Handbook of Materials for Product Design

1409 Pages·20.275 MB·English

by  Harper Ch.

00Front.a Page iii Thursday, May 31, 2001 10:25 AM
HANDBOOK OF
MATERIALS FOR
PRODUCT DESIGN
Charles A. Harper
Editor in Chief
Technology Seminars, Inc., Lutherville, Maryland
Third Edition
McGRAW-HILL
New York Chicago San Francisco Lisbon London Madrid
Mexico City Milan New Delhi San Juan Seoul
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iii
00Front.a Page iv Thursday, May 31, 2001 10:25 AM
Library of Congress Cataloging-in-Publication Data
Handbook of materials and product design / Charles A. Harper, editor in chief.
p. cm.
ISBN 0-07-135406-9
1. Materials—Handbooks, manuals, etc. 2. Engineering design—Handbooks, manuals,
etc. I. Harper, Charles A.
TA403.4.H365 2001
620.1'1—dc21 2001030028
CIP
Copyright © 2001 by McGraw-Hill, Inc. All rights reserved. Printed in the United
States of America. Except as permitted under the United States Copyright Act of
1976, no part of this publication may be reproduced or distributed in any form or
by any means, or stored in a data base or retrieval system, without the prior written
permission of the publisher.
1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 7 6 5 4 3 2 1
ISBN 0-07-135406-9
The sponsoring editor for this book was Kenneth McCombs and the
production supervisor was Pamela A. Pelton. It was set in Century
Schoolbook by J. K. Eckert & Company, Inc.
Printed and bound by R. R. Donnelley & Sons Company.
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iv
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ABOUT THE EDITOR
Charles A. Harper is President of Technology Seminars, Inc., of Lutherville, Maryland. He
is widely recognized as a leader in materials for product design, having worked and taught
extensively in this area. Mr. Harper is also Series Editor for the Materials Science and
Technology Series and the Electronic Packaging and Interconnection Series, both pub-
lished by McGraw-Hill. He has been active in many professional societies, including the
Society of Plastics Engineers, American Society for Materials, and the Society for the
Advancement of Materials Engineering, in which he holds the honorary level of Fellow of
the Society. He is a past President and Fellow of the International Microelectronics and
Packaging Society. Mr. Harper is a graduate of the Johns Hopkins University, Baltimore,
Maryland, where he has also served as Adjunct Professor.
E.1
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CONTENTS
Contributors xiii
Preface xi
Chapter 1. Ferrous Metals 1.1
1.1 Introduction 1.1
1.2 The Structure of Iron 1.2
1.3 Steelmaking 1.6
1.4 Carbon and Alloy Steels 1.11
1.5 Selection of Alloy Steels 1.29
1.6 Selection and Specification 1.43
1.7 Welding Ferrous Metals 1.61
1.8 Summary 1.91
References 1.92
Chapter 2. Aluminum and Its Alloys 2.1
2.1 Introduction 2.1
2.2 Alloy and Temper Designation System 2.5
2.3 Physical Properties 2.27
2.4 Mechanical Properties 2.41
2.5 Corrosion Resistance 2.92
2.6 Product Forms 2.107
2.7 Fabrication 2.129
2.8 Joining 2.138
2.9 Finishes 2.162
2.10 Glossary 2.174
References 2.177
Chapter 3. Titanium 3.1
3.1 Introduction 3.1
3.2 Basic Metallurgy 3.4
3.3 Alloy Classification and Overview 3.12
3.4 Properties 3.16
3.5 Corrosion and Corrosion Resistance 3.27
3.6 Alloys for Cryogenic Applications 3.33
