1437

INDEX

Aberteldy Bridge (Scotland), 1413–1415About.com web site, 471Abrasion resistance testing (plastics), 564Abrasive barrel finishing (metals), 962Abrasive belt finishing (metals), 962Abrasive machining (metals), 894–899

abrasive flow machining, 901, 904abrasive jet machining, 901, 904

Abrasive wear, 758, 760Abrasive wear model (ceramics), 424ABS (American Bureau of Ships), 53Absolute materials requirements, 834–835Absolute viscosity, 599Absorption:

chemical, 1232in electronic packaging applications, 1232of energy by aluminum alloys, 90with orthopedic biomaterials, 1177–1178of X-radiation in nondestructive inspection,

664–666ABS (ter-polymer), 338, 339Accelerated weathering tests (plastics), 584–

589Accelerometers, 1313–1314ACI, see American Concrete InstituteAC178 (ICBO), 1384, 1385Acoustic impedance, 657Addition polymers, 1425Additives:

indirect, 617in plastics, 1429–1430

Adhesion:between diamond films and substrates,

1297–1300with metallic materials, 540

Adhesives:in composite structures, 1361in electronic packaging applications, 1250–

1251Adhesive wear, 710, 756–759ADS (Aluminum Design System), 23Advanced composites, 1132–1136. See also

specific materialsatomic oxygen effects on, 1141definition of, 1132polymer matrices in, 1135–1136reinforcement fibers in, 1134–1135spacecraft applications of, 1131–1162stress-strain equations for, 1133thermal cycle-induced microcracking of,

1142

vacuum-induced outgassing of, 1142Aerospace applications:

advanced composite materials in spacecraft,1131–1162

all-composite mirrors, 1161–1162antennas, 1159–1160coefficient of thermal expansion of,

1137–1138deployable structures, 1152–1153electronics enclosures, 1153–1157EMI shielding and electrical

characteristics of, 1140–1141environmental durability of, 1141–1142examples of, 1149–1162FORTE, 1150high specific stiffness / strength of, 1138,

1139hybrid composite mirrors, 1160–1161inflatable structures, 1153isogrid structures, 1145joints in, 1145manufacturing methods used with, 1146–

1149material properties for, 1137–1142Midcourse Space Experiment, 1151–

1152mirrors, 1159–1162optical benches and instrument

structures, 1157–1159primary spacecraft bus /chassis structure,

1150–1152properties / characteristics of, 1137–1142qualities of advanced composites used in,

1132–1136reflectors, 1159–1162sandwich structures, 1143–1144solid laminate construction of, 1142–

1143standard structural forms of, 1142–1145thermal conductivity of, 1139–1140truss structures, 1144

of aluminum alloys, 132complex laminates used in, 1057specifications for, 53turbine blades, 841–842

Aerospace Materials Specifications (AMS), 53AFM (abrasive flow machining), 901, 904AFNOR (Association Francaise de

Normalisation) standards, 53Age-hardening martensitic stainless steels, 67,

80

1438 INDEX

Aging process (steels), 55Aircraft applications (aluminum alloys), 132AISI (American Iron and Steel Institute), 52AJM (abrasive jet machining), 901, 904Alkyd resins, 353All-composites structural applications (PFRP),

1401–1416bridge applications, 1408, 1410–1416buildings applications, 1406, 1408–1410research and development of, 1402–1407

Allied-Signal’s Metals, 282Alloys. See also specific types

for cutting tools, 860electrical resistivities / conductivities of, 699number of, 3shape memory, 414–415

Alloy Digest (CD), 469Alloy Finder (CD), 468–469Alloy steels, see SteelsAlpha iron, see FerriteAlumina, fibers based on (in composite

materials), 367Alumina particle-reinforced aluminum, 382,

383Aluminum:

in alloy steels, 48–49alumina particle-reinforced, 382, 383anodizing of, 1237in electronic packaging applications, 1242–

1244in magnesium alloys, 261, 267–268, 271,

278–282silicon carbide particle-reinforced, 382, 383wrought, 100, 112

Aluminum alloys, 89–133aircraft / aerospace applications of, 132applications of

cast, 124, 126–131by market areas, 131–133wrought, 100, 112–127

building /construction applications of, 131cast

advantages of, 90–91applications of, 124, 126–131designation systems for, 95, 97–100limitations of, 92–93properties of, 106–112

chemical industry applications of, 133designation systems for, 93–100

cast, 95, 97–100temper designation, 98, 100wrought, 93–97

electrical applications of, 131in electronic packaging applications, 1242–

1244marine transportation applications of, 132–

133

packaging applications of, 133petroleum industry applications of, 133properties of

cast, 106–112wrought, 101–106

railcar applications of, 133temper designation system for, 98, 100vehicle applications of, 131–132wrought

advantages of, 90–91applications of, 100, 112–127designation systems for, 93–97limitations of, 92–93properties of, 101–106

Aluminum Association, Inc., 89–90, 93, 468Aluminum Association Alloy and Temper

Designation Systems:for cast aluminum alloys, 95, 97–100temper designation system, 98, 100for wrought aluminum alloys, 93–97

Aluminum–copper alloys, 113–116, 127Aluminum Design System (ADS), 23Aluminum–magnesium alloys, 117–125, 130Aluminum–magnesium–silicon alloys, 119–

121, 126Aluminum–manganese alloys, 114, 116, 118,

119Aluminum oxide abrasives, 894Aluminum–silicon alloys, 116, 117, 130Aluminum–silicon � copper or magnesium

alloys, 128Aluminum–silicon deoxidized (killed) steels,

48, 49, 51Aluminum–tin alloys, 130–131Aluminum–zinc alloys, 122, 123, 127, 130American Bureau of Ships (ABS), 53American Ceramic Society, 433American Chemical Society, 469American Concrete Institute, 1401, 1419American Concrete Institute (ACI), 1417–

1418American Iron and Steel Institute (AISI), 52American National Standards, 616American National Standards Institute

(ANSI), 615–616, 1417American Railway Engineering and

Maintenance of Way Association(AREMA), 53

American Society for Testing and Materials(ASTM), 520, 616. See also ASTMstandards

resources available from, 520steel specifications developed by, 53

American Society of Civil Engineers (ASCE),1417, 1419

American Society of Mechanical Engineers(ASME), 53, 63, 863

INDEX 1439

Amino resins, 354Amorphous polymers, 336, 1427AMS (Aerospace Materials Specifications), 53Analytical comparisons, materials properties

data for, 458–460Angle bending (metals), 943Angles, tool, 861Annealing (steels), 51Anodic coatings:

for aluminum, 1237for magnesium alloys, 264, 287–288

Anodizing (metals), 966ANSI, see American National Standards

InstituteAntennas, space, 1159–1160Anticoagulation properties (vascular

prostheses), 1185, 1187Antimony, 50Antireflection (AR) coatings

(telecommunications), 1324AOD process, see Argon–oxygen

decarburization processAPDs (avalance photodiodes), 1317Applied Research in Remotely-Queried

Embedded Microsensors (ARRQEM),1147–1149

Aqueous corrosion resistance, 76, 276–277Aramid fibers (Kevlar), 367, 1346AR (antireflection) coatings

(telecommunications), 1324Architecture:

all-composites structural materials used in,1406, 1408–1410

copper and copper alloys in, 143Arc resistance testing (plastics), 578–582AREMA (American Railway Engineering and

Maintenance of Way Association), 53Argon–oxygen decarburization (AOD)

process:for stainless steels, 29, 77for superalloys, 319–321

ARRQEM, see Applied Research inRemotely-Queried EmbeddedMicrosensors

Arsenic, 50Arteries, 1180–1181ASCE, see American Society of Civil

EngineersAshby’s material selection charts, 9, 10ASME, see American Society of Mechanical

EngineersASM Handbook, 468, 631ASM International:

directory of materials property databases,21

materials properties data from, 468–469ASM Metal Selector, 22

ASM Metals Handbook, 54, 59, 62ASSET project, 1416Association Francaise de Normalisation

(AFNOR) standards, 53ASTM, see American Society for Testing and

MaterialsASTM Committee E 49, 498, 500ASTM standards, 520, 616

for Brookfield viscometer, 597for ceramics, 434

compression, 626electrical resistance, 647fatigue, 638for fatigue strength estimation, 636flexural strength, 647for flexure, 628for fracture toughness, 632, 633for hardness, 632for tensile creep, 630tensile testing, 626ultrasonic testing, 646

for heat reversion technique, 783–784for instrumentation and data acquisition

systems, 524for metallic materials testing, 520

bending strength, 540compression, 526creep, 526fatigue, 536, 537, 540fracture toughness, 532, 535hardness, 528impact, 530, 531stress relaxation, 528tensile properties, 524

for nondestructive evaluation, 651penetrant process, 654ultrasonic, 656

for plasticsabrasion resistance, 564differential scanning calorimetry, 602–

604electrical properties, 575–582flexural fatigue, 565–566flexural properties, 549–551hardness, 567–568impact, 556–558, 562melt index test, 592, 594–595tensile properties, 547–548thermal properties, 569–575weathering, 584–589

for stainless steels, 77for test machines, 522for two-parameter Weibull distribution, 811

Asynchronous transfer mode (ATM), 1308Atlas Weathering Services Group, 621ATM (asynchronous transfer mode), 1308Atmospheric corrosion (magnesium), 276

1440 INDEX

Atomic oxygen, 1141Attributes, database, 487

definition of, 487–490values for, 491

Austenite (gamma iron), 30–33, 36, 44Austenitic manganese steels, 47Austenitic stainless steels, 48–50, 59–60, 67,

80–82, 85–86Autoclave processing:

of prepreg, 1067–1076automated lay-up, 1071–1072cure monitoring sensors, 1072hand lay-up, 1069–1071operation of autoclave, 1073–1076prepreg cutting, 1069tooling for, 1068tool preparation for curing, 1072–1073

of sandwich panels, 1358Automated drilling systems, 1359Automated machine lamination, 1385, 1387Automotive applications:

aluminum alloys in, 131–132ceramic materials in, 426–427specifications for, 53ultrahigh-strength wires in, 64

Automotive Composites Consortium, 500Automotive wire, 142Avalance photodiodes (APDs), 1317

Bainite, 38–40Bake-hardening steels, 55Bamboo, 841Band saws, 893Bandwidth, 1303–1304

of copper cable, 1304, 1305of optical fiber, 1306–1307of wireless networks, 1308

Barrel finishing, 962Bars, copper, 185Bats:

baseball, 1266, 1267cricket, 1264softball, 1267

Battelle Memorial Institute, 621Bcc arrangement, see Body-centered cubic

arrangementBearings, ceramic materials for, 424, 425Bending (of metals), 942–943Bending strength test (metallic materials), 540Bend tests (brittle materials), 821–823Beryllium coppers, 165Beryllium (in magnesium alloys), 272Bicycles, 1260–1262Binary Phase Diagrams on CD-ROM, 469Biocompatibility issues:

with blood-contacting biomaterials, 1183–1186

with orthopedic biomaterials, 1174–1178with space-filling biomaterials, 1188–1191

Biological corrosion, 709, 768–769Biomechanics, 1255Biomedical applications, 1165–1192

biocompatibility issues inwith blood-contacting biomaterials,

1183–1186with orthopedic biomaterials, 1174–1178with space-filling biomaterials, 1188–

1191blood-contacting biomaterials, 1180–1188

biocompatibility of, 1183–1186blood transport by, 1181–1183coagulation with, 1184–1186functioning of, 1181–1183hemolysis with, 1184hemostasis with, 1184material selection for, 1186–1188neointima formation with, 1183–1184property degradation with, 1186

blood transport, 1181–1183breast implants, 1188–1191capsule formation (space-filling

biomaterials), 1188–1190carcinogenesis complications (space-filling

biomaterials), 1190–1191coagulation with, 1184–1186corrosion (orthopedic materials), 1174–

1177function of

blood-contacting biomaterials, 1181–1183

orthopedic biomaterials, 1167–1173space-filling biomaterials, 1188

hemolysis with, 1184hemostasis with, 1184immunological complications (space-filling

biomaterials), 1190–1191joint motion (orthopedic biomaterials),

1171–1173leaching /absorption (orthopedic

biomaterials), 1177–1178load support (orthopedic biomaterials),

1167–1171material selection for

blood-contacting biomaterials, 1186–1188

orthopedic biomaterials, 1178–1180space-filling biomaterials, 1191

neointima formation with, 1183–1184orthopedic biomaterials, 1166–1180

biocompatibility of, 1174–1178corrosion of, 1174–1177functioning of, 1167–1173joint motion with, 1171–1173leaching /absorption with, 1177–1178

INDEX 1441

load support with, 1167–1171material selection for, 1178–1180wear debris from, 1178

property degradation (blood-contactingmaterials), 1186

space-filling biomaterials, 1188–1191biocompatibility of, 1188–1191capsule formation with, 1188–1190carcinogenesis / immunological

complications with, 1190–1191functioning of, 1188material selection for, 1191

of titanium and titanium alloys, 231–232total hip arthroplasty, 1166–1180vascular prostheses, 1180–1188wear debris (orthopedic biomaterials), 1178

Biomimetric (smart structures), 402BIOSIS database, 454Blanking, chemical, 921Blanks, metal, 935, 945–946Blasting (metals), 962Blistering, hydrogen, 768Blood-contacting biomaterials, 1180–1188

biocompatibility of, 1183–1186blood transport by, 1181–1183coagulation with, 1184–1186functioning of, 1181–1183hemolysis with, 1184hemostasis with, 1184material selection for, 1186–1188neointima formation with, 1183–1184property degradation with, 1186

Blow molding (plastics), 958, 977–979,1026–1027

BMC, see Bulk molding compoundBoats, 1267–1268Body-centered cubic (bcc) arrangement, 30,

31, 47Body-centered tetragonal (bct) arrangement,

30, 31Boiler and Pressure Vessel Code (ASME), 63Boilercode specifications, 53Bonderizing, 966Bonding:

reaction bonding (ceramics), 1120structural bonding (composites), 1358,

1360–1361Bonding materials (grinding), 894Bond strength requirements (reinforced

concrete /masonry structure repair /retrofit), 1391

Book of Standards (ASTM), 616Bootstrap samples, 825Boring, 863Boron fibers (in composite materials), 367,

1345Boron (in alloy steels), 49

Borosilicate glasses, 1250Brasses, 139–140

cast, 140in electrical / electronic applications, 150in industrial applications, 165, 185wrought, 139, 140

Brazing:of superalloys, 295of titanium and titanium alloys, 231

Breast implants, 1188–1191biocompatibility of, 1188–1191capsule formation with, 1188–1190carcinogenesis / immunological

complications with, 1190–1191functioning of, 1188material selection for, 1191

Bridge applications (composite structuralmaterials), 1373, 1408, 1410–1416

Brinnel hardness scale, 43, 1229Brinnelling failure (metals), 708British Standards (BS), 53Brittle-coating stress analysis (plastics), 781Brittle fracture failure (metals), 708Brittle materials:

failure analysis of, 809–925bend tests in, 821–823and confidence limits, 816, 824–825dynamic fatigue measurements in, 815–

816, 823–824and environmentally enhanced fracture,

813–815indented inert strength measurements,

816, 824and initial strength distribution, 811–813and lifetime prediction process, 809–818strength tests in, 821–823Weibull tests in, 818–821

lifetime prediction for, 809–818confidence limits in, 816, 824–825dynamic fatigue measurements in, 815–

816, 823–824environmentally enhanced fracture, 813–

815indented inert strength measurements,

816initial strength distribution, 811–813process of, 816–818strength tests in, 821–823Weibull tests in, 818–821

Brittleness (of ceramic materials), 422–423Brittleness temperature testing (plastics), 574,

575Broaching (in metals manufacturing), 886–

890cutting horsepowers for, 854tool wear factors in, 855

Brodkey model, 1002–1004

1442 INDEX

Bronzes, 140–141Brookfield viscometer, 597Broutman, L.J., Associates Ltd., 621BS (British Standards), 53Buckling failure (metals), 707, 712Buckyball (buckminsterfullerene), 415Buffing, 899, 963Building applications:

all-composites structural materials in, 1406,1408–1410

of aluminum alloys, 131Building wire, 142Bulk molding compound (BMC), 353, 373–

374, 1044, 1095, 1099Bulk resonators, 1328, 1329Burnishing (metals), 941Bus /chassis structure (spacecraft), 1150–1152Buyers Guide (Ceramic Industry Magazine),

433

Cable networks, 1304–1306Cadmium, 1244CAE, see Computer-aided engineeringCalcium:

in alloy steels, 49in magnesium alloys, 272–274, 283–284

Calcium sulfate (plaster), 955Calendered film adhesives, 1361Calendering (plastics), 974–975, 1018–1019Calorimetry differential scanning, see

Differential scanning calorimetryCambridge Materials Selector (CES3), 496–

497Cameras, infrared, 679CAMPUS database, 500Cancer, breast implants and, 1190–1191Capillary rheometer, 597–599Capsule formation (with space-filling

biomaterials), 1188–1190Carbides:

for cutting tools, 860in superalloys, 294–295

Carbon:in alloy steels, 44–46and intergranular corrosion, 75, 76iron-carbon equilibrium diagrams, 30–38,

