Materials for Engineers and Technicians, Fourth Edition

This renowned text has provided many thousands of students with an easily accessible introduction to the wide ranging subject area of materials engineering and manufacturing processes for over thirty years. Avoiding the excessive technical jargon and mathematical complexity so often found in textbooks for this subject, and retaining the practical down-to-earth approach for which this book is noted, Materials for Engineers and Technicians is now thoroughly updated and fully in line with current syllabus requirements. Offering a comprehensive guide to materials used by engineers, their applications and selection in a single volume, the fourth edition focuses on applications and selection – reflecting the increased emphasis on this aspect of materials engineering now seen within current vocational and university courses. Materials properties and relevance to particular uses are addressed in detail from the outset, with all subsequent chapters linking back to these essential concepts. Detailed discussion of examples of materials, and additional applications of processes have been incorporated throughout the text, with expanded sections addressing the causes of failure as this relates to material selection. Updated sections in the fourth edition provide a wider ranging discussion of titanium, printed-circuit-board materials and production, silicon chip production, and the applications and forms of modern composite materials. This new edition has been matched closely to the relevant units of the BTEC Higher National Engineering program, as well as catering fully for the requirements of a Level 3 audience. Students of BTEC Nationals will find that the new edition structure covers all the essential topics required for their courses in the early chapters (chapters 1 – 8). Those students following higher level qualifications (HNC / D Engineering, and first year undergraduate Engineering Materials modules within Mechanical, Manufacturing Systems and also Electrical & Electronic Engineering degree courses) will find additional more advanced topics are addressed in the second half of the book. In addition to meeting the requirements of vocational and undergraduate engineering syllabuses, this text will also prove a valuable desktop reference for professional engineers working in product design, who require a quick source of information on materials and manufacturing processes. • Established and renowned text, now completely restructured to match current BTEC National and Higher National syllabus specifications • New edition provides greater emphasis on materials selection, with a new chapter outlining material properties and their relevance to a variety of uses, reflecting current FE and HE course requirements • Avoids excessive technical jargon and mathematical complexity common in textbooks for this subject This renowned text has provided many thousands of students with an easily accessible introduction to the wide ranging subject area of materials engineering and manufacturing processes for over thirty years. Avoiding the excessive technical jargon and mathematical complexity so often found in textbooks for this subject, and retaining the practical down-to-earth approach for which this book is noted, Materials for the Engineering Technician is now thoroughly updated and fully in line with current syllabus requirements. Offering a comprehensive guide to materials used by engineers, their applications and selection in a single volume, the fourth edition focuses on applications and selection - reflecting the increased emphasis on this aspect of materials engineering now seen within current vocational and university courses. Materials properties and relevance to particular uses are addressed in detail from the outset, with all subsequent chapters linking back to these essential concepts. Detailed discussion of examples of materials, and additional applications of processes have been incorporated throughout the text, and expanded sections addressing the causes of failure and material selection have also been incorporated. Updated sections in the fourth edition provide a wider ranging discussion of titanium, printed-circuit-board materials and production, silicon chip production, and the applications and forms of modern composite materials. This new edition has been matched closely to the relevant units of the BTEC Higher National Engineering programme, as well as catering fully for the requirements of a Level 3 audience. Students of BTEC Nationals will find that the new editionstructure covers all the essential topics required for their courses in the early chapters (chapters 1 - 8). Those students following higher level qualifications (HNC / D Engineering, and first year undergraduate Engineering Materials modules within Mechanical, Manufacturing Systems and also Electrical & Electronic Engineering degree courses) will find additional more advanced topics are addressed in the second half of the book. A grid mapping chapters to relevant levels of study is included for ease of reference. In addition to meeting the requirements of vocational and undergraduate engineering syllabuses, this text will also prove a valuable desktop reference for professional engineers working in product design, who require a quick source of information on materials and manufacturing processes. Established and renowned text, now completely restructured to match current BTEC National and Higher National syllabus specifications Cover......Page 1 Contents......Page 6 Preface......Page 12 Introduction......Page 16 The requirements......Page 17 The materials......Page 18 Structure of materials......Page 21 The materials society......Page 27 Properties......Page 28 Costs......Page 33 Data sources......Page 34 The tensile test......Page 37 Hardness tests......Page 42 Impact tests......Page 48 Creep......Page 51 Fatigue......Page 52 Other mechanical tests......Page 54 Factor of safety......Page 57 From gas to solid......Page 58 Metal crystals......Page 59 Impurities in cast metals......Page 63 The influence of cooling rates on crystal size......Page 64 Ingot casting......Page 67 Sand-casting......Page 68 Die-casting......Page 69 Centrifugal casting......Page 71 Investment-casting......Page 72 Full-mould process......Page 74 The choice of casting process......Page 75 Slip......Page 77 Annealing......Page 81 Cold-working processes......Page 83 Hot-working processes......Page 85 Grain flow and fibre......Page 86 Metallurgical furnaces......Page 88 Hot-working processes......Page 92 Cold-working processes......Page 95 Powder