Acknowledgments v
1.0 Introduction 3
2.0 Overview 5
3.0 Metals 9
3.1 Properties of Metals 10
3.2 Ferrous Metals 12
3.3 Powdered Metallurgy 17
3.4 Nonferrous Metals 18
4.0 Metal Forming 25
4.1 Liquid State Forming 26
4.1.1 Expendable Molds/Waste Molds 31
4.1.2 Nonexpendable Molds 37
4.2 Plastic State Forming 44
4.2.1 Rolling 46
4.2.2 Forging and Swaging 47
4.2.3 Drawn Wire 50
4.2.4 Extrusions 48
4.3 Solid State Forming 50
4.3.1 Simple Bending 51
4.3.2 Compound Bending 55
4.3.3 Form and Cut 58
5.0 Metal Cutting 61
5.1 Sheet Punching and Shearing 62
5.2 Chip Forming Cutting 66
5.3 Nonchip Forming Cutting 71
5.4 Flamel1hermal Cutting 74
6.0 Metal Joining 79
6.1 Soldering 81
6.2 Brazing/Welding 82
6.2.1 Gas Welding 84
6.2.2 A/C Welding 85
6.2.3 Resistance Welding 90
6.2.4 Solid State Welding 92
6.2.5 High Technology Welding 93
6.3 Adhesives 94
6.4 Mechanical Fasteners 97
7.0 Appearance Finishing and Coatings 102
7.1 Formed Textures/Molded In 103
7.2 Cut Patterns and Abrasive Finishing 106
7.3 Coatings 113
8.0 Plastics 118
8.1 Properties of Molded Plastics 126
8.2 Thermosets 134
8.3 Thermoplastics 139
9.0 Plastic Forming Processes 161
9.1 Liquid State Forming 165
9.2 Plastic State Forming 181
9.3 Solid State Forming 187
10.0 Machining Plastics 188
11.0 Joining Plastics190
11.1 Chemical Bonds 191
11.2 Welding Plastics 192
11.3 Mechanical Fastening 195
12.0 Finishing Plastics 198
12.1 Formed 199
12.2 Paintings/Coatings 200
13.0 Rubbers and Elastomers 204
13.1 Thermoset Rubbers 205
13.2 Thermoplastic Elastomers 211
14.0 Natural Engineering Materials 214
14.1 Engineering Ceramics 216
14.2 Glass 219
14.3 Manufactured Carbon 226
14.4 Refractory Hard Metals 227
15.0 Composites 228
15.1 Metal-Matrix Composites 229
15.2 Plastic-Matrix Composites 230
15.3 Advanced Composite Materials 231
16.0 Rapid Prototyping 232
Index 235