44levels of, in stainless steels, 76–77in stainless steels, 75–77

Carbon arc-type light, exposure of plastics to,586

Carbon /carbon composites (CCCs), 358materials used in, 372mechanical properties of, 385–386physical properties of, 397

Carbon fibers (in composite materials), 361,366–367

Carbon steels:classification of, 53–55high manganese, 53, 54as hypoeutectoid steels, 37nonresulfurized, 53–54rephosphorized and resulfurized, 53, 54specifications for, 53–55welding of stainless steels vs., 82–85

Carcinogenesis complications (with space-filling biomaterials), 1190–1191

Carothers equation, 1429CARS (Computerized Application and

Reference System), 22Cartridge brass, 150CAS database, 455Casting, 837, 949–957. See also Molding

centrifugal casting, 951–953continuous casting, 29of copper and copper alloys, 188, 198die casting, 954–955investment casting

of metals, 956–957of titanium and titanium alloys, 229

of metals, 949–957centrifugal casting, 951–953die casting, 954–955investment casting, 956–957permanent-mold casting, 953–955plaster-mold casting, 955–956sand casting, 949–952

permanent-mold casting, 953–955plaster-mold casting, 955–956of plastic parts, 982, 983, 995, 1032–1033as quiescent process, 995, 1032–1033sand casting, 949–952of steels, 29strand casting, 29of superalloys, 295, 323–324of titanium and titanium alloys, 229

Catalysts, smart, 414Caustic stress-corrosion cracking, 73Cavitation corrosion, 709, 768CBN, see Cubic boron nitrideCCCs, see Carbon /carbon compositesCCCT, see Critical crevice corrosion

temperatureCDA (Copper Development Association), 136CDMA (code division multiple access), 1308CEF model, see Criminale–Ericksen–Filbrey

modelCementite, 37, 44, 51CEN standards, see Committee for European

Normalisation standardsCenTOR Software, Inc., 495Centrifugal casting (metals), 951–953

INDEX 1443

Ceramic materials, 419–436in automotive and light-truck engines, 426–

427for bearings, 424, 425calorimetry testing for, 644compression testing of, 626compressive creep testing for, 630–631compressive strength measurement for,

798–799conventional manufacturing of, 1115–1116corrosion resistance of, 429creep rupture in, 806–807creep strain in, 805–806creep testing for, 628–631for cutting tool inserts, 425, 426delayed failure of, 792–794design with

and brittleness, 422–423as factor in failure, 788, 798–803

differential scanning calorimetry testing for,644

dilatometry testing for, 639, 640electrical resistance testing, at elevated

temperatures, 647electrical testing of, 646–648

electrical resistance at elevatedtemperatures, 647

flexural strength of electronic-gradeceramics, 647–648

in electronic packaging applications, 1249energy sources used with, 1117–1120

mechanochemical synthesis, 1118–1120microwave processing, 1117–1118reaction bonding, 1120self-propagating high-temperature

synthesis, 1118failure analysis of, 790–807

compressive strength measurement, 798–799

creep rupture, 806–807creep strain, 805–806delayed, 792–794and fracture mechanics, 789–791at high temperatures, 805multiaxial Weibull statistics for, 798–803scatter of lifetime, 797, 798scatter of strength, 794–797strength prediction, 792under thermal shock conditions, 803–804

failure of, 787–790delayed, 792–794design as factor in, 788, 798–803and intrinsic vs. extrinsic flaws, 789–790materials selection as factor in, 787–788,

803–805modes of failure, 788

probability of, 789process as factor in, 788–790service conditions as factor in, 803–807under thermal shock conditions, 803–804

fatigue testing for, 634–638flaws in, 789–790flexural strength testing, 647–648flexure creep testing for, 629, 630flexure testing for (fracture strength), 627–

628fracture strength testing for, 624–628fracture toughness testing for, 632–633future trends in, 435–436glass, 1250guarded hot plate testing for, 641–642hardness testing for, 631–632heat capacity testing for, 643–644high strain rate testing for, 633–634at high temperatures, 805information sources for, 433–435intrinsic vs. extrinsic flaws in, 789–790laser flash testing for, 642–643layered manufacturing of, 1122–1123major commercial applications for, 420manufacturing of, 1113–1127

common steps in, 1116conventional processes in, 1115–1116engineering factors involved in, 1114layered manufacturing, 1122–1123mechanochemical synthesis, 1118–1120and microstructure of products, 1114microwave processing, 1117–1118nanotechnology in, 1120–1122new energy sources in, 1117–1120new precursors in, 1123–1127new shapes in, 1120–1123polymer precursors, 1123processing vs., 1115reaction bonding, 1120self-propagating high-temperature

synthesis, 1118sol-gel processing, 1123–1127

market value of, 623materials selection

as factor in failure of, 787–788for thermal shock conditions, 803–805

mechanical testing of, 624–638compression, 626compressive creep, 630–631creep, 628–631fatigue, 634–638flexure, 627–628flexure creep, 629, 630fracture strength, 624–625fracture toughness, 632–633hardness, 631–632

1444 INDEX

Ceramic materials (continued )high strain rate, 633–634tensile creep, 630tension, 625–626

mechanochemical synthesis of, 1118–1120microstructure of finished products, 1114microwave processing of, 1117–1118nanotechnology in processing of, 1120–

1122nondestructive evaluation testing of, 644–

646in passive electronics, 430–431piezoceramics, 431–432piezoelectric, 404, 405, 407precursors in processing of, 1123–1127

polymer precursors, 1123sol-gel processing, 1123–1127

processing of, 420–422as factor in failure, 788–790manufacturing vs., 1115

radiographic testing of, 646reaction bonding of, 1120scatter of lifetime in, 797, 798scatter of strength in, 794–797self-propagating high-temperature synthesis

of, 1118service conditions as factor in failure of,

803–807sol-gel processing of, 1123–1127standards for, 434–435strength prediction for, 792for telecommunications device packaging,

1312tensile creep testing for, 630tension testing for, 625–626testing of, 623–648

electrical, 646–648mechanical, 624–638nondestructive, 644–646radiography, 646thermal, 638–644ultrasonic, 645–646

thermal conductivity testing for, 640–643thermal expansion testing for, 638–640under thermal shock conditions, 803–804thermal testing of, 638–644

calorimetry, 644differential scanning calorimetry, 644dilatometry, 639, 640guarded hot plate, 641–642heat capacity, 643–644laser flash, 642–643thermal conductivity, 640–643thermal expansion, 638–640

thermostructural applications of, 427–429for tool inserts, 860transparent, 432, 433

ultrasonic properties of, 697ultrasonic testing of, 645–646in wear applications, 423–427

bearings, 424, 425cutting tool inserts, 425, 426

as wear materials, 1281Ceramic matrix composites (CMCs), 358

materials used in, 371–372mechanical properties of, 384, 385physical properties of, 397standards for, 434–435

Ceramic Source (American Ceramic Society),433

CERF (Civil Engineering ResearchFoundation), 1419

Cerium, 50, 271Certified data, 460CES3, see Cambridge Materials SelectorCGDS, see Columnar grain directional

solidificationChalk trays, 840Charpy impact test, 530, 556–557Charpy V-notch (CVN) test, 530, 531Chemical blanking, 921Chemical compounds /classes, variations in,

446–447Chemical conversions:

for magnesium alloys, 264of metals, 966–967

anodizing, 966chemical oxide coatings, 967chromate coatings, 966phosphate coatings, 966

Chemical Corrosion Expert System, 23–24Chemical failure (plastics), 778Chemical industry, aluminum alloys in, 133Chemical machining (CHM), 919–921Chemical milling, 921Chemical oxide coatings (metals), 967Chemical resistance (in electronic packaging

applications), 1226Chemical stress analysis (plastics), 782Chemical / thermal analysis (for identification

of polymers), 613Chemical vapor deposition (CVD):

for diamond films, 1287–1300fibers made from, 363historical background of, 1287–1289metal–organic chemical vapor deposition,

1314, 1315for telecommunications applications, 1334–

1335Chemir /Polytech Laboratories, Inc., 621Chemistry control:

for stainless steels, 78with superalloys, 318–319

INDEX 1445

Chemung County Bridge (New York), 1410–1412

Chile, copper production in, 136Chloride stress-corrosion cracking, 72–73, 80CHM, see Chemical machiningChopped strand mat (CSM), 373, 374, 1040,

1041Chromate coatings (metals), 966Chromium:

in alloy steels, 48in electronic packaging applications, 1244in stainless steels, 67–69

Circular saws, 892–893Civil Engineering Research Foundation

(CERF), 1419Cleaning (of metals), 960–963

abrasive barrel finishing, 962abrasive belt finishing, 962blasting, 962buffing, 963electropolishing, 963liquid and vapor baths, 960–962polishing, 963wire brushing, 962

CMCs, see Ceramic matrix compositesCoagulation (with blood-contacting

biomaterials), 1184–1186Coating(s):

anodic, 264antireflection coatings, 1324chemical-conversion, 264chemical oxide, 967chromate, 966for cutting tools, 860electroplating, 965enamel, 55, 964hot-dip plating, 965lacquers, 964for magnesium alloys, 264, 287–288metallizing, 965for metals, 963–967

electroplating, 965enamels, 964hot-dip plating, 965lacquers, 964metallizing, 965organic, 964paints, 964temporary corrosion protection, 965–966vacuum metallizing, 965varnishes, 964vitreous enamels, 964–965

organic, 964paints, 964phosphate, 966with plastics, 980–981

contour, 980–981

planar, 980for steel parts in electronic packaging,

1237–1238for superalloys, 329–330for telecommunications devices, 1324temporary corrosion protection, 965–966vacuum metallizing, 965varnishes, 964vitreous enamels, 964–965for wear resistance, 1278wire coating, 1016–1018

Cobalt-base superalloys, 294, 303, 305, 307,309, 310, 318

Cobalt (in nickel alloys), 248Co-curing (composites), 1357–1358, 1361–

1362Code division multiple access (CDMA), 1308Coefficient of friction:

of diamond, 1290in metal cutting, 851–852

Coefficient of thermal expansion (CTE/COT):of advanced composite materials in

spacecraft, 1136–1138of ceramics, 638–640of composite materials, 362, 372, 386–391in electronic packaging applications, 1225–

1226of sandwich-constructed composite core,

1143–1144Coining (metals), 941Coinjection molding (plastics), 957Cold-chamber die casting, 955Cold drawing, 947Cold forging, 940Cold-roll forming, 944Cold rolling:

of metals, 940of superalloys, 295, 296

Cold spinning, 947Cold welding, 756Cold-working processes (metals), 939–949

bending, 942–944classification of, 939drawing, 947–949shearing, 944–947squeezing processes, 940–941

Columbium, 49Columnar grain directional solidification

(CGDS), 323–324Combined creep and fatigue failure (metals),

708, 712Combined stress theory of failure, 714Combustibility (in electronic packaging),

1231Combustion machining, 923Comex, 136

1446 INDEX

Commingled thermoplastic matrix composites,1103–1106

Committee for European Normalisation(CEN) standards (ceramics), 628, 632

Commodity thermoplastics, 336–341ABS, 339impact polystyrene (IPS), 338polyethylene (PE), 336–337poly(ethylene terephthalate) (PET), 341poly(methyl methacrylate) (PMMA), 341polypropylene (PP), 337, 338polystyrene (PS), 337, 338polyvinyl chloride (PVC), 339–340poly(vinylidene chloride) (PVDC), 340–341styrene /acrylonitrile copolymer (SAN),

338, 339Communications, see Telecommunications

applicationsComparing alternative solutions, 11–13

in case study, 14–17weighted-properties methods for, 11–13

digital logic method, 11–12performance index in, 12–13

Compatibility (of materials /processes), 8, 10COMPENDEX database, 455Completely reversed cyclic stress, 723Complex shear, 995Composite materials, 357–397, 1401–1416

adhesives for, 1361advanced, 1132–1136

definition of, 1132polymer matrices in, 1135–1136reinforcement fibers in, 1134–1135spacecraft applications of, 1131–1162stress-strain equations for, 1133

advantages of, 1345–1347all-composites structural applications,

1401–1416bridge applications, 1408, 1410–1416buildings applications, 1406, 1408–1410research and development of, 1402–1407

applications of, 1343–1347, 1349–1368adhesives, 1361assembly methods for, 1358–1363co-curing, 1357–1358, 1361–1362construction, see Composite materials,

construction applicationsdesign of individual plies, 1357detail design for, 1356–1363drilling systems, 1359environmental concerns with, 1367–1368evaluation of potential products, 1344–

1347flat sandwich panels, 1357–1358historical, 1344–1346joining, 1358–1361and lack of ductility, 1359–1360

localized stiffness for, 1362–1363manufacturing of, 1348–1356materials selection for, 1350–1353, 1356mechanical fastening, 1358–1359number of plies, 1357process selection for, 1350–1356producibility checklist for, 1363–1365product development team for, 1349–

1350quality control requirements for, 1365–

1367and removability from tooling, 1356–

1357structural bonding, 1358, 1360–1361trimming, 1358

assembly methods for, 1358–1363bridge applications, 1408, 1410–1416buildings applications, 1406, 1408–1410bulk molding compounds, 1095, 1099carbon /carbon composites, 358

mechanical properties of, 385–386physical properties of, 397

ceramic matrix composites, 358mechanical properties of, 384, 385physical properties of, 397

classes /characteristics of, 358–359co-curing of, 1357–1358, 1361–1362commercial reinforcement formats for,

1040–1042commingled thermoplastic matrix

composites, 1103–1106comparative properties of, 359–363construction applications, 1369–1420

in aggressive environments, 1370–1371all-composites structural applications,

1401–1416codes and standards for, 1416–1419in internal reinforcement of concrete

members, 1399–1401new strategy for, 1419–1420in repair / retrofit infrastructures systems,

1371–1399contact molding, 1058–1065continuous lamination, 1095cure of thermosetting resins, 1049–1051design with

constraints on, 1347of individual plies, 1357manufacturing process selection, 1350–

1356materials selection, 1350–1353, 1356product development team, 1349–1350product development team for, 1349–

1350of reinforcements to enhance

permeability, 1053–1054detail design for, 1356–1363

INDEX 1447

drape in manufacturing of, 1053drilling systems with, 1359environmental concerns with, 1367–1368evaluation of potential products, 1344–1347feedstock choice in manufacturing of,

1057–1058fibers in, 1038

architecture of, 1039, 1040in construction repair applications, 1379,

1381–1385properties of, 1039

filament winding, 1085–1090filled plastics, 1038flat sandwich panels, 1357–1358flow processes during molding, 1052–1053glass mat thermoplastics, 1099–1101heat transfer in manufacture of, 1051–1052high-performance thermoplastic matrix

composites, 1101–1103historical application of, 1344–1346infiltration in manufacturing of, 1046–1048injection-molded short-fiber-reinforced

thermoplastics, 1107–1110for integrated electronics, 1148joining, 1358–1361lack of ductility in, 1359–1360laminate material properties, 1045localized stiffness in, 1362–1363manufacturing advantages of, 363, 364manufacturing of, 1037–1110, 1348–1356

aims and objectives of, 1045–1046applied pressure in, 1048–1049autoclave processing of prepreg, 1067–

1076bulk molding compounds, 1095, 1099commingled thermoplastic matrix

composites, 1103–1106consolidation in, 1048contact molding, 1058–1065continuous lamination, 1095cure of thermosetting resins, 1049–1051and design of reinforcements to enhance

permeability, 1053–1054drape in, 1053feedstock choice in, 1057–1058filament winding, 1085–1090flow processes during molding, 1052–

1053glass mat thermoplastics, 1099–1101heat transfer in, 1051–1052high-performance thermoplastic matrix

composites, 1101–1103infiltration in, 1046–1048injection-molded short-fiber-reinforced

thermoplastics, 1107–1110prepreg, 1067–1076press molding, 1065–1067

and properties of composites, 1038–1045pultrusion, 1090–1095rate of build in, 1056, 1057resin film infiltration, 1077–1078resin transfer molding, 1078–1086sheet molding compounds, 1095–1099for spacecraft applications, 1146–1149SRIM of monomer precursor

thermoplastics, 1106–1107with thermoplastic matrix systems, 1050,

1051tooling for, 1054–1056tow placement, 1085–1086, 1090

materials selection for, 1350–1353, 1356matrix materials used in, 364, 368–372

carbon, 372ceramic, 371–372metals, 371polymers, 368, 371

mechanical fastening of, 1358–1359mechanical properties of, 375–386, 1039–

1045carbon /carbon composites, 385–386ceramic matrix composites, 384, 385commercial reinforcement formats,