metallurgy......Page 103 Machining metals......Page 105 Introduction......Page 108 Eutectics......Page 109 Solid solutions......Page 110 Summary: alloys......Page 116 Obtaining equilibrium diagrams......Page 118 Types of equilibrium diagram......Page 121 Precipitation from a solid solution......Page 129 Ternary equilibrium diagrams......Page 132 Selecting and mounting a specimen......Page 134 Grinding and polishing the specimen......Page 136 Etching the specimen......Page 139 The metallurgical microscope......Page 140 The electron microscope......Page 144 Smelting......Page 145 Steel-making......Page 147 Composition of steel......Page 149 The structure of plain-carbon steels......Page 150 Heat-treatment of steel......Page 155 Brittle fracture in steels......Page 161 Principles of hardening......Page 162 Tempering......Page 168 Isothermal heat-treatments......Page 170 Hardenability......Page 172 The Jominy test......Page 174 Heat treatment furnaces......Page 176 Introduction......Page 177 Constructional steels......Page 178 Tool and die steels......Page 183 Stainless steels......Page 186 Magnet alloys......Page 190 The principal effects of the main alloying element......Page 193 Case-hardening......Page 194 Heat-treatment after carburising......Page 197 Nitriding......Page 199 Flame-hardening......Page 202 Induction-hardening......Page 203 Summary of surface-hardening processes......Page 204 Composition of cast irons......Page 205 The influence of cooling rate on the properties of a cast iron......Page 208 'Growth' in cast irons......Page 209 Ordinary cast irons......Page 210 High-duty cast irons......Page 211 Malleable cast irons......Page 213 Alloy cast irons......Page 214 Which iron?......Page 215 The extraction of copper......Page 216 Copper and alloys......Page 217 The brasses......Page 218 Tin bronzes......Page 222 Aluminium bronzes......Page 226 Copper-nickel alloys......Page 228 Other copper alloys......Page 229 Extraction of aluminium......Page 231 Properties of aluminium......Page 232 Aluminium alloys......Page 233 Cast alloys which are not heat-treated......Page 235 Wrought alloys which are heat-treated......Page 239 Cast alloys which are heat-treated......Page 243 Nickel and its alloys......Page 245 Titanium and its alloys......Page 249 Magnesium-base alloys......Page 252 Zinc-base alloys......Page 253 Bearing metals......Page 254 Other metals......Page 257 Types of plastics......Page 259 Thermoplastics......Page 262 Thermoplastic materials......Page 264 Thermosets......Page 276 Thermoset materials......Page 277 Elastomers......Page 283 Crystal and glass states......Page 288 Mechanical properties......Page 290 Additives......Page 296 Shaping plastics......Page 298 Silicate-based ceramics......Page 303 Asbestos......Page 306 Clay products......Page 308 Engineering ceramics......Page 310 Properties of ceramics......Page 314 Cement......Page 316 Semiconductors......Page 318 Composition and structure of glass......Page 321 Glass-transition temperature......Page 323 Glass manufacture......Page 324 The properties of glass......Page 326 Metallic glasses......Page 327 Introduction......Page 329 Dispersion-hardened materials......Page 330 Mortar and concrete......Page 332 Tarmacadam......Page 333 Introduction......Page 334 Unidirectional composites......Page 336 Fibres......Page 337 Matrix materials......Page 340 Fibre-composite manufacture......Page 342 Uses of fibre-reinforced composites......Page 344 Reinforced wood......Page 345 Reinforced concrete......Page 347 Adhesives......Page 349 Soldering and brazing......Page 351 Arc-welding processes......Page 353 Electric resistance welding......Page 357 Thermo-chemical welding......Page 359 Solid-state welding......Page 361 Structure of welds......Page 362 Welding of plastics......Page 363 Causes of failure......Page 365 Non-destructive testing......Page 369 Degradation of metals by electrolytic corrosion......Page 375 The protection of metal surfaces......Page 382 Stability of plastics......Page 385 Preservation of timber......Page 387 Service life......Page 389 Introduction......Page 390 Service requirements......Page 392 Choice of shaping process......Page 402 Appendix: Properties of engineering materials......Page 405 Index......Page 407 This renowned text has provided many thousands of students with an easily accessible introduction to the wide ranging subject area of materials engineering and manufacturing processes for over thirty years.Avoiding the excessive technical jargon and mathematical complexity so often found in textbooks for this subject, and retaining the practical down-to-earth approach for which this book is noted, Materials for Engineers and Technicians is now thoroughly updated and fully in line with current syllabus requirements.Offering a comprehensive guide to materials used by engineers, their applications and selection in a single volume, the fourth edition focuses on applications and selection - reflecting the increased emphasis on this aspect of materials engineering now seen within current vocational and university courses. Materials properties and relevance to particular uses are addressed in detail from the outset, with all subsequent chapters linking back to these essential concepts. Detailed discussion of examples of materials, and additional applications of processes have been incorporated throughout the text, with expanded sections addressing the causes of failure as this relates to material selection. Updated sections in the fourth edition provide a wider ranging discussion of titanium, printed-circuit-board materials and production, silicon chip production, and the applications and forms of modern composite materials.This new edition has been matched closely to the relevant units of the BTEC Higher National Engineering programme, as well as catering fully for the requirements of a Level 3 audience. Students of BTEC Nationals will find that the new edition structure covers all the essential topics required for their courses in the early chapters (chapters 1 - 8). Those students following higher level qualifications (HNC/D Engineering, and first year undergraduate Engineering Materials modules within Mechanical, Manufacturing Systems and also Electrical & Electronic Engineering degree courses) will find additional more advanced topics are addressed in the second half of the book.In addition to meeting the requirements of vocational and undergraduate engineering syllabuses, this text will also prove a valuable desktop reference for professional engineers working in product design, who require a quick source of information on materials and manufacturing processes.