5.7 Tool and Die Steels <br> 6. Nonferrous Metals and Alloys: Production, General Properties, and Applications <br> 6.1 Introduction <br> 6.2 Aluminum and Aluminum Alloys <br> 6.3 Magnesium and Magnesium Alloys <br> 6.4 Copper and Copper Alloys <br> 6.5 Nickel and Nickel Alloys <br> 6.6 Superalloys <br> 6.7 Titanium and Titanium Alloys <br> 6.8 Refractory Metals and Alloys <br> 6.9 Beryllium <br> 6.10 Zirconium <br> 6.11 Lithium <br> 6.12 Low-melting Alloys <br> 6.13 Precious Metals <br> 6.14 Shape-memory Alloys (Smart Materials) <br> 6.15 Amorphous Alloys (Metallic Glasses) <br> 6.16 Metal Foams and Metamaterials <br> 6.17 Rare Earth Metals <br> 7. Polymers: Structure, General Properties, and Applications <br> 7.1 Introduction <br> 7.2 The Structure of Polymers <br> 7.3 Thermoplastics <br> 7.4 Thermosetting Plastics <br> 7.5 Additives in Plastics <br> 7.6 General Properties and Applications of Thermoplastics <br> 7.7 General Properties and Applications of Thermosetting Plastics <br> 7.8 Biodegradable Plastics <br> 7.9 Elastomers (Rubbers) <br> 8. Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications <br> 8.1 Introduction <br> 8.2 The Structure of Ceramics <br> 8.3 General Properties and Applications of Ceramics <br> 8.4 Glasses <br> 8.5 Glass Ceramics <br> 8.6 Graphite <br> 8.7 Diamond <br> 8.8 Nanomaterials <br> 9. Composite Materials: Structure, General Properties, and Applications <br> 9.1 Introduction <br> 9.2 The Structure of Reinforced Plastics <br> 9.3 Properties of Reinforced Plastics <br> 9.4 Applications of Reinforced Plastics <br> 9.5 Metal-matrix Composites <br> 9.6 Ceramic-matrix Composites <br> 9.7 Other Composites<br> <br> <strong> PART II: METAL-CASTING PROCESSES AND EQUIPMENT </strong> <br> 10. Fundamentals of Metal Casting <br> 10.1 Introduction <br> 10.2 Solidification of Metals <br> 10.3 Fluid Flow <br> 10.4 Fluidity of Molten Metal <br> 10.5 Heat Transfer <br> 10.6 Defects <br> 11. Metal-casting Processes and Equipment <br> 11.1 Introduction <br> 11.2 Expendable-mold, Permanent-pattern Casting Processes <br> 11.3 Expendable-mold, Expendable-pattern Casting Processes <br> 11.4 Permanent-mold Casting Processes <br> 11.5 Casting Techniques for Single-crystal Components <br> 11.6 Rapid Solidification <br> 11.7 Inspection of Castings <br> 11.8 Melting Practice and Furnaces <br> 11.9 Foundries and Foundry Automation <br> 12. Metal Casting: Design, Materials, and Economics <br> 12.1 Introduction <br> 12.2 Design Considerations in Casting <br> 12.3 Casting Alloys <br> 12.4 Economics of Casting<br> <br> <strong> PART III: FORMING AND SHAPING PROCESSES AND EQUIPMENT </strong> <br> 13. Metal-rolling Processes and Equipment <br> 13.1 Introduction <br> 13.2 The Flat-rolling Process <br> 13.3 Flat-rolling Practice <br> 13.4 Rolling Mills <br> 13.5 Various Rolling Processes and Mills <br> 14. Metal-forging Processes and Equipment <br> 14.1 Introduction <br> 14.2 Open-die Forging <br> 14.3 Impression-die and Closed-die Forging <br> 14.4 Various Forging Operations <br> 14.5 Forgeability of Metals; Forging Defects <br> 14.6 Die Design, Die Materials, and Lubrication <br> 14.7 Die-manufacturing Methods and Die Failure <br> 14.8 Forging Machines <br> 14.9 Economics of Forging <br> 15. Metal Extrusion and Drawing Processes and Equipment <br> 15.1 Introduction <br> 15.2 The Extrusion Process <br> 15.3 Hot Extrusion <br> 15.4 Cold Extrusion <br> 15.5 Extrusion Defects <br> 15.6 Design Considerations <br> 15.7 Extrusion Equipment <br> 15.8 The Drawing Process <br> 15.9 