1040–1042fiber architecture, 1039, 1040fiber properties, 1039laminates, 1045metal matrix composites, 378, 380–384moldings, 1045polymer matrix composites, 375–380precompounded reinforcements with

thermosetting matrices, 1042–1044thermoplastic matrices, 1044–1045

metal matrix composites, 358mechanical properties of, 378, 380–384physical properties of, 392, 395–396

metals vs., 1347, 1348moldings, mechanical properties of, 1045multiphase piezoelectric, 405nature of, 1038number of plies in, 1357particulate composites, 1038physical properties of, 386–397

carbon /carbon composites, 397ceramic matrix composites, 397metal matrix composites, 392, 395–396polymer matrix composites, 392–394

polymer matrix composites, 358mechanical properties of, 375–380physical properties of, 392–394

and precompounded reinforcements withthermosetting matrices, 1042–1044

prepreg, 1067–1076press molding, 1065–1067process selection for, 1350–1356

1448 INDEX

Composite materials (continued )producibility checklist for, 1363–1365product development team with, 1349–1350properties of, 372–397, 1038–1045

mechanical, 375–386physical, 386–397for spacecraft applications, 1137–1142

pultrusion, 1090–1095quality control requirements for, 1365–

1367rate of build in manufacturing of, 1056,

1057in reinforced concrete /masonry structure

repair / retrofit, 1388–1398axial load capacity upgrade, 1393–1398flexural capacity upgrade (concrete

members), 1388–1391minimum bond strength requirements,

1391shear and torsional strengths upgrade,

1392–1393reinforcements used in, 358, 359, 364–367

aramid fibers, 367boron fibers, 367carbon (graphite) fibers, 366–367fibers, 364–367fibers based on alumina, 367fibers based on silicon carbide, 367glass fibers, 365, 366high-density polyethylene fibers, 367

removability from tooling with, 1356–1357in repair / retrofit infrastructure systems,

1371–1399automated machine lamination, 1385,

1387design considerations for (FRP

composites), 1385, 1387–1388design philosophy for (FRP composites),

1388–1398durability and long-term performance of,

1398–1399prefabricated composite laminates or

shells, 1385, 1386preimpregnated (prepreg) composite

systems, 1385reinforced concrete and masonry

structures, 1388–1398wet /hand lay-up method, 1375–1376,

1379, 1381–1385resin film infiltration, 1077–1078resin transfer molding, 1078–1086sheet molding compounds, 1095–1099spacecraft applications of, 1131–1162

in all-composite mirrors, 1161–1162in antennas, 1159–1160in deployable structures, 1152–1153in electronics enclosures, 1153–1157

examples of, 1149–1162FORTE, 1150in hybrid composite mirrors, 1160–1161in inflatable structures, 1153manufacturing methods used with, 1146–

1149material properties for, 1137–1142Midcourse Space Experiment, 1151–

1152in mirrors, 1159–1162in optical benches and instrument

structures, 1157–1159in primary spacecraft bus /chassis

structure, 1150–1152qualities of advanced composites used in,

1132–1136in reflectors, 1159–1162standard structural forms of, 1142–1145

SRIM of monomer precursorthermoplastics, 1106–1107

structural bonding of, 1358, 1360–1361with thermoplastic matrices, 1044–1045with thermoplastic matrix systems, 1050,

1051tooling for manufacture with, 1054–1056tow placement, 1085–1086, 1090trimming of, 1358

Composite Optics Inc., 1155, 1160Compression molding:

of medical products made from PP pellets,1218, 1219

of plastics, 983–984, 1026Compression testing:

for ceramics, 626, 798–799of metallic materials, 526

Compressive creep testing (ceramics), 630–631

Compromisable materials requirements, 834,835

Computed tomography (CT), 646, 671–672Computer-aided engineering (CAE), 477–478Computer-Aided Materials Preselection by

Uniforms Standards (CAMPUS R), 500Computer-assisted materials selection, 21–24

expert systems for, 23–24final selection using, 22–23MAPS 1 system, 9–11materials databases, 22

Computerized Application and ReferenceSystem (CARS), 22

Computerized materials databases, 21, 22,477

Concurrent engineering, 4Condensation, exposure of plastics to, 583–

586Conduction heat transfer, 1235Cone-and-plate viscometer, 597

INDEX 1449

Confidence in materials properties, 683Confidence limits (brittle materials), 816,

824–825Consolidation, 837, 1048Constant life diagrams, 729, 734Constant probability of failure, curves of, see

S–N–P curvesConstruction applications:

of aluminum alloys, 131of composites, 1369–1420

in aggressive environments, 1370–1371all-composites structural applications,

1401–1416codes and standards for, 1416–1419in internal reinforcement of concrete

members, 1399–1401new strategy for, 1419–1420in repair / retrofit infrastructures systems,

1371–1399Contact molding (composites), 1058–1065

economics of, 1064–1065key factors /variations in, 1059–1061laminate design for, 1061–1064prewetting of reinforcement, 1062–1064spray-up, 1064vacuum bagging, 1062

Continuous casting (steels), 29Continuous-cooling transformation (CT)

diagram, 41Continuous fiber-reinforced MMCs, 380, 395Continuous fibers (in composites), 1038Continuous lamination, 1095Continuous manufacturing processes (plastic

parts), 994, 1011–1022calendering, 1018–1019extension dominated, 1019–1022extrusion, 1011–1016fiber spinning, 1019–1020film blowing, 1020–1022shear dominated, 1011–1019wire coating, 1016–1018

Continuous random mat (CRM), 1040, 1041Convection heat transfer, 1235Conversion, principle of (wear control), 761Copper:

in alloy steels, 47, 50and corrosion of magnesium alloys, 278,

279in stainless steels, 69

Copper alloys, 135–200in architecture applications, 143cast, 188–199

brasses, 140bronzes, 140–141casting methods for, 188, 198copper–nickels, 141families of, 137, 139

high-copper alloys, 139leaded coppers, 141mechanical properties of, 189–197nickel–silvers, 141in sleeve bearings, 199special alloys, 141, 142temper designations for, 137, 139uses for, 198–199

designations forcast, 137, 139wrought, 137, 138

in electrical / electronic applicationssheet / strip /plate products, 150, 165wire products, 142–143

in electronic packaging applications, 1244families of, 137, 139–142

brasses, 139–140bronzes, 140–141copper–nickels, 141coppers, 137, 139high-copper alloys, 139leaded coppers, 141miscellaneous copper–zinc alloys, 141–

142nickel–silvers, 141special alloys, 141, 142

in industrial applications, 165, 185mechanical properties of

cast coppers and copper alloys, 189–197rod, bar, and mechanical wire alloys,

167–182of sheet and strip alloys, 151–164of tube alloys, 183–184

physical properties of, 143–149product forms of, 142rod, bar, and mechanical wire, 185–188

forgings, 187machined products, 186–187mechanical properties of, 167–182mechanical wire, 187–188

sheet / strip /plate products, 143, 150–165,185

in architecture, 143in electrical / electronics applications,

150, 165in industrial products, 165, 185

and structure of copper industry, 136–137temper designations for, 137–139

cast, 137, 139wrought, 137, 138

tubes and fittings, 183–185wire products, 142–143wrought

brasses, 139, 140bronzes, 140, 141copper–nickels, 141families of, 137

1450 INDEX

Copper alloys (continued )high-copper alloys, 139miscellaneous copper–zinc alloys, 141–

142nickel–silvers, 141temper designations for, 137, 138

Copper Data Center, 136Copper Development Association (CDA), 136Copper–nickel alloys, 141Copper–nickel–tin alloys, 165The Copper Page web site, 136, 143Copper wire test (plastics), 613Copper–zinc alloys, miscellaneous, 141–142Corotational Jeffreys model, 1004–1005Corrosion. See also Corrosion resistance

biological, 709, 768–769cavitation, 709, 768cost of, 248, 761crevice, 709, 764, 766decarburization, 768by direct chemical attack, 709, 762–763in electronic packaging applications, 1226–

1227erosion, 709, 767fretting, 711galvanic, 709, 763–765of hip implants, 1174–1177hydrogen damage, 768by hydrogen damage, 709intergranular, 709of magnesium and magnesium alloys, 274–

289and electrochemical properties of

magnesium, 274, 275improving resistance to, 278–289and surface films in various

environments, 276–279types of corrosion, 274–276

of metals, 707, 709, 761–770biological corrosion, 768–769cavitation corrosion, 768crevice corrosion, 764, 766decarburization, 768direct chemical attack, 762–763erosion corrosion, 767galvanic corrosion, 763–765hydrogen damage, 768intergranular, 766–767pitting corrosion, 766selective leaching, 767stress corrosion cracking, 769–770

with orthopedic biomaterials, 1174–1177pitting, 251–252, 709, 766–767repair of, 1371selective leaching, 767by selective leaching, 709stress, 709

stress corrosion cracking, 769–770of superalloys, 329–330wet vs. dry, 249

Corrosion fatigue failure (metals), 708, 712Corrosion protection (metals), 963–967

chemical conversions, 966–967coatings, 963–966temporary, 965–966

Corrosion resistance:alloy selection for, 81, 87of aluminum alloys, 90of ceramic materials, 429hot-corrosion resistance, superalloys for,

330of magnesium and magnesium alloys, 264,

278–289and alloying, 280–284and control of impurities, 278–280and processing methods, 284–287and surface protection, 287–288

of nickel and nickel alloys, 87, 248–252of stainless steels, 58, 69–76, 87

to crevice corrosion, 74to galvanic corrosion, 75–76to general corrosion, 71–72to intergranular corrosion, 75to pitting corrosion, 74, 75to stress-corrosion cracking, 72–73

of steels, 56of superalloys, 294, 316of titanium and titanium alloys, 203, 231

Corrosion wear failure (metals), 708, 712Corrosive wear, 710Cost(s):

of corrosion, 248, 761of feedstock for composite processes, 1058of machining metals, 856–859of materials, 509performance requirement analysis for, 6per unit stiffness, 8, 9per unit strength, 8weighting factor for, 13

Cost–benefit analysis (materials substitution),20–21

Cost per unit property (material screening), 8,9

COT, see Coefficient of thermal expansionCo-woven fabrics, 1104–1105CPT (critical pitting temperature), 74CP titanium, 208, 214–216Crack detection capabilities, 686–690Cracking, see Failure analysisCrack-tip stress analysis, 718–722Creep:

in composite materials, 378in electronic packaging applications, 1231–

1232

INDEX 1451

in heat-resistant steels, 63prediction of long-term creep behavior,

742–743in steels, 48in superalloys, 311, 317testing for

in ceramics, 628–631in metallic materials, 526–528in plastics, 551–553, 574

Creep buckling failure (metals), 707, 712Creep failure (metals), 707, 711Creep rupture, 740–742

in ceramics, 806–807in composite materials, 378in metals, 740–746

creep under uniaxial state of stress, 743–746

prediction of long-term creep behavior,742–743

in plastics, 574with superalloys, 311, 312

Creep strain (ceramics), 805–806Crevice corrosion, 709

in magnesium alloys, 275of metals, 764, 766resistance of stainless steels to, 74

Cricket bats, 1264Criminale–Ericksen–Filbrey (CEF) model,

1005–1006Critical crevice corrosion temperature

(CCCT), 74–75Critical pitting temperature (CPT), 74Critical stress intensity, 719CRM, see Continuous random matCRT (California Resin Testing) Labs Inc., 621Cryogenic applications (titanium and titanium

alloys), 232Cryogenic toughness (aluminum alloys), 90Crystal growth, 1336Crystalline ceramics, 839–840Crystalline polymers, 1427Crystal polystyrene, see General-purpose

polystyreneCSM, see Chopped strand matCT, see Computed tomographyCT (continuous-cooling) transformation

diagrams, 41CTE, see Coefficient of thermal expansionCTFE (poly(chlorotrifluoroethylene)), 349Cubic boron nitride (CBN), 1277

in abrasive machining, 894for cutting tools, 860

Curing (composites), 1357–1358co-curing, 1357–1358, 1361–1362cure monitoring sensors, 1072low pressure, ambient cure RTM, 1083–

1084

of thermosetting resins, 1049–1051tool preparation for, 1072–1073

Curves of constant probability of failure, seeS–N–P curves

Cutting. See also Sawingof metals, 892–893

cutoff operations, 947economics of, 856–869force for, 946machining power and cutting forces,

852–855principles of, 848–852

oblique, 848, 850orthogonal, 848, 850thread cutting and forming, 884–886tool steels for, 62

Cutting-edge angles, 861Cutting fluids, 861, 862Cutting tools:

ceramic inserts for, 425, 426, 860fluids used with, 861–862geometry of, 861, 862and machinability, 862materials for, 859–861oxide inserts for, 860speeds and feeds with, 862–863

CVD, see Chemical vapor depositionCVN test, see Charpy V-notch testCyclic fatigue, 792–793Cyclic manufacturing processes (plastic parts),

994, 1022–1033blow molding, 1026–1027casting, 1032–1033compression molding, 1026extension dominated, 1026–1032melt injection molding, 1022–1025quiescent, 1032–1033reaction injection molding, 1025rotational molding, 1032shear dominated, 1022–1025thermoforming, 1027–1032transfer molding, 1025

Cyclic properties (superalloys), 312, 317

Damage-tolerant design, 684–685, 687DAP, see Diallyl phthalateDargie’s method (materials screening), 9–11Data, materials, see Materials dataDatabases. See also Materials data

managementattributes defined in, 487–490certified data from, 460–461computerized, 21, 22evaluated data from, 460interactive, 22for material properties, 447, 454–456, 463–

465

1452 INDEX

Databases (continued )for materials data management, 484–493

building the database, 491–492design of database, 486–490end-user data requirements definition,

485–486functional requirements definition, 486populating the database, 490–491project team definition, 485prototype database development, 490qualifying the database, 492–493user interface customization, 492

numeric, materials properties data from,464

platform variety for, 467–468prototype, 490quality / reliability of data from, 465–467textual, materials properties data from,

463–464Database management systems (DBMSs),

480, 482, 494–497. See also Materialsdata management

Data fusion, 652Data management, see Materials data

managementData transfer rate, 1304

of cable modems/digital subscriber lines,1306

of telephone networks, 1305of wireless networks, 1308

Data transmission, 1309DBMSs, see Database management systemsDe Beer’s law, 667Deburring, electrochemical, 908, 909Decarburization (metals), 768Deep drawing (metals), 947–948Deep-quality special-killed (DQSK) steels, 55Deformation, 837

elastic deformation failure, 708, 710, 712–713

resistance to, 252–253wear, deformation, 710

Degassing, 29, 50Delamination theory of fretting, 749Delayed failure:

of brittle materials, 814of ceramic materials, 792–794

Delsen Testing Laboratories, Inc., 621Delta iron, see FerriteDemagnetization of parts, 682–683Denier, 1040Dense WDM (DWDM), 1307, 1308Densification, 1122Density:

of composite materials, 386, 388, 390in electronic packaging applications, 1228

Deoxidizers, 48

Deployable space structures, 1152–1153Deposition:

chemical vapor depositionfor diamond films, 1287–1300fibers made from, 363historical background of, 1287–1289metal–organic chemical vapor deposition,

1314, 1315for telecommunications applications,

1334–1335crystal growth, 1336of diamond films, 1291–1295epitaxy, 1335–1336evaporation, 1330, 1334–1335metal–organic chemical vapor deposition,

1314, 1315modified chemical vapor deposition, 1321,

1322plating, 1337sputtering, 1330for telecommunication materials, 1330,

1334–1337Derwent World Patents Index, 456Design:

of ceramic materialsand brittleness, 422–423handbooks for, 435

with composite materials, 1355–1363FRP composites in repair and retrofit

infrastructure systems, 1385, 1387–1398

individual plies, 1357concurrent engineering in, 4configuration (embodiment), 5damage-tolerant, 684–685detail (parametric), 5deterministic, 422to enhance permeability of composite

reinforcements, 1053–1054as factor in failure

of ceramics, 788, 798–803of plastics, 776, 777

final, materials properties data for, 460–461inspectability considerations in

confidence in materials properties, 683probability of detection, 691–693quantification of NDE capabilities, 690–

691quantified crack detection capabilities,

686–690structural integrity, 683–686

manufacturing concerns in, 835of materials database, 486–490

pilot application design and testing phaseof, 483–484

system design phase of, 481–483materials properties information sources

INDEX 1453

for final design, 460–461for preliminary design, 460

materials selection in, 833–834of medical products, 1199of plastic parts, 1431–1435preliminary /conceptual, 5, 460probabilistic, 422process selection concerns in, 833–834safe-life, 684, 687of sports equipment, 1255–1256stages of, 4, 5as step in manufacturing process, 833–837with superalloys, data for, 296–297

Design problem (plastics manufacturing),997–998

Design solution algorithm (plasticsmanufacturing), 998–1007

Desktop library, 448–450Deterministic design, 422Detroit Testing Laboratory, Inc., 621Deutsches Institut fur Normung (DIN)

standards, 53Dezincification, 767DFB lasers, see Distributed feedback lasersDiallyl phthalate (DAP), 353–354Diamonds:

for abrasive machining, 894for cutting tools

polycrystalline, 861single-crystal, 860–861

Diamond films, 1287–1300adhesion of, 1297–1300deposition of, 1291–1295historical background of, 1287–1289modification of CVD diamond properties,