3.7 Titanium Alloys for High-Temperature Applications 3.34
3.8 Casting Alloys 3.41
3.9 Precipitate and Dispersoid Strengthened Alloys 3.43
Wrought Alloy Processing 3.44
References 3.60
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vi HANDBOOK OF MATERIALS FOR PRODUCT DESIGN
Chapter 4. Plastics 4.1
4.1 Introduction 4.1
4.2 The Nature of Plastics 4.6
4.3 Polymer Structures and Polymerization Reactions 4.8
4.4 Plastic-Processing Methods and Design Guidelines 4.10
4.5 Thermosetting Plastics 4.18
4.6 Thermoplastics 4.34
4.7 Glass-Fiber-Reinforced Thermoplastics 4.75
4.8 Plastic Films and Tapes 4.76
4.9 Plastic Surface Finishing 4.78
4.10 Material Selection 4.80
References 4.106
Chapter 5. Composite Materials and Processes 5.1
5.1 Introduction 5.1
5.2 Material Systems 5.5
5.3 Ply Orientations, Symmetry, and Balance 5.25
5.4 Quasi-isotropic Laminate 5.31
5.5 Analysis 5.32
5.6 Composite Failure and Design Allowables 5.35
5.7 Composite Fabrication Techniques 5.40
5.8 Analysis 5.76
5.9 Design of Composite Structures 5.78
5.10 Damage Tolerance 5.85
5.11 Composite Repairs 5.88
5.12 Adhesive Bonding and Mechanical Fastening 5.91
5.13 Environmental Effects 5.96
5.14 Composite Testing 5.98
5.15 Safety Issues with Composite Materials 5.103
References 5.105
Chapter 6. Part 1: Natural and Synthetic Rubbers 6.1
6.1 Historical 6.1
6.2 Properties of Polymers 6.3
6.3 General-Purpose Rubbers 6.5
6.4 Specialty Rubbers 6.7
6.5 Thermoplastic Elastomers 6.9
6.6 Characterizing Heat and Oil Resistance 6.10
6.7 Other Properties 6.15
6.8 Compounding Rubber 6.28
References 6.31
Suggested Readings 6.31
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CONTENTS vii
Chapter 6. Part 2: Elastomeric Materials and Processes 6.35
6.9 Introduction 6.35
6.10 Thermoplastic Elastomers (TPEs) 6.35
6.11 Polyurethane Thermoplastic Elastomers (TPUs) 6.45
6.12 Polyamides 6.56
6.13 Melt Processable Rubber (MPR) 6.58
6.14 Thermoplastic Vulcanizate (TPV) 6.60
6.15 Synthetic Rubbers (SRs) 6.67
6.16 Natural Rubber (NR) 6.83
6.17 Conclusion 6.85
References 6.85
Chapter 7. Ceramics and Ceramic Composites 7.1
7.1 Introduction 7.1
7.2 Ceramic Fabrication 7.3
7.3 Surface Properties of Ceramics 7.6
7.4 Thermal Properties of Ceramic Materials 7.9
7.5 Mechanical Properties of Ceramic Substrates 7.14
7.6 Electrical Properties of Ceramics 7.22
7.7 Metallization of Ceramic Substrates 7.29
7.8 Ceramic Materials 7.40
7.9 Composite Materials 7.49
7.10 Forming Ceramics and Composites to Shape 7.57
References 7.60
Chapter 8. Inorganic Glasses 8.1
8.1 Commercial Glass Families 8.1
8.2 Special Glasses 8.37
8.3 Glass Making I—Glass Melting 8.82
8.4 Glass Making II—Glass Forming 8.102
8.5 Annealing and Tempering 8.119
8.6 Glass Fiber 8.145
8.7 Optical Communications Fiber 8.163
8.8 Notes and Acknowledgments 8.170
References 8.170
Bibliography 8.172
Chapter 9. Coatings and Finishes 9.1
9.1 Introduction 9.1
9.2 Environment and Safety 9.5
9.3 Surface Preparation 9.6
9.4 Coating Selection 9.12
9.5 Coating Materials 9.22
9.6 Application Methods 9.41
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viii HANDBOOK OF MATERIALS FOR PRODUCT DESIGN
9.7 Curing 9.55
9.8 Summary 9.58
References 9.59
Chapter 10. Metallic Finishes and Processes 10.1
10.1 Fundamentals 10.1
10.2 Metallic Finishes and Processes 10.2
10.3 Aluminum Coatings 10.5