Drawing Practice <br> 15.10 Drawing Defects and Residual Stresses <br> 15.11 Drawing Equipment <br> 16. Sheet-Metal Forming Processes and Equipment <br> 16.1 Introduction <br> 16.2 Shearing <br> 16.3 Sheet-metal Characteristics and Formability <br> 16.4 Formability Tests for Sheet Metals <br> 16.5 Bending Sheets, Plates, and Tubes <br> 16.6 Miscellaneous Bending and Related Forming Operations <br> 16.7 Deep Drawing <br> 16.8 Rubber Forming and Hydroforming <br> 16.9 Spinning <br> 16.10 Superplastic Forming <br> 16.11 Hot Stamping <br> 16.12 Specialized Forming Processes <br> 16.13 Manufacturing of Metal Honeycomb Structures <br> 16.14 Design Considerations in Sheet-metal Forming <br> 16.15 Equipment for Sheet-metal Forming <br> 16.16 Economics of Sheet-forming Operations <br> 17. Powder Metal Processes and Equipment <br> 17.1 Introduction <br> 17.2 Production of Metal Powders <br> 17.3 Compaction of Metal Powders <br> 17.4 Sintering <br> 17.5 Secondary and Finishing Operations <br> 17.6 Design Considerations <br> 17.7 Economics of Powder Metallurgy <br> 18. Ceramics, Glasses, and Superconductors: Processing and Equipment <br> 18.1 Introduction <br> 18.2 Shaping Ceramics <br> 18.3 Forming and Shaping of Glass <br> 18.4 Techniques for Strengthening and Annealing Glass <br> 18.5 Design Considerations for Ceramics and Glasses <br> 18.6 Processing of Superconductors <br> 19. Plastics and Composite Materials: Forming and Shaping <br> 19.1 Introduction <br> 19.2 Extrusion <br> 19.3 Injection Molding <br> 19.4 Blow Molding <br> 19.5 Rotational Molding <br> 19.6 Thermoforming <br> 19.7 Compression Molding <br> 19.8 Transfer Molding <br> 19.9 Casting <br> 19.10 Foam Molding <br> 19.11 Cold Forming and Solid-phase Forming <br> 19.12 Processing Elastomers <br> 19.13 Processing Polymer-matrix Composites <br> 19.14 Processing Metal-matrix and Ceramic-matrix Composites <br> 19.15 Design Considerations <br> 19.16 Economics of Processing Plastics and Composite Materials <br> 20. Additive Manufacturing <br> 20.1 Introduction <br> 20.2 Additive Manufacturing Methodology <br> 20.3 Extrusion-based Processes <br> 20.4 Photopolymerization <br> 20.5 Material Jetting <br> 20.6 Powder Bed Processes <br> 20.7 Laminated-object Manufacturing <br> 20.8 Miscellaneous Processes <br> 20.9 Emerging AM Applications <br> 20.10 Direct Manufacturing and Rapid Tooling <br> 20.11 Design for Additive Manufacturing <br> 20.12 Additive Manufacturing Economics<br> <br> <strong> PART IV: MACHINING PROCESSES AND MACHINE TOOLS </strong> <br> 21. Fundamentals of Machining <br> 21.1 Introduction <br> 21.2 Mechanics of Cutting <br> 21.3 Cutting Forces and Power <br> 21.4 Temperatures in Cutting <br> 21.5 Tool Life: Wear and Failure <br> 21.6 Surface Finish and Integrity <br> 21.7 Machinability <br> 22. Cutting-Tool Materials and Cutting Fluids <br> 22.1 Introduction <br> 22.2 High-speed Steels <br> 22.3 Cast-cobalt Alloys <br> 22.4 Carbides <br> 22.5 Coated Tools <br> 22.6 Alumina-based Ceramics <br> 22.7 Cubic Boron Nitride <br> 22.8 Silicon-Nitride-based Ceramics <br> 22.9 Diamond <br> 22.10 Whisker-reinforced Materials and Nanomaterials <br> 22.11 Tool Costs and Reconditioning of Tools <br> 22.12 Cutting Fluids <br> 23. Machining Processes: Turning and Hole Making <br> 23.1 Introduction <br> 23.2 The Turning Process <br> 23.3 Lathes and Lathe Operations <br> 23.4 Boring and Boring Machines <br> 23.5 Drilling, Drills, and Drilling Machines <br> 23.6 Reaming and Reamers <br> 23.7 Tapping and Taps <br> 24. Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing <br> 24.1 Introduction <br> 24.2 Milling and Milling Machines <br> 24.3 Planing and Shaping <br> 24.4 Broaching and Broaching Machines <br> 24.5 Sawing <br> 24.6 Filing <br> 24.7 Gear Manufacturing by Machining <br> 25. Machining Centers, Machine-tool Structures, and Machining Economics <br> 25.1 Introduction <br> 25.2 Machining Centers <br> 25.3 Machine-tool Structures <br> 25.4 Vibration and Chatter in Machining Operations <br> 25.5 High-speed Machining <br> 25.6 Hard Machining <br> 25.7 Ultraprecision Machining <br> 25.8 Machining Economics <br> 26. Abrasive Machining and Finishing Operations <br> 26.1 Introduction <br> 26.2 Abrasives and Bonded Abrasives <br> 26.3 The Grinding Process <br> 26.4 Grinding Operations and Machines <br> 26.5 Design Considerations for Grinding <br> 26.6 Ultrasonic Machining <br> 26.7 Finishing Operations <br> 26.8 Deburring Operations <br> 26.9 Economics of Abrasive Machining and Finishing Operations <br> 27. Advanced Machining Processes <br> 27.1 Introduction <br> 27.2 Chemical Machining <br> 27.3 Electrochemical Machining <br> 27.4 Electrochemical Grinding <br> 27.5 Electrical-discharge Machining <br> 27.6 Laser-beam Machining <br> 27.7 Electron-beam Machining <br> 27.8 Water-jet Machining <br> 27.9 Abrasive-jet Machining <br> 27.10 Hybrid Machining Systems <br> 27.11 Economics of Advanced Machining Processes<br> <br> <strong> PART V: MICROMANUFACTURING AND FABRICATION OF MICROELECTRONIC DEVICES </strong> <br> 28. Fabrication of Microelectronic Devices <br> 28.1 Introduction <br> 28.2 Clean Rooms <br> 28.3 Semiconductors and Silicon <br> 28.4 Crystal Growing and Wafer Preparation <br> 28.5 Film Deposition <br> 28.6 Oxidation <br> 28.7 Lithography <br> 28.8 Etching <br> 28.9 Diffusion and Ion Implantation <br> 28.10 Metallization and Testing <br> 28.11 Wire Bonding and Packaging <br> 28.12 Yield and Reliability <br> 28.13 Printed Circuit Boards <br> 28.14 Roll-to-Roll Printing of Flexible Electronics <br> 28.15 Flexible Hybrid Electronics <br> 29. Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing <br> 29.1 Introduction <br> 29.2 Micromachining of MEMS Devices <br> 29.3 Electroforming-based Processes <br> 29.4 Solid Free-form Fabrication of Devices <br> 29.5 Mesoscale Manufacturing <br> 29.6 Nanoscale Manufacturing<br> <br> <strong> PART VI: JOINING PROCESSES AND EQUIPMENT </strong> <br> 30. Fusion Welding Processes <br> 30.1 Introduction <br> 30.2 Oxyfuel-Gas Welding <br> 30.3 Arc-welding Processes: Nonconsumable Electrode <br> 30.4 Arc-welding Processes: Consumable Electrode <br> 30.5 Electrodes for Arc Welding <br> 30.6 Electron-beam Welding <br> 30.7 Laser-beam Welding <br> 30.8 Cutting <br> 30.9 The Weld Joint, Quality, and Testing <br> 30.10 Joint Design and Process Selection <br> 31. Solid-State Welding Processes <br> 31.1 Introduction <br> 31.2 Cold Welding and Roll Bonding <br> 31.3 Ultrasonic Welding <br> 31.4 Friction Welding <br> 31.5 Resistance Welding <br> 31.6 Explosion Welding <br> 31.7 Diffusion Bonding <br> 31.8 Economics of Welding Operations <br> 32. Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes <br> 32.1 Introduction <br> 32.2 Brazing <br> 32.3 Soldering <br> 32.4 Adhesive Bonding <br> 32.5 Mechanical Fastening <br> 32.6 Joining Plastics, Ceramics, and Glasses <br> 32.7 Economics of Joining Operations<br> <br> <strong> PART VII: SURFACE TECHNOLOGY </strong> <br> 33. Surface Roughness and Measurement; Friction, Wear, and Lubrication <br> 33.1 Introduction <br> 33.2 Surface Structure and Integrity <br> 33.3 Surface Texture and Roughness <br> 33.4 Friction <br> 33.5 Wear <br> 33.6 Lubrication <br> 33.7 Metalworking Fluids and Their Selection <br> 34. Surface Treatments, Coatings, and Cleaning <br> 34.1 Introduction <br> 34.2 Mechanical Surface Treatments <br> 34.3 Mechanical Plating and Cladding <br> 34.4 Case Hardening and Hard Facing <br> 34.5 Thermal Spraying <br> 34.6 Vapor Deposition <br> 34.7 Ion Implantation and Diffusion Coating <br> 34.8 Laser Treatments <br> 34.9 Electroplating, Electroless Plating, and Electroforming <br> 34.10 Conversion Coatings <br> 34.11 Hot Dipping <br> 34.12 Porcelain Enameling; Ceramic and Organic Coatings <br> 34.13 Diamond Coating and Diamondlike Carbon <br> 34.14 Surface Texturing <br> 34.15 Painting <br> 34.16 Cleaning of Surfaces</p> <p><strong> PART VIII: ENGINEERING METROLOGY, INSTRUMENTATION, AND QUALITY ASSURANCE </strong> <br> 35. Surface Treatments, Coatings, and Cleaning <br> 35.1 Introduction <br> 35.2 Measurement Standards <br> 35.3 Geometric Features of Parts: Analog and Digital Measurements <br> 35.4 Traditional Measuring Methods and Instruments <br> 35.5 Modern Measuring Instruments and Machines <br> 35.6 Automated Measurement <br> 35.7 General Characteristics and Selection of Measuring Instruments <br> 35.8 Geometric Dimensioning and Tolerancing <br> 36. Quality Assurance, Testing, and Inspection <br> 36.1 Introduction <br> 36.2 Product Quality <br> 36.3 Quality Assurance <br> 36.4 Total Quality Management <br> 36.5 Taguchi Methods <br> 36.6 The ISO and QS Standards <br> 36.7 Statistical Methods of Quality Control <br> 36.8 Statistical Process Control <br> 36.9 Reliability of Products and Processes <br> 36.10 Nondestructive Testing <br> 36.11 Destructive Testing <br> 36.12 Automated Inspection</p> <p><strong> PART IX: MANUFACTURING IN A COMPETITIVE ENVIRONMENT </strong> <br> 37. Automation of Manufacturing Processes and Operations <br> 37.1 Introduction <br> 37.2 Automation <br> 37.3 Numerical Control <br> 37.4 Adaptive Control <br> 37.5 Material Handling and Movement <br> 37.6 Industrial Robots <br> 37.7 Sensor Technology <br> 37.8 Flexible Fixturing <br> 37.9 Assembly Systems <br> 37.10 Design Considerations for Fixturing, Assembly, Disassembly, and Servicing <br> 37.11 Economic Considerations <br> 38. Computer-aided Manufacturing <br> 38.1 Introduction <br> 38.2 Manufacturing Systems <br> 38.3 Computer-integrated Manufacturing <br> 38.4 Computer-aided Design and Engineering <br> 38.5 Computer-aided Manufacturing <br> 38.6 Computer-aided Process Planning <br> 38.7 Computer Simulation of Manufacturing Processes and Systems <br> 38.8 Group Technology <br> 39. Computer-integrated Manufacturing Systems <br> 39.1 Introduction <br> 39.2 Cellular Manufacturing <br> 39.3 Flexible Manufacturing Systems <br> 39.4 Mass Customization <br> 39.5 Holonic Manufacturing <br> 39.6 Just-in-time Production <br> 39.7 Lean Manufacturing <br> 39.8 Communications Networks in Manufacturing <br> 39.9 Artificial Intelligence and Machine Learning <br> 39.10 Economic Considerations <br> 40. Product Design and Manufacturing in a Competitive Environment <br> 40.1 Introduction <br> 40.2 Product Design <br> 40.3 Product Quality <br> 40.4 Life-cycle Assessment and Sustainable Manufacturing <br> 40.5 Energy Consumption in Manufacturing <br> 40.6 Material Selection for Products <br> 40.7 Material Substitution <br> 40.8 Manufacturing Process Capabilities <br> 40.9 Process Selection <br> 40.10 Manufacturing Costs and Cost Reduction </p>