1295and properties of CVD diamond, 1289–

1291roughness of, 1295–1296thickness of, 1296–1297

Diamond particle-reinforced copper MMCs,395–396

Diaphragm molding, 1103Die casting:

of magnesium alloys, 261, 262, 284of metals, 954–955

Dielectric constant testing (plastics), 576, 577Dielectric strength testing (plastics), 575–576Differential scanning calorimetry (DSC):

for ceramics, 644for plastics, 602–604of polymers, 1426

Diffusion, 32Digital logic (weighted-properties), 11–12Dilatometers, 41, 639, 640Dilatometry testing (ceramics), 639, 640Dimensionality (of plastic parts), 993

DIMOX (directed metal oxidation) process,1120

DIN (Deutsches Institut fur Normung)standards, 53

Dinking (metals), 947Direct chemical attack, corrosion by, 709,

762–763Directed metal oxidation (DIMOX) process,

1120Directory of Testing Labs (ASTM), 520Discontinuous fibers (in composites), 1038Discontinuous fiber-reinforced MMCs, 380,

382Displacement-based sensors, 1326–1327Disposable medical products, 1195–1196Disposal of materials, 513–515Dissipation factor testing (plastics), 576, 577Distortion energy theory of failure, 714–715Distributed feedback (DFB) lasers, 1315,

1316Diversion, principle of (wear control), 761DMA (dynamic mechanical analyses), 1427DMC (dough molding compound), 1095Document-type definition (DTD), 501–502Dough molding compound (DMC), 1095. See

also Bulk molding compoundDQSK steels, see Deep-quality special-killed

steels; Drawing-quality special-killedsteels

Drag-flow manufacturing processes (plastics),996

Drape (composite processing), 1053Drawability (of steels), 54–55Drawing (metals):

cold, 947–949hot, 933–936

Drawing-quality special-killed (DQSK) steels,48–49

Drilling:automated drilling systems, 1359of composites, 1359cutting horsepowers for, 854tool steels for, 62tool wear factors in, 855

Drilling machines:accuracy of, 876alignment charts for, 871–876classification of, 877for metals manufacturing, 869–877

Dry circuit switching, 1244Dry corrosion, 249Dry sand molds, 950DSC, see Differential scanning calorimetryDTD, see Document-type definitionDual-phase steels, 57–58Ductile rupture failure (metals), 708

1454 INDEX

Ductility, 1230of composites, 1359–1360in electronic packaging applications, 1230of steels, 37, 39, 49, 51of superalloys, 316

Duplex austenitic–ferritic stainless steels, 67,80

Duplex stainless steels, 61, 86–87Durability (of composites), 1398–1399Durometer hardness test, 568DWDM, see Dense WDMDynamic fatigue measurements (brittle

materials), 815–816, 823–824Dynamic mechanical analyses (DMA), 1427Dynamic viscosity, 599Dynepco Inc., 621

E-beam radiation, see Electron beam radiationEBM, see Electron-beam machining;

Extrusion blow moldingECD, see Electrochemical deburringECDG, see Electrochemical discharge

grindingECG, see Electrochemical grindingECH, see Electrochemical honingE-commerce, 515ECP, see Electrochemical polishingECS, see Electrochemical sharpeningECT, see Electrochemical turningECTFE, see Poly(ethylene

chlorotrifluoroethylene)Eddy current inspection, 653, 672–678

impedance plane, 673–676lift-off of inspection coil from specimen,

676–678and skin effect, 673

EDG (electrical discharge grinding), 916EDM, see Electrical discharge machiningEDS, see Electrical discharge sawingEDWC (electrical discharge wire cutting), 918Elastic deformation failure, 708, 710, 712–

713Elastic modulus, 8, 9Elastomers, 336, 354, 1424

in electronic packaging applications, 1246,1249

general-purpose, 350, 354specialty, 351, 354thermal behavior of, 1426

Elastorestrictive materials, 409Electrical applications:

of aluminum alloys, 131of copper and copper alloys, 142, 150, 165HSLA steels for, 57

Electrical conductivity, 1129. See alsoElectrical resistance

of aluminum alloys, 90

of diamond films, 1291in electronic packaging applications, 1224–

1225of metals / alloys, 699

Electrical contacts, materials selection for,1239

Electrical discharge grinding (EDG), 916Electrical discharge machining (EDM), 916,

917Electrical discharge sawing (EDS), 917–918Electrical discharge wire cutting (EDWC),

918Electrical resistance:

of ceramics at elevated temperatures, 647of metals / alloys, 699of plastics, 577–578

Electrical steels, 49, 55Electrical testing:

of ceramics, 646–648electrical resistance at elevated

temperatures, 647flexural strength of electronic-grade

ceramics, 647–648of plastics, 575–582

arc resistance, 578–582dielectric constant and dissipation factor,

576–577dielectric strength, 575–576electrical resistance tests, 577–578

Electroabsorption modulated lasers (EML),1315–1317

Electrochemical deburring (ECD), 908, 909Electrochemical discharge grinding (ECDG),

908, 909Electrochemical grinding (ECG), 909, 910Electrochemical honing (ECH), 910, 911Electrochemical machining (ECM), 910–912Electrochemical polishing (ECP), 912, 913Electrochemical sharpening (ECS), 912, 913Electrochemical turning (ECT), 913, 914Electrodeposition, 1337Electromagnetic interference (EMI) shielding,

579–582, 1140–1141Electromagnetic shielding, 1228, 1234–1235Electromechanical machining (EMM), 905Electron beam (E-beam) radiation, 1207–1210Electron-beam evaporation, 1334Electron-beam machining (EBM), 915–916Electronic packaging applications, 1223–1251

adhesives in, 1250–1251ceramics in, 1249chemical resistance in, 1226combustibility in, 1231composite materials in, 386–391, 395–396corrosion in, 1226–1227creep in, 1231–1232density in, 1228

INDEX 1455

dominant considerations in, 1224–1232ductility in, 1230elastomers in, 1246, 1249electrical conductivity in, 1224–1225electrical contacts, 1239electromagnetic shielding in, 1228electrostatic shielding in, 1228–1229encapsulants, 1239–1241environmental endurance in, 1241equipment attachment, 1233–1234equipment /modules enclosures, 1234–1235equipment racks / frames /mounting

structures, 1234fatigue resistance in, 1229finishes for, 1237–1238general considerations in, 1241glasses in, 1249–1250hardness in, 1229–1230magnetic shielding in, 1229mechanical joints, 1236–1237metals in, 1241–1245

aluminum and aluminum alloys, 1242–1244

cadmium, 1244chromium, 1244copper and copper alloys, 1244gold, 1244–1245iron and iron alloys, 1242lead, 1245magnesium, 1244nickel, 1244rhodium, 1245silver, 1244–1245tin, 1245titanium, 1245zinc, 1244

moisture absorption in, 1232operating / storage temperature ranges for,

1227–1228overriding considerations in, 1232–1233plastics in, 1245–1249

elastomers, 1249thermoplastics, 1246, 1247thermosets, 1247–1249

position-sensitive assemblies, 1238strength in, 1228sublimation in, 1230–1231temperature control, 1235–1236thermal conductivity in, 1225thermal emissivity in, 1225thermal expansion in, 1225–1226wear resistance in, 1230

Electronics applications:copper and copper alloys in, 142–143, 150,

165enclosures, electronics (in spacecraft),

1153–1157

passive, ceramic materials in, 430–431Electro-optical materials, 1323–1324Electroplating:

of aluminum, 1237of magnesium alloys, 287of metals, 965of steel parts in electronic packaging,

1237–1238for telecommunications applications, 1337

Electropolishing (ELP), 899, 921, 922, 963Electrorheological materials, 409–410Electro slag remelting (ESR), 319, 322–323Electrostatic shielding, 1228–1229, 1234–

1235Electro-stream (ES), 913, 914Electrostrictive materials, 407–408Elevated temperature performance tests

(plastics), 568–574Elongation, 1230ELP, see ElectropolishingEmbedded-sensor technology, 1147–1148Embossing (metals), 948Embrittlement, hydrogen, 768EMI shielding, see Electromagnetic

interference shieldingEML, see Electroabsorption modulated lasersEMM (electromechanical machining), 905Enameling steel, 55Enamels (for metals), 964Encapsulants (in electronic packaging), 1239–

1241Encyclopedias, online, 448End cutting-edge angles, 861Endurance limit, 728Energy absorption capacity (aluminum

alloys), 90Engineered Polymers, 621Engineering, concurrent, 4Engineering thermoplastics, 342–348

modified polyphenylene ether, 347polyacetals, 343, 344polyamides (nylon), 342, 343poly(butylene terephthalate) (PBT), 342polycarbonates, 345–346polyesters, 342polyimides, 347, 348polyphenylene sulfide, 344, 345polysulfone, 346–347

Engines:automotive and light-truck, 426–427flex-fans with, 843

Ente Nazionale Italiano di Unificazione (UNI)standards, 53

EnviroBrasses, 198Environment(s):

aggressive, composites in, 1370–1371

1456 INDEX

Environment(s) (continued )compatibility of medical products with,

1198of composite manufacturing, 1367–1368copper and copper alloys in, 199–200endurance of electronic packaging in, 1241failure of plastics in, 778for magnesium and magnesium alloy use,

267for metallic materials testing, 540–542space, advanced composites in, 1141–1142for superalloys, 316wear phenomena in, 1276

Environmentally enhanced fractures (brittlematerials), 813–815

EOC, see Equation of continuityEpitaxy, 1335–1336Epoxy resins, 352–353, 1240Equation of continuity (EOC), 998–999Erosion corrosion, 709, 767ES, see Electro-streamESR, see Electro slag remeltingEthane, 1424Ethical considerations (in sport equipment

materials selection), 1270–1272Europe, all-composite bridges in, 1413–1416Eutectic reaction, 36Evaluated data, 460Evaluation, nondestructive, see Nondestructive

inspection /evaluationEvaporation (deposition technique), 1330,

1334–1335Expandable-bead molding (plastics), 957Expert systems, 23–24Extensible markup language (XML), 501Extensional flow, 994Extensional-flow-dominated processes (plastic

parts), 995, 1019–1022, 1026–1032blow molding, 1026–1027compression molding, 1026fiber spinning, 1019–1020film blowing, 1020–1022rotational molding, 1032thermoforming, 1027–1032

Extrusion:of metals, 932–933, 940–941of plastics, 958, 969–972, 1001–1016

single screw, 1011–1015twin screw, 1015–1016

Extrusion blow molding (EBM), 977–978Extrusion covering (plastics), 972–973Eyecatcher Project, 1408–1410Eyring model, generalized, 1000–1001

Fabrication. See also specific processesof carbon vs. stainless steels, 85

of magnesium and magnesium alloys, 262–264

of microelectromechanical systems, 1326of nickel and nickel alloys, 252–255of optical fibers, 1320–1322selecting process of, 836–838

Fabrics:co-woven, 1104–1105noncrimp, 1041, 1042woven, 1041, 1042

Face-centered-cubic (fcc) arrangement, 30, 31,47, 294

Failure. See also Failure analysisof ceramics, 787–790

delayed, 792–794design as factor in, 788, 798–803and intrinsic vs. extrinsic flaws, 789–790materials selection as factor in, 787–788,

803–805modes of failure, 788probability of, 789process as factor in, 788–790service conditions as factor in, 803–807under thermal shock conditions, 803–

804delayed, 792–794of metals, 705–712

brinnelling failure, 708brittle fracture failure, 708buckling failure, 707, 712combined creep and fatigue failure, 708,

712corrosion failure, 707, 709corrosion fatigue failure, 708, 712corrosion wear failure, 708, 712creep buckling failure, 707, 712creep failure, 707, 711criteria of failure, 705–706ductile rupture failure, 708elastic deformation failure, 708fatigue failure, 706–709fretting failure, 707, 710–711fretting fatigue failure, 710–711galling and seizure failure, 707, 711impact failure, 707, 710modes of failure, 706–712radiation damage, 707, 712spalling failure, 707, 711–712stress corrosion failure, 708, 712stress rupture failure, 707, 711theories of, 714–716thermal relaxation failure, 707, 711thermal shock failure, 707, 711wear failure, 707, 709–710yielding failure, 708

modes of, 706–712

INDEX 1457

of plastics, 775–778chemical, 778design as factor in, 776, 777environmental, 778material selection as factor in, 775–776mechanical, 776, 778process as factor in, 776service conditions as factor in, 776thermal, 778

Failure analysis:of brittle materials, 809–925

bend tests in, 821–823and confidence limits, 816, 824–825dynamic fatigue experiments for, 815–

816dynamic fatigue measurements in, 823–

824and environmentally enhanced fracture,

813–815indented inert strength measurements,

816, 824and initial strength distribution, 811–813and lifetime prediction process, 809–818strength tests in, 821–823Weibull tests in, 818–821

of ceramics, 790–807compressive strength measurement, 798–

799creep rupture, 806–807creep strain, 805–806delayed, 792–794and fracture mechanics, 789–791at high temperatures, 805multiaxial Weibull statistics for, 798–803scatter of lifetime, 797, 798scatter of strength, 794–797strength prediction, 792under thermal shock conditions, 803–804

materials properties data for, 463of metals, 705–770

corrosion failure, 761–770creep rupture, 740–746and criteria of failure, 705–706elastic deformation failure, 712–713fatigue failure, 722–740and fracture mechanics /unstable crack

growth, 715–722fretting failure, 746–756and modes of failure, 706–712stress corrosion failure, 769–770stress rupture failure, 740–746and theories of, 714–716wear failure, 746–747, 756–761yielding failure, 713–715

of plastics, 778–784heat reversion technique for, 782–783

materials identification analysis, 779–780mechanical testing for, 784microtoming technique for, 783–784nondestructive testing techniques for, 784stress analysis, 780–783thermal analysis for, 784by visual examination, 778–779

theories of, 714–716combined stress theory, 714distortion energy theory, 714–715maximum normal stress theory, 715–716maximum shearing stress theory, 714–

715Failure Analysis on CD-ROM, 469Faraday rotators, isolators incorporating, 1325Fast on-orbit recording of transient events

(FORTE) spacecraft, 1150Fatigue:

cyclic, 792–793high-cycle, 708, 722low-cycle, 708, 722static, 792, 814surface, 708–709thermal, 708thermomechanical, 543

Fatigue failure. See also Fatigue testingof composite materials, 378of metals, 706–709, 722–740

fatigue crack propagation, 735–740fatigue loading and laboratory testing,

723–727nonzero mean stress, 729, 733–735S-N-P curves, 727–233

of superalloys, 312Fatigue life (titanium), 219Fatigue limit, 728Fatigue resistance (electronic packaging),

1229Fatigue strength, 728

of aluminum alloys, 90at a specified life, 728

Fatigue testing:for ceramics, 634–638machines for, 726for metallic materials

fatigue crack propagation, 537–540fatigue fracture, 535–537

for plastics, 564–566Fcc arrangement, see Face-centered-cubic

arrangementFDA, see Food and Drug AdministrationFDMA (frequency division multiple access),

1308Feed, cutting, 862–863FEP (fluorinated ethylene–propylene), 349Ferrite (alpha iron /delta iron), 30–36Ferritic stainless steels, 49, 50, 60–61, 67,

78–79

1458 INDEX

Fibers:in composite materials, 364–367, 1038. See

also Composite materialsoptical, 1318–1323

Fiber Bragg gratings (FBSs), 1322, 1323Fiberglass, 1344–1345, 1362–1363Fiber-optic cables, 1322, 1323Fiber-reinforced polymer (FRP) composite

materials, 360–362construction applications of, 1369–1420

in aggressive environments, 1370–1371all-composites structural applications,

1401–1416codes and standards for, 1416–1419in internal reinforcement of concrete

members, 1399–1401new strategy for, 1419–1420in repair / retrofit infrastructures systems,

1371–1399pultruded (PFRP), 1401–1416

bridge applications, 1408, 1410–1416buildings applications, 1406, 1408–1410research and development of, 1402–1407

Fiber reinforcements (composite materials),358, 359, 364–367

aramid fibers, 367boron fibers, 367carbon (graphite) fibers, 366–367fibers, 364–367fibers based on alumina, 367fibers based on silicon carbide, 367glass fibers, 365, 366high-density polyethylene fibers, 367

Fiber spinning (plastics), 1019–1020Filament winding (composite processing),

1085–1090, 1351Filled plastics, 1038Fillers (plastics), 1430Film-based radiography, 668–669Film blowing, 973–974, 1020–1022Film thickness:

diamond, 1296–1297for wear materials, 1280–1281

Fine-grain steels, 48Finishes. See also Coating(s)

for aluminum alloys, 91for electronic packaging applications,

1237–1238for magnesium and magnesium alloys, 264for steel in electronic packaging, 1237–

1238Finishing:

of gears, 884of metals, 894, 899

Flanging (metals), 944Flex-fans, 843

Flexural properties:of ceramics

flexural strength testing for, 647–648flexure creep testing for, 629, 630testing of, 627–628

of plasticscreep testing, 552, 553fatigue test, 565–566testing for, 549–551

in reinforced concrete /masonry structurerepair / retrofit, 1388–1391

Flip-chips, 1314Flip-chip brazing, 1296Fluorescent UV lamps, exposure of plastics

to, 583–586Fluorinated ethylene–propylene (FEP), 349Fluorinated thermoplastics, 348–349, 352

fluorinated ethylene–propylene (FEP), 349poly(chlorotrifluoroethylene) (CTFE), 349poly(ethylene chlorotrifluoroethylene)