10.4 Cadmium Coatings 10.27
10.5 Chromium Coatings 10.35
10.6 Copper Coatings 10.44
10.7 Copper Alloy Coatings 10.50
10.8 Tin and Tin Alloy Coatings 10.54
10.9 Silver Coatings 10.63
References 10.66
Chapter 11. Plastics Joining Materials and Processes 11.1
11.1 Introduction 11.1
11.2 General Types of Plastic Materials 11.2
11.3 Types of Plastic Joining Processes 11.4
11.4 Direct Heat Welding 11.5
11.5 Indirect Heating Methods 11.20
11.6 Friction Welding 11.25
11.7 Solvent Cementing 11.37
11.8 Methods of Mechanical Joining 11.40
11.9 Recommended Assembly Processes for Common Plastics 11.50
11.10 More Information on Joining Plastics 11.61
References 11.62
Chapter 12. Plastics and Elastomers as Adhesives 12.1
12.1 Introduction to Adhesives 12.1
12.2 Design and Test of Adhesive Joints 12.15
12.3 Surface Preparation 12.32
12.4 Types of Adhesives 12.60
12.5 Selecting an Adhesive 12.82
12.6 Effect of the Environment 12.95
12.7 Processing and Quality Control of Adhesive Joints 12.107
References 12.119
Chapter 13. Testing of Materials 13.1
13.1 Introduction 13.1
Typical Paint and Coating Test Program 13.6
13.2 Chemical Characterization 13.14
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CONTENTS ix
13.3 Thermal Analysis 13.24
13.4 Thermal Testing 13.32
13.5 Mechanical Testing 13.36
13.6 Miscellaneous Testing 13.44
Recommended Readings 13.54
References 13.54
Chapter 14. Materials Recycling 14.1
14.1 Introduction 14.1
14.2 Collection of Materials for Recycling 14.18
14.3 Ferrous Metal Recycling 14.22
14.4 Aluminum Recycling 14.26
14.5 Recycling of Other Nonferrous Metals 14.29
14.6 Glass Recycling 14.29
14.7 Paper Recycling 14.32
14.8 Plastics Recycling 14.50
14.9 Recycling of Rubber 14.97
14.10 Recycling of Textiles 14.98
14.11 Recycling of Wood 14.99
References 14.100
Index I.1
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CONTRIBUTORS
Thomas A. Andersen Northrop-Grumman Corporation, Baltimore, Maryland (CHAP. 10)
R. J. Del Vecchio Technical Consulting Services, Fuquay-Varina, North Carolina (CHAP. 6)
Simon Durham Pratt & Whitney Canada, Longuevil, Quebec, Canada (CHAP. 3)
J. Donald Gardner Northrup Grumman Electronic Sensors and Systems Sector, Columbia,
Maryland (CHAP. 1)
Carl P. Izzo Industrial Paint Consultant, Export, Pennsylvania (CHAP. 9)
J. Randolph Kissell TGB Partnership, Hillsborough, North Carolina (CHAP. 2)
James Margolis Consultant, Montreal, Quebec, Canada (CHAP. 6)
Perry L. Martin Martin Testing Laboratories, Yuba City, California, www.martintesting.com
(CHAP. 13)
Robert Ohm Uniroyal Chemical, Naugatuck, Connecticut (CHAP. 6)
Stanley T. Peters Process Research, Mountain View, California, www.process-research.com
(CHAP. 5)
Edward M. Petrie ABB Power T & D Company, Inc., Raleigh, North Carolina (CHAPS. 11, 12)
Jordon I. Rotheiser Rotheiser Design, Inc., Highland Park, Illinois (CHAP. 4)
Susan E.M. Selke School of Packaging, Michigan State University, East Lansing, Michigan
(CHAP. 14)
Jerry E. Sergent TCA Inc., Corbin, Kentucky (CHAP. 7)
Thomas P. Seward III New York State College of Ceramics, Alfred University, Alfred, New York
(CHAP. 8)
Arun Varshneya New York State College of Ceramics, Alfred University, Alfred, New York
(CHAP. 8)
Steven Yue McGill University, Montreal, Quebec, Canada (CHAP. 3)
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