(ECTFE), 349, 352poly(tetrafluoroethylene) (PTFE), 348–349poly(vinyl fluoride), 352polyvinylidene fluoride (PVDF), 349

Foamed PVC, 340Food and Drug Administration (FDA), 616–

617breast implant regulation by, 1188, 1190ISO 10093-1 modified test matrix, 1197medical product regulation by, 1195–1196

Forged steels, 29Forging:

cold forging, 940of copper rod, bar, and mechanical wire,

187impression-die drop forging, 931of metals, 929–932

cold forging, 940impression-die drop forging, 931open-die hammer forging, 930–931press forging, 931roll forging, 932swaging, 932upset forging, 931, 932

open-die hammer forging, 930–931and oriented grain flow, 842, 843of plastic parts, 958press forging, 931roll forging, 932of steels, 29of superalloys, 324swaging, 932of titanium and titanium alloys, 227–229upset forging, 931, 932

Forging brass, 187Form cutting (gears), 883–884

INDEX 1459

Forming:of magnesium and magnesium alloys, 263,

264of metals, 948of superalloys, 295, 296

FORTE (fast on-orbit recording of transientevents) spacecraft, 1150

Fourier transform infrared (FT-IR)spectrometry, 607

Fracture mechanics:and flaw extension behavior in ceramics,

789–791and unstable crack growth in metals, 715–

722Fracture strength testing (ceramics), 624–628Fracture toughness, 717–722

of aluminum alloys, 90of ceramics, 632–633, 780–791of metallic materials, 531–535plane-strain, 720of structural metallic alloys /monolithic

ceramics /CMCs, 384of titanium alloys, 219, 223, 224

France, steel standards in, 53Free-cutting brass, 186–187Free-machining steels, 47Frequency division multiple access (FDMA),

1308Fretting corrosion, 711, 754–756Fretting failure:

fretting corrosion, 754–756fretting fatigue, 748–750fretting wear, 750–754of metals, 707, 710–711, 746–756

delamination theory of fretting, 749friction-generated cyclic stress fretting

hypotheiss, 748–749major variables affecting, 747–748

Fretting fatigue failure, 710–711, 748Fretting wear, 710, 711, 750–754Friction force (metal cutting), 852Friction-generated cyclic stress fretting

hypotheiss, 748–749Friction of surfaces:

diamond, 1290testing for, 540

Frit, 964–965FRP composite materials, see Fiber-reinforced

polymer composite materialsFT-IR (Fourier transform infrared)

spectrometry, 607Fullerenes, 415Full-mold casting, 956–957Functional requirements, performance

requirement analysis for, 4, 6Fungus nutrient / fungus resistant materials,

1232

Galling, 707, 711, 757Galvanic corrosion, 709

in electronic packaging applications, 1226–1227

of metals, 763–765resistance of stainless steels to, 75–76

Gamma iron, see AusteniteGamma loop, 44, 61Gamma radiation, 1201–1207Gas–metal arc welding (GMAW), 83–84Gaynes Testing Laboratories, Ltd., 621Gear manufacturing, 880, 883–884Gels:

hydrogels, 413–414magnetic, 415smart (intelligent), 413–414

Gel permeation chromatography (GPC), 599–601

Gel permeation (size exclusion)chromatography, 1426

General Electric, 510–511General-purpose polystyrene (GP PS), 337,

338Generating process (gears), 883–884Germany, steel standards in, 53Ghesquire Plastic Testing, Inc., 621Glass(es), 1249–1250. See also Transparent

ceramic materialsfor telecommunications device packaging,

1312as wear materials, 1281

Glass ceramics, 1250Glass fibers (in composite materials), 365,

366Glass mat thermoplastics (GMTs), 1099–1101Glass optical fiber, 1319–1321Glass transition, 1428Glass transition temperature, 336

of amorphous thermoplastics, 1050of polymers, 1427–1429

Globalization, 515GMAW, see Gas–metal arc weldingGmelins Handbuch der Anorganischen

Chemie, 447–448GMTs, see Glass mat thermoplasticsGold (in electronic packaging), 1244–1245Goldsmith empirical model, 1006Golf clubs, 1264–1266Goodman relationships, 734–735GPC, see Gel permeation chromatographyGP PS, see General-purpose polystyreneGrain flow, oriented, 842, 843Granta Design Limited, 496Graphite fibers, 1346. See also Carbon fibers

(in composite materials)Graphitization, 767

1460 INDEX

Gravitational-influenced manufacturingprocesses (plastics), 997

Gray cast iron, 260Green sand molds, 950Grinding:

electrical discharge, 916electrochemical, 909, 910electrochemical discharge, 908, 909in gear finishing, 884low-stress, 901, 905of metals, 894–899

Grinding fluids, 898Guarded hot plate testing (ceramics), 641–642Gun drills, 876Gypsum (plaster), 955

Hadfield, Sir Robert, 63Hadfield manganese steels, 47Hardenability (of steels), 41–43, 47–49, 56Hardness:

of diamond, 1290in electronic packaging applications, 1229–

1230of nickel and nickel alloys, 252–253of steels, 44

Hardness tests:for ceramics, 631–632Durometer, 568Knoop, 631, 632for metallic materials, 528–529for plastics, 566–568Rockwell, 567Vickers, 631, 632

Hardpoints (in sandwich panels), 1144HCF, see High-cycle fatigueHDM, see Hydrodynamic machiningHDPE, see High-density polyethyleneHDT, see Heat deflection temperatureHeat capacity testing (ceramics), 643–644Heat deflection temperature (HDT), 569–570Heat-resistant steels, 63, 87Heat reversion technique (plastics failure

analysis), 782–783Heat transfer:

in composites manufacturing, 1051–1052in electronic packaging applications, 1235–

1236Heat treatment:

of magnesium alloys, 284of nickel and nickel alloys, 254–256of steels, 50–52

annealing (full annealing), 51normalizing, 51process annealing (recrystallization

annealing), 51quenching, 52spheriodizing, 51, 52

stress relieving, 51tempering, 52

Hemolysis (with blood-contactingbiomaterials), 1184

Hemostasis (with blood-contactingbiomaterials), 1184

Heteroepitaxy, 1335–1336High-carbon steels, 860High-copper alloys, 139

cast, 139in electrical / electronic applications, 150,

165wrought, 139

High-cycle fatigue (HCF), 312, 316, 708, 722High-density polyethylene fibers (in

composite materials), 367High-density polyethylene (HDPE), 336, 337High-energy-rate forming (metals), 948, 949Higher alloy steels, 58–64High-impact polystyrene (HIPS), 338High manganese carbon steels, 53, 54High-molybdenum stainless steels, 87High-performance steels, 58High-performance thermoplastic matrix

composites, 1101–1103High-speed steels (HSS), 860High strain rate testing:

for ceramics, 633–634for metallic materials, 540

High-strength, low-alloy (HSLA) steels, seeMicroalloyed steels

High temperatures:ceramics at, 427–429, 805heat-resistant steels for, 63metals at, 297, 311stainless steels at, 76, 77superalloys at, 311–314, 332–333titanium alloys at, 205–207, 221

Hip replacement, see Total hip arthroplastyHIPS (high-impact polystyrene), 338Hobbing (metals), 941Hockey sticks, 1270Holding adhesives, 1251Homoepitaxy, 1335Honing, 899, 910, 911Hooke’s law, 713Hot-chamber die casting, 955Hot-corrosion resistance, 330Hot deformation (of superalloys), 295Hot-dip plating (metals), 965Hot rolling (metals), 927–929Hot shortness, 46, 47Hot stamping, see ForgingHot-working processes (metals), 926–938

drawing, 933–936extrusion, 932–933forging, 929–932

INDEX 1461

piercing, 938pipe welding, 937, 938rolling, 927–929spinning, 935, 937

HSLA steels, see Microalloyed steelsHSS (high-speed steels), 860HTML (hypertext markup language), 501Human health, copper and copper alloys in,

199–200Hunter Associates Laboratory, Inc., 621Hydrodynamic machining (HDM), 901, 905Hydrogels, 413–414Hydrogen:

in alloy steels, 50in titanium and titanium alloys, 214–215

Hydrogen blistering, 768Hydrogen damage, 709, 768Hydrogen embrittlement, 768Hydrogen flakes, 50Hydrostatic extrusion, 940, 941Hypereutectoid steels, 37Hypertext markup language (HTML), 501Hypoeutectoid steels, 36, 37

IACS, see International Annealed CopperStandard

ICBO, see International Conference ofBuilding Officials

ICBO publications, 1384, 1385, 1388–1393,1395, 1398, 1399

Ideal product, 831Identification analysis (plastics), 607–608,

610–613, 779–780chemical / thermal analysis for polymer

identification, 613copper wire test, 613melting point determination, 610, 612solubility test, 612specific gravity test, 613

IDES, Inc., 496IEC standards (plastics testing), 575–578IF steels, see Interstitial-free steelsIGES, see Initial Graphics Exchange

SpecificationImmunological complications (with space-

filling biomaterials), 1190–1191Impact deformation, 710Impact extrusion, 940Impact failure (metals), 707, 710Impact polystyrene (IPS), 338Impact testing:

for metallic materials, 530–531for plastics, 555–564

falling-weight impact test, 557–560high-speed impact tests, 562–564instrumented impact testing, 560–561pendulum impact test, 556–557

Impedance plane, 673–676Implants, see Biomedical applicationsImpression-die drop forging (metals), 931Indented inert strength measurements (brittle

materials), 816Independent testing laboratories, 621–622Indirect additives, 617Industrial applications (copper and copper

alloys), 165, 185Inert strength for indented specimens (brittle

materials), 816, 824Infiltration (composite processing), 1046–

1048Inflatable deployable space structures, 1152–

1153Information Handling Services, specifications

available from, 507Information sources:

for ceramic materials, 433–435for copper / alloy applications, 165, 187,

188for copper casting, 188for disposal and recycling of materials,

514–515for materials properties data, 441–472

for analytical comparisons, 458–460from ASM International, 468–469and chemical compound /class variations,

446–447from company’s external resources, 451–

452and database platform variety, 467–468from databases, 454–456, 463–465data quality / reliability judgments in,

465–467defining the question step in, 444–447desktop library for, 448–450for failure analysis, 463for final design, 460–461and four categories of data, 465from in-house experts, 450–451and intended uses for data, 458–463from the Internet, 470–472logic puzzle approach to, 441–443for manufacturing, 461–462for material specifications, 461for materials selection, 458–459from metadata, 464–465for modeling material /product

performance, 458from numeric databases, 464for preliminary design, 460process of, 444–454for quality assurance, 462quality issues in, 452–453redefining the question step in, 453resource grid for, 442–443

1462 INDEX

Information sources (continued )search strategy for, 447–448and spelling variations, 445from STN International, 469–470and terminology changes, 445–446from textual databases, 463–464

for materials selection procedures, 21–24for procurement of materials, 505–511

purchasing, 507, 509standards and specifications, 511–513

for superalloys, 296–297, 325–326, 328–329

for titanium and titanium alloys, 203, 204,233

for wear materials, 1279–1280Infrared cameras, 679InGaAsP, 1314–1318In-house experts, materials properties data

from, 450–451Initial Graphics Exchange Specification

(IGES), 498–499Initial screening of materials, 4, 6–11

in case study, 14performance requirement analysis in

for cost, 6functional requirements, 4, 6for processability, 6for reliability, 6for resistance to service conditions, 6–7

quantitative methods for, 7–11Ashby’s material selection charts, 9, 10cost per unit property method, 8, 9Dargie’s method, 9–11limits on material properties, 7–8

Initial strength distribution (brittle materials),811–813

Injection molding:of medical products made from PP pellets,

1217–1219of plastics, 957, 986–989of short-fiber-reinforced thermoplastics,

1107–1110Ink-jet technology, 1314INSPEC database, 454Inspectability, materials selection for, 683–

693confidence in consistent properties, 683general process control, 693probability of detection assessment, 691–

693quantified crack detection capabilities, 686–

690structural integrity, 683–686

Inspection of materials, nondestructive, seeNondestructive inspection /evaluation

Institute for Computer Sciences andTechnology, 617

Integrated Design, Inc., 621Integrated electronics, 1148Intelligent manufacturing, 1115Intelligent materials, see Smart materialsIntelligent processing, 1115Interaction effects (crack growth), 739Interactive databases, 22Interferometry (ceramics testing), 640Intergranular corrosion, 709

carbon content and, 76in magnesium alloys, 275of metals, 766–767resistance of stainless steels to, 75and weld decay, 766–767

International Annealed Copper Standard(IACS), 142–143

International Conference of Building Officials(ICBO), 1384, 1385, 1418, 1419

Internet:data transfer via, 1309distribution of materials information using,

478materials properties data from, 470–472quality / availability of information on, 451

Internet protocol (IP), 1308Interstitial alloying elements, 32Interstitial-free (IF) steels, 49, 54Investment casting:

of magnesium and magnesium alloys, 261,262

of metals, 956–957of superalloys, 323–324of titanium and titanium alloys, 229

IP (Internet protocol), 1308IPS (impact polystyrene), 338Iron and iron alloys. See also specific alloys

and corrosion of magnesium alloys, 278,279

in electronic packaging applications, 1242influence of carbon on strength of, 44–45

Iron-base superalloys, 305, 309Iron-carbon equilibrium diagrams (steels), 30–

38, 44Ironing (metals), 948Ironmaking, 28Iron–nickel-base superalloys, 294–295Iron–nickel–chromium alloys, 236Isogrid construction (composite panels), 1145Isolators (incorporating Faraday rotators),

1325ISO standards:

for ceramicsfracture toughness, 633hardness, 632

INDEX 1463

for medical product tests, 1196, 1197for plastics

melt index test, 592, 594–595thermal properties testing, 569–571,

574–575weathering of, 584–587

ISO 10303 (STEP), 498–500Isothermal forging (superalloys), 324Isothermal rolling (metals), 927–929Isothermal transformation (IT) diagram

(steels), 38–40Italy, steel standards in, 53IT diagrams, see Isothermal transformation

diagramIzod impact tests, 530, 556–557

Japan:copper production in, 136film deposition work in, 1288–1289steel standards in, 53

Japanese Industrial Standards (JIS)Committee, 53. See also JIS standards

Javelins, 1268, 1269Jeffreys model, corotational, 1004–1005JHU-APL, see Johns Hopkins University

Applied Physics LaboratoryJIS (Japanese Industrial Standards)

Committee, 53JIS standards (for ceramics), 434–435

compression, 626fatigue, 637, 638for flexure, 628for fracture toughness, 632for hardness, 632tensile testing, 626for uniaxial flexural tests, 635

Johns Hopkins University Applied PhysicsLaboratory (JHU-APL), 1155–1157

Joining. See also specific processesadhesives for, 1250, 1251of advanced composite materials in

spacecraft, 1145of aluminum alloys, 91of composites, 1145, 1358–1361

mechanical fastening, 1358–1359structural bonding, 1358, 1360–1361

in electronic packaging applicationsequipment attachment, 1233–1234mechanical joints, 1236–1237

of magnesium and magnesium alloys, 262,263

of plastics, 1431of superalloys, 325of titanium and titanium alloys, 230–231

Joint motion (with orthopedic biomaterials),1171–1173

Jominy test, 41–42Just-in-time logistics management, 515

Kevlar, 367, 1346, 1359Killed steels, see Aluminum–silicon

deoxidized steelsKinematics, 994Kinematic viscosity, 599Knoop hardness test, 631, 632Knowledge-based systems, see Expert systemsKofler method (melting point), 612

LabVIEW, 523Lacquers (metals), 964Lactams, 1106Laminates. See also Composite materials

in advanced composites, 1132–1134magnetorestrictive, 408mechanical properties of, 1045quasi-iostropic, 376, 377, 379sandwich, 1143–1144solid, 1142–1143steel, 55unidirectional, 376, 381

Lamination, continuous, 1095Lancing (metals), 946Lanthanum, 50, 271Lapping, 884, 899Larson–Miller theory, 743Lasers:

distributed feedback lasers, 1315, 1316electroabsorption modulated, 1315–1317solid-state, 1314–1317

Laser-beam machining (LBM), 918, 919Laser-beam torch (LBT), 919, 920Laser flash testing, 642–643Laser rastering, 1122Laterites, 235Layered manufacturing (ceramics), 1122–

1123LBM, see Laser-beam machiningLBT, see Laser-beam torchLCF, see Low-cycle fatigueLDPE, see Low-density polyethyleneLeaching:

with orthopedic biomaterials, 1177–1178selective, 709

Lead:in alloy steels, 50in electronic packaging applications, 1245

Lead alkali borosilicate glasses, 1250Leaded coppers, 141Lead zirconate titanates (PZT), 432, 1118–

1119

1464 INDEX

Libraries:desktop, 448–450as information sources, 451–452

Life extension, design for, 687–690Lifetime prediction:

for brittle materialsconfidence limits in, 816, 824–825dynamic fatigue measurements in, 815–

816, 823–824environmentally enhanced fracture, 813–

815indented inert strength measurements,

816initial strength distribution, 811–813process of, 816–818strength tests in, 821–823Weibull tests in, 818–821

for other materials, see Failure analysisLight-sensitive materials, 412Limits (on material properties), 7–8Linear low density polyethylene (LLDPE),

336, 337blown-film processing of, 1214, 1215pelletization processing of, 1213–1214

Liquids, ultrasonic properties of, 694Liquid baths (metals), 960–962Liquid-crystal polymers, 1427Liquid penetrants (nondestructive inspection),

652–656Liquid phase sintering, 1113LLDPE, see Linear low density polyethyleneLoading frames, 520–522Load support (with orthopedic biomaterials),

1167–1171Logic puzzle approach (materials properties

data searches), 441–443Log-log stress–time creep law, 745London Metal Exchange, 136Long discontinuous fibers (in composites),

1038Long-term heat resistance test (plastics), 571Lost wax process, see Investment castingLow-alloy steels, 56–58Low-carbon steels, 54–55Low-cycle fatigue (LCF), 312, 316, 708, 722Low-density polyethylene (LDPE), 336, 337Lower bainite, 38, 39Low-stress grinding (LSG) (metals), 901, 905

Machinability:of stainless steels, 78of steels, 47, 50, 56

Machine Design’s Materials Selection, 23Machined products, copper, 186–187Machining:

abrasive, 894–899abrasive flow, 901, 904

abrasive jet, 901, 904chemical, 919–921combustion, 923conventional processes of, 848, 849electrical discharge, 916, 917electrochemical, 910–912electromechanical, 905electron-beam, 915–916hydrodynamic, 901, 905laser-beam, 918, 919of magnesium and magnesium alloys, 262of nickel and nickel alloys, 257photochemical, 922–923plasma-beam, 919–921of plastics, 893shaped-tube electrolytic, 914, 915of superalloys, 295thermally assisted, 901, 905, 906thermochemical, 923of titanium and titanium alloys, 229–230total form, 906ultrasonic, 907water-jet, 907, 908

MA constituent, 57Magnesium:

electrochemical properties of, 274in electronic packaging applications, 1244in powder form, 260stress–corrosion cracking resistance of, 276

Magnesium alloys, 259–264, 267–289alloying elements in, 260, 261, 267–268aluminum in, 280–282anodic coatings for, 264applications for, 268calcium in, 283–284cast, 261–262chemical-conversion coatings for, 264conventional processing of, 284–287corrosion of, 274–289

and electrochemical properties ofmagnesium, 274, 275

improving resistance to, 278–289and surface films in various

environments, 276–279types of corrosion, 274–276

corrosion resistance of, 264, 278–289and alloying, 280–284and control of impurities, 278–280and processing methods, 284–287and surface protection, 287–288

fabrication of, 262–264finishing of, 264forming of, 263, 264joining of, 262, 263machining of, 262mechanical properties of, 261–263nonstructural applications of, 259–260

INDEX 1465

oxidation of, 268–274at ambient temperature, 268–270at high temperature, 270–274

painting of, 264physical properties of, 262–264rapid solidification of, 285–287rare earth elements in, 282silicon in, 283stress–corrosion cracking resistance of, 276structural applications of, 260–261wrought, 262, 263zinc in, 282–283zirconium in, 283

Magnesium Elektron Ltd., 282Magnetic gels, 415Magnetic particle method (nondestructive

testing), 653, 680–682continuous vs. noncontinuous fields in,

681–682demagnetizing of part after, 682–683inspection process with, 682magnetizing field in, 680–681

Magnetic shielding (electronic packaging),1229, 1234–1235

Magnetorestrictive materials, 408–409Magnetorheological materials, 410–411Magnet wire, 142Maintenance, design for, 687Maintenance issues, materials properties data

for, 462Major Poisson’s ratio, 376Malleability, 1230Manganese:

in alloy steels, 46–47in high manganese carbon steels, 53, 54

Manufacturing, 831–845. See also Fabricationadvantages of composite materials in, 363,

364approaches to, 832–833of ceramics, 1113–1127

common steps in, 1116conventional processes in, 1115–1116engineering factors involved in, 1114layered manufacturing, 1122–1123mechanochemical synthesis, 1118–1120and microstructure of products, 1114microwave processing, 1117–1118nanotechnology in, 1120–1122new energy sources in, 1117–1120new precursors in, 1123–1127new shapes in, 1120–1123polymer precursors, 1123processing vs., 1115reaction bonding, 1120self-propagating high-temperature

synthesis, 1118sol-gel processing, 1123–1127

of composites, 1037–1110, 1348–1356aims and objectives of, 1045–1046applied pressure in, 1048–1049autoclave processing of prepreg, 1067–

1076bulk molding compounds, 1095, 1099commingled thermoplastic matrix

composites, 1103–1106consolidation in, 1048contact molding, 1058–1065continuous lamination, 1095cure of thermosetting resins, 1049–1051and design of reinforcements to enhance

permeability, 1053–1054drape in, 1053feedstock choice in, 1057–1058filament winding, 1085–1090flow processes during molding, 1052–

1053glass mat thermoplastics, 1099–1101heat transfer in, 1051–1052high-performance thermoplastic matrix

composites, 1101–1103infiltration in, 1046–1048injection-molded short-fiber-reinforced

thermoplastics, 1107–1110prepreg, 1067–1076press molding, 1065–1067and properties of composites, 1038–1045pultrusion, 1090–1095rate of build in, 1056, 1057resin film infiltration, 1077–1078resin transfer molding, 1078–1086sheet molding compounds, 1095–1099for spacecraft applications, 1146–1149SRIM of monomer precursor

thermoplastics, 1106–1107with thermoplastic matrix systems, 1050,

1051tooling for, 1054–1056tow placement, 1085–1086, 1090

design as step in, 833–837fabrication process selection in, 836–838of gears, 880, 883–884intelligent, 1115interrelationships in (examples), 839–845LLDPE blown-film processing effects,

1214, 1215LLDPE pelletization processing effects,

1213–1214and machining of plastics, 893of magnesium alloys, 284–287material selection as step in, 836, 837materials properties data for, 461–462of medical products, 1213–1219

LLDPE blown-film processing effects,1214, 1215

1466 INDEX

Manufacturing (continued )LLDPE pelletization processing effects,

1213–1214materials selection for, 1213–1219metallocene ULDPE tubing extrusion

throughput rate improvement, 1216–1218

PP compression-molding processingeffect, 1218, 1219

PP injection-molding processing effect,1217–1219

metallocene ULDPE tubing extrusionthroughput rate improvement, 1216–1218

of metals, 847–923, 925–957, 959–967abrasive flow machining, 901, 904abrasive jet machining, 901, 904abrasive machining, 894–899bending, 942–944broaching, 886–890casting /molding processes, 949–957centrifugal casting, 951–953chemical conversions, 966–967chemical machining, 919–921cleaning processes, 960–963coatings, 963–966cold-working processes, 939–949cutting off, 892–893die casting, 954–955drawing (cold), 947–949drawing (hot), 933–936drilling machines, 869–877electrical discharge grinding, 916electrical discharge machining, 916, 917electrical discharge sawing, 917–918electrical discharge wire cutting

(traveling wire), 918electrochemical deburring, 908, 909electrochemical discharge grinding, 908,

909electrochemical grinding, 909, 910electrochemical honing, 910, 911electrochemical machining, 910–912electrochemical polishing, 912, 913electrochemical sharpening, 912, 913electrochemical turning, 913, 914electromechanical machining, 905electron-beam machining, 915–916electropolishing, 921, 922electro-stream, 913, 914extrusion, 932–933finishing, 894, 899forging, 929–932gear manufacturing, 880, 883–884grinding, 894–899hot-working processes, 926–938hydrodynamic machining, 901, 905

investment casting, 956–957laser-beam machining, 918, 919laser-beam torch, 919, 920low-stress grinding, 901, 905machining power and cutting forces,

852–855metal-cutting economics, 856–869metal-cutting principles, 848–852milling processes, 877–882nonconventional machining processes,

899–923permanent-mold casting, 953–955photochemical machining, 922–923piercing, 938pipe welding, 937, 938planing, 888, 891–892plasma-beam machining, 919–921plaster-mold casting, 955–956powder metallurgy, 959–960rolling, 927–292sand casting, 949–952sawing, 892–893shaped-tube electrolytic machining, 914,

915shaping, 888, 891–892shearing, 892–893, 944–947slotting, 888, 891–892spinning, 935, 937squeezing processes, 940–941steels, 28–29surface treatment, 960–967thermally assisted machining, 901, 905,

906thermochemical machining, 923thread cutting and forming, 884–886tool life, 855–857total form machining, 906turning machines, 863–869ultrasonic machining, 907water-jet machining, 907, 908

nontraditional machining in, 899–923abrasive flow machining, 901, 904abrasive jet machining, 901, 904chemical machining, 919–921electrical discharge grinding, 916electrical discharge machining, 916, 917electrical discharge sawing, 917–918electrical discharge wire cutting

(traveling wire), 918electrochemical deburring, 908, 909electrochemical discharge grinding, 908,

909electrochemical grinding, 909, 910electrochemical honing, 910, 911electrochemical machining, 910–912electrochemical polishing, 912, 913electrochemical sharpening, 912, 913

INDEX 1467

electrochemical turning, 913, 914electromechanical machining, 905electron-beam machining, 915–916electropolishing, 921, 922electro-stream, 913, 914hydrodynamic machining, 901, 905laser-beam machining, 918, 919laser-beam torch, 919, 920low-stress grinding, 901, 905photochemical machining, 922–923plasma-beam machining, 919–921shaped-tube electrolytic machining, 914,

915thermally assisted machining, 901, 905,

906thermochemical machining, 923total form machining, 906ultrasonic machining, 907water-jet machining, 907, 908

objective of, 831of plastic parts, 969–991, 993–1033

blow molding, 977–979, 1026–1027calendering, 974–975, 1018–1019casting, 982, 983, 995, 1032–1033centrifugal-based process, rotational

molding as, 997classification of processes, 993–997coating, 980–981compression molding, 983–984, 1026continuous processes, 994, 1011–1022cyclic processes, 994, 1022–1033design problem in, 997–998design solution algorithm in, 998–1007drag-flow processes, 996extensional-flow-dominated processes,

995, 1019–1022, 1026–1032extrusion, 969–972, 1001–1016extrusion covering, 972–973fiber spinning, 1019–1020film blowing, 973–974, 1020–1022gravitational-influenced processes, 997injection molding, 986–989melt injection molding, 1022–1025pressure effects in, 1008–1009pressure-flow processes, 996quiescent process, casting as, 995, 1032–

1033reaction injection molding, 990–991,

1025rotational molding, 980–982, 997, 1032shear-flow-dominated processes, 994–

995, 1011–1019, 1022–1025sheet thermoforming, 975–977sources of momentum in, 996–997steady state processes, 994temperature effects in, 1007–1008thermoforming, 1027–1032

transfer molding, 984, 985, 1025unsteady state processes, 994wire coating, 1016–1018

PP compression-molding processing effect,1218, 1219

PP injection-molding processing effect,1217–1219

processes of, as failure factorof ceramics, 788–790of plastics, 776

process selection for, 4, 5secondary processes in, 838selecting best alternative for, 839sequence of activities in, 831, 832of steels, 28–29of superalloys, 295, 296, 319–329

casting, 323–324forging, 324joining, 325melting / remelting, 319–323powder metallurgy, 324–325refining, 319–323sources of information on, 325–326,

328–329of wear materials, 1278–1279

MAPP, 497MAPS 1 system, 9–11Maraging steel, 63–64Marine applications:

of aluminum alloys, 132–133product specifications for, 53

Martensite, 39, 40, 51Martensitic age hardening stainless steels, 67Martensitic stainless steels, 50, 61–62, 67, 79Masonry structures, FRP composite repair of,

1388–1398Master diagrams, 729, 734Matec Materials Technology Software and

Data Services, 497Materials. See also specific materials

databases of, 22disposal of, 513–515information sources on

for disposal and recycling, 514–515for purchasing, 507, 509standards and specifications, 511–513

procurement of, 505–511cost determination in, 509at General Electric, 510–511information sources for, 507, 509, 511–

513recycling of, 513–515

Material characterization tests (plastics), 591–609

differential scanning calorimetry, 602–604gel permeation chromatography, 599–601melt index test, 592, 594–596

1468 INDEX

Material characterization tests (plastics)(continued )

rheology, 595–599spectroscopy, 607–609thermal analysis techniques, 602–609thermogravimetric analysis, 604–605thermomechanical analysis, 605–606viscosity tests, 599

Material removal processes, 837Materials data. See also Materials properties

for analytical comparisons, 458–460from ASM International, 468–469categories of, 465and chemical compound /class variations,

446–447from company’s external resources, 451–

452and database platform variety, 467–468from databases, 454–456, 463–465defining the question step in, 444–447desktop library for, 448–450for failure analysis, 463for final design, 460–461from in-house experts, 450–451intended uses of, 458–463from the Internet, 470–472logic puzzle approach to, 441–443for maintenance issues, 462management of, see Materials data

managementfor manufacturing, 461–462for material specifications, 461for materials selection, 458–459from metadata, 464–465for modeling material /product

performance, 458from numeric databases, 464for preliminary design, 460process of, 444–454for quality assurance, 462quality issues in, 452–453quality / reliability judgments of, 465–467redefining the question step in, 453resource grid for, 442–443search strategy for, 447–448and spelling variations, 445standardization for Web access to, 500–502from STN International, 469–470and terminology changes, 445–446from textual databases, 463–464

Materials data management, 475–502commercial systems for, 494–497creating database for, 484–493

building the database, 491–492design of database, 486–490end-user data requirements definition,

485–486

functional requirements definition, 486populating the database, 490–491project team definition, 485prototype database development, 490qualifying the database, 492–493user interface customization, 492

history of, 476–479implementing system for, 479–484

analysis phase of, 480–481deployment and support phase of, 484pilot application design and testing phase

of, 483–484planning prior to, 480process of, 483system design phase of, 481–483

standards for data, 497–502ASTM Committee E 49, 498IGES/PDES, 498–499ISO/STEP, 499–500from materials consortia, 500and XML applications, 500–502

Material Selection and Design (for fatigue lifepredictions), 23

Materials identification analysis (plasticsfailure analysis), 779–780

Material specifications, materials propertiesdata for, 461

Materials properties. See also Materialsselection; specific properties

confidence in, 683limits on, 7–8locating information on, see Materials datamanufacturing effects on, 1213–1214of steel, controlling, 29–30of superalloys, 296–297of wear materials, 1276weighted-properties values, 11–13

Materials selection, 3–24. See also specificmaterials

absolute vs. compromisable requirementsin, 834–835

for biomedical applications, 1165–1192blood-contacting biomaterials, 1180–

1188breast implants, 1188–1191orthopedic biomaterials, 1166–1180space-filling biomaterials, 1188–1191total hip arthroplasty, 1166–1180vascular prostheses, 1180–1188

for blood-contacting biomaterials, 1186–1188

case study in, 13–19comparing alternative solutions, 14–17initial screening, 14performance requirements analysis, 14selecting optimum solution, 15–19

INDEX 1469

comparing alternative solutions step in, 11–13

in case study, 14–17digital logic method for, 11–13performance index in, 12–13weighted-properties method for, 11–13

computer-assisted, 21–24in design process, 833–834for electronic packaging, 1223–1251

adhesives, 1250–1251ceramics, 1249chemical inertness of, 1226combustibility of, 1231corrosion of, 1226–1227creep in, 1231–1232density of, 1228dominant considerations in, 1224–1232ductility of, 1230elastomers, 1249electrical conductivity of, 1224–1225electrical contacts, 1239electromagnetic shielding of, 1228electrostatic shielding of, 1228–1229encapsulants, 1239–1241and environmental endurance of, 1239–

1241equipment attachment, 1233–1234equipment /module enclosures, 1234–

1235equipment racks / frames /mounting

structures, 1234fatigue resistance of, 1229finishes, 1237–1238general considerations in, 1241glasses, 1249–1250hardness of, 1229–1230magnetic shielding of, 1229mechanical joints, 1236–1237metals, 1241–1245moisture absorption of, 1232operating / storage temperature ranges of,

1227, 1228overriding considerations in, 1232–1233plastics, 1245–1249position-sensitive assemblies, 1238steps in, 1224strength of, 1228and sublimation, 1230–1231and temperature control, 1235–1236thermal conductivity of, 1225thermal emissivity of, 1225thermal expansion of, 1225–1226wear resistance of, 1230

as factor in failureof ceramics, 787–788, 803–805of plastics, 775–776

initial screening step in, 4, 6–11

in case study, 14performance requirements analysis, 4, 6–

7quantitative methods for, 7–11

for inspectability, 683–693confidence in consistent properties, 683general process control, 693probability of detection assessment, 691–

693quantified crack detection capabilities,

686–690structural integrity, 683–686

materials properties data for, 458–459and materials substitution, 19–21

case study in, 21cost–benefit analysis for, 20–21Pugh method for, 19

for medical products, 1195–1221challenges of, 1198–1199and electron beam radiation effect,

1207–1210and gamma radiation effect, 1201–1207and manufacturing processes, 1213–1219polyolefin-based materials, 1210–1213product design, 1199product development factors, 1199–1213product performance issues in, 1219–

1221for MEMS devices, 1326–1328for orthopedic biomaterials, 1178–1180selecting optimum solution step in, 13, 15–

19sources of information for, 21–24for space-filling biomaterials, 1191for sports equipment, 1253–1272

baseball bats, 1266, 1267bicycles, 1260–1262boats, 1267–1268cricket bats, 1264ethical considerations in, 1270–1272golf clubs, 1264–1266hockey sticks, 1270javelins, 1268, 1269for optimum design, 1255–1256for performance enhancement, 1256–

1270running shoes, 1256–1259skis, 1269, 1270softball bats, 1267squash rackets, 1264surfboards, 1267–1268tennis rackets, 1262–1264vaulting poles, 1259–1260watercraft, 1267–1268wheelchairs, athletic, 1264, 1265wind surfing fins, 1267–1268

stages of, 4, 5

1470 INDEX

Materials selection (continued )as step in manufacturing process, 836, 837for telecommunications, 1303–1338

antireflection coatings, 1324cable networks, 1304–1306and chemical vapor deposition, 1334–

1335and crystal growth, 1336data transmission, 1309and deposition methods, 1330, 1334–

1337electro-optical materials, 1323–1324and epitaxy, 1335–1336and evaporation, 1330, 1334–1335and future communication components,

1337–1338isolators incorporating Faraday rotators,

1325microelectromechanical systems, 1325–

1328microwave radio-frequency resonators,

1328–1329multilayer ceramic integrated circuits,

1329–1330for networks, 1304–1308optical fiber, 1318–1323optical filters, 1324optical networks, 1306–1308packaging, 1311–1314photodetectors, 1317, 1318and plating, 1337repeaters, 1329solid-state semiconductor lasers, 1314–

1317for specific components, 1309–1311,

1330–1333and sputtering, 1330switches, 1329for transmission, 1309wireless networks, 1308

for wear resistance, 1275–1281examples of, 1281film thickness, 1280–1281information resources for, 1279–1280and manufacturing process selection,

1278–1279process of, 1276–1278and properties of wear materials, 1276substrate selection, 1280surface modifications, 1280

Materials substitution, 19–21case study in, 21cost–benefit analysis for, 20–21Pugh method for, 19reasons for, 19

MatML, 501–502

Maximum normal stress theory of failure,715–716

Maximum shearing stress theory of failure,714–715

M-Base Engineering � Software, GmbH, 496MBE (molecular beam epitaxy), 1335MCICs, see Multilayer ceramic integrated

circuitsMCVD, see Modified chemical vapor

depositionMDPE (medium density polyethylene), 337Measurement Technology Corp. (Measure

Tech), 621Measurement Technology Inc., 621Mechanical fastening (composites), 1358–

1359Mechanical joints (electronic packaging

applications), 1236–1237Mechanical properties, see specific materialsMechanical properties testing:

of ceramics, 624–638compression (fracture strength), 626compressive creep, 630–631creep, 628–631fatigue, 634–638flexure creep, 629, 630flexure (fracture strength), 627–628fracture strength, 624–625fracture toughness, 632–633hardness, 631–632high strain rate, 633–634tensile creep, 630tension (fracture strength), 625–626

of metals, 520–524, 540of plastics, 545–568

creep properties, 551–553failure analysis, 784fatigue resistance, 564–566flexural properties, 549–551hardness tests, 566–568impact properties, 555–565material characterization tests, 591–609mechanical properties, 547–568standard methods of, 546–547stress relaxation, 552, 554–555tensile tests, 547–548

Mechanical wire, copper and copper alloysfor, 187–188

Mechanochemical synthesis (ceramics), 1118–1120

Medical products, 1195–1221. See alsoBiomedical applications

challenges in developing, 1198–1199disposable, 1195–1196environmental compatibility of, 1198manufacturing processing and materials

properties of, 1213–1219

INDEX 1471

materials selection for, 1195–1221challenges of, 1198–1199and electron beam radiation effect,

1207–1210and gamma radiation effect, 1201–1207and manufacturing processes, 1213–1219polyolefin-based materials, 1210–1213product design, 1199product development factors, 1199–1213product performance issues in, 1219–

1221optical clarity in, 1196, 1198polyolefin-based materials for, 1210–1213product development factors for, 1199–

1213electron beam radiation effect, 1207–

1210gamma radiation effect, 1201–1207manufacturing processes, 1213materials selection, 1199–1213product design, 1199

product performance issues with, 1219–1221

PVC vs. metallocene-based polyolefins for,1211–1213

safety /efficacy of, 1196sterile delivery of, 1198

Medium density polyethylene (MDPE), 337MEDLINE database, 454–455Melt index (melt flow rate) (MFR), 592, 594–

596, 1425–1426Melting:

of aluminum alloys, 92plastics melting point determination, 610,

612of superalloys, 319–323vacuum arc, 226–227

Melt injection molding (plastic parts), 1022–1025

MEMS, see Microelectromechanical systemsMetadata, materials properties data from,

464–465Metals. See also specific materials

adhesion / friction /wear testing for, 540angle bending, 943ASTM standards for testing of, 520bending, 942–944bending strength tests for, 540in biomedical implants, 1174–1177blanking, 935, 945–946brinnelling failure of, 708brittle fracture failure of, 708buckling failure of, 707, 712burnishing, 941casting and molding processes with, 949–

957

centrifugal casting, 951–953die casting, 954–955investment casting, 956–957permanent-mold casting, 953–955plaster-mold casting, 955–956sand casting, 949–952

centrifugal casting, 951–953chemical conversions (for corrosion

protection), 966–967anodizing, 966chemical oxide coatings, 967chromate coatings, 966phosphate coatings, 966

cleaning of, 960–963abrasive barrel finishing, 962abrasive belt finishing, 962blasting, 962buffing, 963electropolishing, 963liquid and vapor baths, 960–962polishing, 963wire brushing, 962

coatings for, 963–966electroplating, 965enamels, 964hot-dip plating, 965lacquers, 964metallizing, 965organic, 964paints, 964temporary corrosion protection, 965–966vacuum metallizing, 965varnishes, 964vitreous enamels, 964–965

coining, 941cold forging, 940cold-roll forming, 944cold rolling, 940cold spinning, 947cold-working processes with, 939–949

bending, 942–944classification of, 939drawing, 947–949shearing, 944–947squeezing processes, 940–941

combined creep and fatigue failure of, 708,712

composites vs., 1348, 1349corrosion failure of, 707, 709, 761–770

biological corrosion, 768–769cavitation corrosion, 768crevice corrosion, 764, 766decarburization, 768direct chemical attack, 762–763erosion corrosion, 767galvanic corrosion, 763–765hydrogen damage, 768

1472 INDEX

Metals (continued )intergranular, 766–767pitting corrosion, 766selective leaching, 767stress corrosion cracking, 769–770

corrosion fatigue failure of, 708, 712corrosion protection of, 963–967

chemical conversions, 966–967coatings, 963–966

corrosion wear failure of, 708, 712creep buckling failure of, 707, 712creep failure of, 707, 711creep rupture in, 740–746

creep under uniaxial state of stress, 743–746

prediction of long-term creep behavior,742–743

creep testing for, 526–528criteria of failure in, 705–706cutoff operations with, 947cutting of, 892–893

economics of, 856–869force for, 946principles of, 848–852

deep drawing, 947–948die casting, 954–955dinking, 947drawing

cold, 947–949hot, 933–936

ductile rupture failure of, 708elastic deformation failure of, 708, 712–

713electrical resistivities / conductivities of, 699in electronic packaging applications, 1241–

1245aluminum and aluminum alloys, 1242–

1244cadmium, 1244chromium, 1244copper and copper alloys, 1244gold, 1244–1245iron and iron alloys, 1242lead, 1245magnesium, 1244nickel, 1244rhodium, 1245silver, 1244–1245tin, 1245titanium, 1245zinc, 1244

embossing, 948environmental considerations in testing of,

540–542extrusion

cold, 940–941hot, 932–933

failure analysis ofcorrosion failure, 761–770creep rupture, 740–746elastic deformation failure, 712–713fatigue failure, 722–740and fracture mechanics /unstable crack

growth, 715–722fretting failure, 746–756stress corrosion failure, 769–770stress rupture, 740–746wear failure, 746–747, 756–761yielding failure, 713–715

failure of, 705–712brinnelling failure, 708brittle fracture failure, 708buckling failure, 707, 712combined creep and fatigue failure, 708,

712corrosion failure, 707, 709corrosion fatigue failure, 708, 712corrosion wear failure, 708, 712creep buckling failure, 707, 712creep failure, 707, 711criteria of failure, 705–706ductile rupture failure, 708elastic deformation failure, 708fatigue failure, 706–709fretting failure, 707, 710–711fretting fatigue failure, 710–711galling and seizure failure, 707, 711impact failure, 707, 710modes of failure, 706–712radiation damage, 707, 712spalling failure, 707, 711–712stress corrosion failure, 708, 712stress rupture failure, 707, 711theories of, 714–716thermal relaxation failure, 707, 711thermal shock failure, 707, 711wear failure, 707, 709–710yielding failure, 708

fatigue failure of, 706–709, 722–740fatigue crack propagation, 735–740fatigue loading and laboratory testing,

723–727nonzero mean stress, 729, 733–735S–N–P curves, 727–233

fatigue testing of, 535–540flanging, 944forging of, 929–932

impression-die drop forging, 931open-die hammer forging, 930–931press forging, 931roll forging, 932swaging, 932upset forging, 931, 932

forming with rubber or fluid pressure, 948

INDEX 1473

and fracture mechanics /unstable crackgrowth, 715–722

fracture toughness testing of, 531–535fretting failure of, 707, 710–711, 746–756fretting fatigue failure of, 710–711galling and seizure failure of, 707, 711hardness testing of, 528–529high-energy-rate forming, 948, 949high strain rate testing of, 540at high temperatures, 297, 311hobbing, 941hot rolling of, 927–929hot-working processes with, 926–938

drawing, 933–936extrusion, 932–933forging, 929–932piercing, 938pipe welding, 937, 938rolling, 927–929spinning, 935, 937

impact failure of, 707, 710impact tests for, 530–531investment casting, 956–957ironing, 948isothermal rolling of, 927–929lancing, 946manufacturing of, 847–923, 925–957, 959–

967abrasive flow machining, 901, 904abrasive jet machining, 901, 904abrasive machining, 894–899bending, 942–944broaching, 886–890casting /molding processes, 949–957centrifugal casting, 951–953chemical conversions, 966–967chemical machining, 919–921cleaning processes, 960–963coatings, 963–966cold-working processes, 939–949cutting off, 892–893die casting, 954–955drawing (cold), 947–949drawing (hot), 933–936drilling machines, 869–877electrical discharge grinding, 916electrical discharge machining, 916, 917electrical discharge sawing, 917–918electrical discharge wire cutting

(traveling wire), 918electrochemical deburring, 908, 909electrochemical discharge grinding, 908,

909electrochemical grinding, 909, 910electrochemical honing, 910, 911electrochemical machining, 910–912electrochemical polishing, 912, 913

electrochemical sharpening, 912, 913electrochemical turning, 913, 914electromechanical machining, 905electron-beam machining, 915–916electropolishing, 921, 922electro-stream, 913, 914extrusion, 932–933finishing, 894, 899forging, 929–932gear manufacturing, 880, 883–884grinding, 894–899hot-working processes, 926–938hydrodynamic machining, 901, 905investment casting, 956–957laser-beam machining, 918, 919laser-beam torch, 919, 920low-stress grinding, 901, 905machining power and cutting forces,

852–855metal-cutting economics, 856–869metal-cutting principles, 848–852milling processes, 877–882nontraditional (nonconventional)

machining processes, 899–923permanent-mold casting, 953–955photochemical machining, 922–923piercing, 938pipe welding, 937, 938planing, 888, 891–892plasma-beam machining, 919–921plaster-mold casting, 955–956powder metallurgy, 959–960rolling, 927–292sand casting, 949–952sawing, 892–893shaped-tube electrolytic machining, 914,

915shaping, 888, 891–892shearing, 892–893, 944–947slotting, 888, 891–892spinning, 935, 937squeezing processes, 940–941surface treatment, 960–967thermally assisted machining, 901, 905,

906thermochemical machining, 923thread cutting and forming, 884–886tool life, 855–857total form machining, 906turning machines, 863–869ultrasonic machining, 907water-jet machining, 907, 908

nibbling, 946notching, 946peening, 941perforating, 946permanent-mold casting, 953–955

1474 INDEX

Metals (continued )piercing, 938, 946pipe welding, 937, 938plaster-mold casting, 955–956powder metallurgy, 959–960radiation damage of, 707, 712riveting, 941roll bending, 943, 944rolling, 927–292sand casting, 949–952seaming, 944shape memory alloys of, 414–415shaving, 946shearing, 944–947shell drawing, 947–948sizing, 940spalling failure of, 707, 711–712spinning, 935, 937squeezing processes, 940–941staking, 941straightening, 944stress corrosion failure of, 708, 712, 769–

770stress relaxation testing of, 528stress rupture failure of, 707, 711, 740–746

creep under uniaxial state of stress, 743–746

prediction of long-term creep behavior,742–743

stretch forming, 947surface treatment of, 960–967

chemical conversions, 966–967cleaning processes, 960–963coatings, 963–966

swaging (cold), 940for telecommunications device packaging,

1312tensile (compressive) test for, 524–526testing of, 519–542

adhesion / friction /wear of surfaces, 540ASTM standards for, 520bending strength, 540creep, 526–528environmental considerations in, 540–

542fatigue, 535–540fracture toughness, 531–535hardness, 528–529high strain rate, 540impact tests, 530–531mechanical, 520–524sensors / instrumentation for, 522–524stress relaxation, 528tensile (compressive) test, 524–526test machine (loading frame) for, 520–

522thermomechanical fatigue, 543

thermal relaxation failure of, 707, 711thermal shock failure of, 707, 711thermomechanical fatigue of, 543thread rolling, 941trimming, 947tube spinning of, 937, 938ultrasonic properties of, 695–696wear failure of, 707, 709–710, 746–747,

756–761yielding failure of, 708, 713–715

Metallizing, 965Metallocene-based polyolefins (medical

products), 1211–1213Metallocene-ultra low density polyethylene

(m-ULDPE) processing, 1216–1218Metal matrix composites (MMCs), 358

materials used in, 371mechanical properties of, 378, 380–384physical properties of, 392, 395–396

Metal–organic chemical vapor deposition(MOCVD), 1314, 1315

Metal products, repair welds in, 844–845Metcut Research Associates, Inc., 863Meter model, generalized, 1002MFR, see Melt index (melt flow rate)Microalloyed (high-strength, low-alloy) steels,

48–50, 52, 57Microelectromechanical systems (MEMS),

652, 1313–1314, 1325–1328Microorganisms, effect on plastics of, 583–

584Microradiography, 646Microtoming (plastics failure analysis), 783–

784Microwave Limb Sounder (MLS) primary

reflector, 1161–1162Microwave processing (ceramics), 1117–1118Microwave radio-frequency (RF) resonators,

1328–1329Midcourse Space Experiment (MSX), 1151–

1152Military specifications:

Mil-Handbook 17, 500MIL-HDBK-5, 460–461for ultrasonic testing, 656

Mill finish, 82Milling processes:

chemical, 921cutting horsepowers for, 854for metals, 877–882

alignment charts for, 880–882feed in, 877, 878material removal rate in, 879–880speed in, 879

tool wear factors in, 855vertical /horizontal milling machines, 878

INDEX 1475

Mirrors, space, 1159–1162all-composite, 1161–1162hybrid composites, 1160–1161

Mish metal, 50Mixed-mode fatigue crack growth, 739–740MLS primary reflector, see Microwave Limb

Sounder primary reflectorMMCs, see Metal matrix compositesMOCVD, see Metal–organic chemical vapor

depositionModeling material /product performance,

materials properties data for, 458Modern Plastic Encyclopedia, 1433Modified chemical vapor deposition (MCVD),

1321, 1322Modified polyphenylene ether, 347Modulus of elasticity:

of aluminum alloys, 90, 92of plastics, 550–551of superalloys, 316

Moisture absorption (electronic packaging),1232

Molding. See also Castingblow molding

of plastic parts, 977–979, 1026–1027of plastics, 958

bulk molding compounds, 1095, 1099coinjection molding (of plastics), 957of composites

contact molding, 1058–1065flow processes during, 1052–1053press molding, 1065–1067resin transfer molding, 1078–1086sheet molding compounds, 1095–1099

compression moldingof medical products made from PP

pellets, 1218, 1219of plastic parts, 983–984, 1026

contact molding (of composites), 1058–1065

expandable-bead molding (of plastics), 957extruding (of plastics), 958flow processes during, 1052–1053of forged-plastic parts, 958injection molding

of medical products made from PPpellets, 1217–1219

of plastic parts, 986–989of plastics, 957

of medical products made from PP pelletscompression molding, 1218, 1219injection molding, 1217–1219

melt injection molding (of plastic parts),1022–1025

of metals, see Casting, of metalsof plastic parts

blow molding, 977–979, 1026–1027

compression molding, 983–984, 1026injection molding, 986–989melt injection molding, 1022–1025reaction injection molding, 990–991,

1025rotational molding, 980–982, 997, 1032transfer molding, 984, 985, 1025

of plastics, 957–958blow molding, 958coinjection molding, 957expandable-bead molding, 957extruding, 958forged-plastic parts, 958injection molding, 957reinforced-plastic molding, 958rotomolding, 957thermoforming, 958

PP compression-molding processing effect,1218, 1219

PP injection-molding processing effect,1217–1219

press molding (of composites), 1065–1067reaction injection molding (of plastic parts),

990–991, 1025of reinforced-plastics, 958resin transfer molding (of composites),

1078–1086rotational molding (of plastic parts), 980–

982, 997, 1032rotomolding (of plastics), 957sheet molding compounds, 1095–1099thermoforming (of plastics), 958transfer molding (of plastic parts), 984,

985, 1025Moldings, mechanical properties of, 1045Molecular beam epitaxy (MBE), 1335Molybdenum:

in alloy steels, 48in stainless steels, 69

Momentum:sources of (plastics manufacturing), 996–

997technological, 1255

Monarch Analytical Laboratories, Inc., 621Monomer precursor thermoplastics, 1106–

1107MSC.Enterprise Mvision, 494–495MSC.Mvision, 494MSC.Software Corporation, 494MSX, see Midcourse Space Experimentm-ULDPE processing, see Metallocene-ultra

low density polyehtylene processingMultiaxial fracture criteria (ceramics):

global, 799local, 799–803

Multicavity dies, 955

1476 INDEX

Multilayer ceramic integrated circuits(MCICs), 1329–1330

Multiphase piezoelectric composites, 405Music wire, 64

Nanotechnology, in ceramics processing,1120–1122

National Electrical Manufacturers Association(NEMA), 617

National Electrical Safety Codes, 617National Engineering Laboratory, 617National Fire Protection Association (NFPA),

617–618National Institute of Standards and

Technology (NIST), 471–472, 617National Measurement Laboratory, 617National Sanitation Foundation (NSF), 618National Science Foundation (NSF), 1419NDE, see Nondestructive inspection /

evaluationNDI, see Nondestructive inspection /

evaluationNecking, 714NEMA (National Electrical Manufacturers

Association), 617Neointima formation (with blood-contacting

biomaterials), 1183–1184Networks, telecommunications, 1304–1308

cable, 1304–1306optical fiber, 1306–1308wireless, 1308

Neutron radiography, 666–667Newtonian fluid, 596Newton’s law, 1000Next Generation Space Telescope Mirror

System Demonstrator (NGST NMSD),1160

NFPA, see National Fire ProtectionAssociation

NGST NMSD (Next Generation SpaceTelescope Mirror System Demonstrator),1160

Nibbling (metals), 946Nickel, 236

as alloying element, 236in alloy steels, 47–48and corrosion of magnesium alloys, 278,

279in electronic packaging applications, 1244stainless steel alloys using, 80–82in stainless steels, 69

Nickel alloys, 235–258chemical composition of, 238–239classification of, 236–237compositional modifications producing

special properties in, 243and corrosion resistance, 248–252

deformation resistance of, 252–253fabrication of, 252–255heat treatment of, 254–256machining of, 257mechanical properties of, 240nickel–chromium–iron alloys, 238, 240–

244nickel–chromium–molybdenum alloys,

239–241, 246–247nickel–copper alloys, 237, 238, 240–242nickel–iron alloys, 238, 240, 246nickel–iron–chromium alloys, 238, 240,

241, 244–245nickel powder alloys

dispersion strengthened, 239–241, 247mechanically alloyed, 239–241, 247–248

rupture stress of, 241strain hardening of, 253–255welding of, 256–257

Nickel-base steels, stainless steels vs., 67Nickel-base superalloys, 294–295, 302, 304–

310, 317Nickel–chromium alloys, 251Nickel–chromium–iron alloys, 251Nickel–chromium–molybdenum–iron alloys,

237Nickel–copper alloys, 236, 249Nickel–iron alloys, 236, 249Nickel–silvers, 141Niobium (columbium), in alloy steels, 49NIST, see National Institute of Standards and

TechnologyNitrogen:

in alloy steels, 50interstitial (free), 49in stainless steels, 77, 78in titanium and titanium alloys, 215

NLO (nonlinear optical) phenomena, 1323Noncrimp fabrics, 1041, 1042Nondestructive inspection /evaluation (NDI /

NDE), 649–694, 650–652of ceramics, 644–646eddy current methods for, 653, 672–678

impedance plane, 673–676lift-off of inspection coil from specimen,

676–678and skin effect, 673

of flaws in brittle materials, 813information on methods for, 651–652liquid penetrants for, 652–656magnetic particle method of, 653, 680–682

continuous vs. noncontinuous fields in,681–682

demagnetizing of part after, 682–683inspection process with, 682magnetizing field in, 680–681

of plastics, 784

INDEX 1477

quantitative, 689–691radiography for, 653, 663–672

and attenuation of X-radiation, 667, 668computed tomography, 671–672film-based, 668–669and generation /absorption of X-

radiation, 664–666neutron radiography, 666–667penetrameters used in, 669–670real-time, 670–671

and selection of materials for inspectability,683–693

confidence in consistent properties, 683general process control, 693probability of detection assessment, 691–

693quantified crack detection capabilities,

686–690structural integrity, 683–686

thermal methods of, 653, 678–680infrared cameras, 679thermal paints, 679thermal testing, 679–680

ultrasonic methods of, 653, 656–663inspection process, 662–663and reflection / transmission of sound,

657–660and refraction of sound, 660–662and sound wave characteristics, 657

Nonlinear optical (NLO) phenomena, 1323Nonresulfurized carbon steels, 53–54Nonzero mean cyclic stresses, 729Normalizing (steels), 51Norton’s law, 806Nose radiuses, 861Notching:

of metals, 946of titanium alloys, 223

Notch toughness, 46, 53NSF (National Sanitation Foundation), 618NSF (National Science Foundation), 1419Numeric databases, materials properties data

from, 464Nylon (polyamides), 342, 343, 1186, 1425

Oblique cutting, 848, 850Octahedral shear stress theory, see Distortion

energy theory of failureOF coppers, see Oxygen-free coppersOIT, see Oxidative induction timeOlympics, 1257–1260, 1262, 1269, 1271Online encyclopedias, 448Open-die hammer forging (metals), 930–931Operating temperature ranges (electronic

packaging), 1227–1228Optical benches (spacecraft), 1157–1159Optical clarity:

in medical products, 1196, 1198of polymers, 1425, 1427

Optical cross connect MEMS mirrors, 1327–1328

Optical fibers, 1318–1323device fabrication with, 1322–1323fabrication of, 1320–1322in fiber-optic cables, 1322, 1323glass, 1319–1320plastic, 1320plastic-clad, 1320

Optical fiber networks, 1306–1308Optical filters, 1324Optical MEMS, 1314Optimum design, sports equipment material

selection for, 1255–1256Optoelectronics, 1323Organic coatings (metals), 964Organic materials, electro-optical, 1324Orthogonal cutting, 848, 850Orthopedic biomaterials, 1166–1180

biocompatibility of, 1174–1178corrosion of, 1174–1177functioning of, 1167–1173joint motion with, 1171–1173leaching /absorption with, 1177–1178load support with, 1167–1171material selection for, 1178–1180wear debris from, 1178

Outdoor weathering tests (plastics), 587–589Outgassing, vacuum-induced, 1142Outside vapor-phase oxidation (OVPO), 1321Overload proof test, 812–813OVPO (outside vapor-phase oxidation), 1321Oxidation, 251

of carbon /carbon composites, 386of magnesium and magnesium alloys, 268–

274at ambient temperature, 268–270at high temperature, 270–274

outside vapor-phase, 1321Oxidative induction time (OIT), 1201–1210Oxide tool inserts, 860Oxidizing acids, 70–71Oxygen-free (OF) coppers, 142–143Oxygen (in titanium and titanium alloys), 215

Packaging. See also Electronic packagingapplications

aluminum alloys in, 133of lasers and amplifiers, 1313MEMS, 1313–1314of telecommunications devices, 1311–1314

PAI, see PolyamideimidesPaint(s):

for magnesium and magnesium alloys, 287,288

1478 INDEX

Paint(s) (continued )for metals, 964as radiation heat transfer impediment, 1236thermal, 679

PAN fibers, see Polyacrilonitrile-based fibersParalympics, 1258–1259Parkerizing, 966Particle-reinforced MMCs, 382–383, 395–396Particulate composites, 1038PASSC (polythionic acid stress-corrosion

cracking), 73Passive electronics, ceramic materials in,

430–431Paste adhesives, 1361Patenting process (music wire), 64PBM, see Plasma-beam machiningPBT (poly(butylene terephthalate)), 342PC, see PolycarbonatesPCM, see Photochemical machiningPDES, see Product Data Exchange

SpecificationPDM systems, see Product data management

systemsPE, see PolyethylenePearlite, 36–38, 51Peening (metals), 941PEI, see PolyetherimidesPendulum impact test, 530–531Penetrameters, 669–670Percent reduction in area, carbon and, 45, 46Perforating (metals), 946Performance:

of autoclave-processes prepreg, 1076of composites in repair and retrofit

infrastructure systems, 1398–1399materials properties data for modeling, 458measurement of, in design problem, 997–

998of medical products, 1219–1221requirements analysis

for cost, 6for functional requirements, 4, 6for processability, 6for reliability, 6for resistance to service conditions, 6–7

sports equipment materials for enhancing,1256–1270

Performance index (in weighted-propertiesmethod), 12–13

Permanent-mold casting:of copper and copper alloys, 198of magnesium and magnesium alloys, 261,

262of metals, 953–955

Permeability, design of compositereinforcements to enhance, 1053–1054

PET, see Polyethylene terephthalate

Petroleum industry, aluminum alloys in, 133PFRP composites, see Pultruded fiber-

reinforced polymeric compositesPhenolic resins, 352Phosphate coatings (metals), 966Phosphor bronzes, 150Phosphorus (in alloy steels), 47Photochemical machining (PCM), 922–923Photodetectors, 1317, 1318Photoelastic coating technique (plastics), 780–

781Photoelastic stress analysis (plastics), 780–

781pH-sensitive materials, 411–412Pickling process, 961Piercing (metals), 938, 946Piezoceramics, 431–432Piezoelectric materials, 403–407, 1323Pig iron, 28Pilling–Bedworth ratio, 168–169, 1271Pin photodiodes, 1317Pipe welding (metals), 937, 938Pitting corrosion, 251–252, 709

in magnesium alloys, 275–276of metals, 766resistance of stainless steels to, 74, 75

Plain-carbon steels, see Carbon steelsPlane-strain fracture toughness, 720–722Planing (of metals), 854, 888, 891–892Plasma-beam machining (PBM), 919–921Plaster-mold casting (metals), 955–956Plastics, 335–354. See also Polymers

abrasion resistance testing of, 564additives in, 1429–1430blow molding, 958, 977–979, 1026–1027calendering, 974–975, 1018–1019casting, 982, 983, 995, 1032–1033centrifugal-based process, rotational

molding as, 997chemical failure of, 778chemical / thermal analysis for polymer

identification, 613classifications of, 336coating with, 980–981coinjection molding, 957commodity thermoplastics, 336–341

ABS, 339impact polystyrene (IPS), 338polyethylene (PE), 336–337poly(ethylene terephthalate) (PET), 341poly(methyl methacrylate) (PMMA), 341polypropylene (PP), 337, 338polystyrene (PS), 337, 338polyvinyl chloride (PVC), 339–340poly(vinylidene chloride) (PVDC), 340–

341

INDEX 1479

styrene /acrylonitrile copolymer (SAN),338, 339

compression molding, 983–984, 1026continuous manufacturing processes, 994,

1011–1022calendering, 1018–1019extension dominated, 1019–1022extrusion, 1011–1016fiber spinning, 1019–1020film blowing, 1020–1022shear dominated, 1011–1019wire coating, 1016–1018

copper wire test for, 613cyclic manufacturing processes, 994, 1022–

1033blow molding, 1026–1027casting, 1032–1033compression molding, 1026extension dominated, 1026–1032melt injection molding, 1022–1025quiescent, 1032–1033reaction injection molding, 1025rotational molding, 1032shear dominated, 1022–1025thermoforming, 1027–1032transfer molding, 1025

definition of, 1429design of

and design problem, 997–998and design solution algorithm, 998–1007as failure factor, 776, 777for plastic parts, 1431–1435

differential scanning calorimetry for, 602–604

drag-flow manufacturing processes, 996elastomers, 354, 1424

general-purpose, 350, 354specialty, 351, 354thermal behavior of, 1426

electrical properties tests for, 575–582arc resistance, 578–582dielectric constant and dissipation factor,

576–577dielectric strength, 575–576electrical resistance tests, 577–578

in electronic packaging applications, 1245–1249

elastomers, 1249finishes for, 1238thermoplastics, 1246, 1247thermosets, 1247–1249

engineering thermoplastics, 342–348modified polyphenylene ether, 347polyacetals, 343, 344polyamides (nylon), 342, 343poly(butylene terephthalate) (PBT), 342polycarbonates, 345–346

polyesters, 342polyimides, 347, 348polyphenylene sulfide, 344, 345polysulfone, 346–347

environmental failure of, 778expandable-bead molding, 957extensional-flow-dominated manufacturing

processes, 995, 1019–1022, 1026–1032

blow molding, 1026–1027compression molding, 1026fiber spinning, 1019–1020film blowing, 1020–1022rotational molding, 1032thermoforming, 1027–1032

extrusion, 958, 969–972, 1001–1016extrusion covering, 972–973failure analysis with, 778–784

heat reversion technique for, 782–783materials identification analysis, 779–780mechanical testing for, 784microtoming technique for, 783–784nondestructive testing techniques for, 784stress analysis, 780–783thermal analysis for, 784by visual examination, 778–779

failure of, 775–778chemical, 778design as factor in, 776, 777environmental, 778material selection as factor in, 775–776mechanical, 776, 778process as factor in, 776service conditions as factor in, 776thermal, 778

fiber spinning, 1019–1020film blowing, 973–974, 1020–1022fluorinated thermoplastics, 348–349, 352

fluorinated ethylene–propylene (FEP),349

poly(chlorotrifluoroethylene) (CTFE),349

poly(ethylene chlorotrifluoroethylene)(ECTFE), 349, 352

poly(tetrafluoroethylene) (PTFE), 348–349

poly(vinyl fluoride), 352polyvinylidene fluoride (PVDF), 349

forged-plastic parts, 958gel permeation chromatography for, 599–

601gravitational-influenced manufacturing

processes, 997identification analysis of, 607–608, 610–

613chemical / thermal analysis for polymer

identification, 613

1480 INDEX

Plastics (continued )copper wire test, 613melting point determination, 610, 612solubility test, 612specific gravity test, 613

injection molding, 957, 986–989joining techniques for, 1431manufacturing processes for, 969–991,

993–1033blow molding, 977–979, 1026–1027calendering, 974–975, 1018–1019casting, 982, 983, 995, 1032–1033centrifugal-based process, rotational

molding as, 997classification of processes, 993–997coating, 980–981compression molding, 983–984, 1026continuous processes, 994, 1011–1022cyclic processes, 994, 1022–1033design problem in, 997–998design solution algorithm in, 998–1007drag-flow processes, 996extensional-flow-dominated processes,

995, 1019–1022, 1026–1032extrusion, 969–972, 1001–1016extrusion covering, 972–973fiber spinning, 1019–1020film blowing, 973–974, 1020–1022gravitational-influenced processes, 997injection molding, 986–989machining, 893melt injection molding, 1022–1025pressure effects in, 1008–1009pressure-flow processes, 996quiescent process, casting as, 995, 1032–

1033reaction injection molding, 990–991,

1025rotational molding, 980–982, 997, 1032shear-flow-dominated processes, 994–

995, 1011–1019, 1022–1025sheet thermoforming, 975–977sources of momentum in, 996–997steady state processes, 994temperature effects in, 1007–1008thermoforming, 1027–1032transfer molding, 984, 985, 1025unsteady state processes, 994wire coating, 1016–1018

material characterization tests for, 591–609differential scanning calorimetry, 602–

604gel permeation chromatography, 599–601melt index test, 592, 594–596rheology, 595–599spectroscopy, 607–609thermal analysis techniques, 602–609

thermogravimetric analysis, 604–605thermomechanical analysis, 605–606viscosity tests, 599

material selection as failure factor with,775–776

materials selection for, 1423–1431additives in, 1429–1430polymers in, 1424–1429reinforced plastics, 1430terms /concepts related to, 1424–1430

mechanical failure of, 776, 778mechanical properties tests for

creep properties, 551–553fatigue resistance, 564–566flexural properties, 549–551hardness tests, 566–568impact properties, 555–565material characterization tests, 591–609mechanical properties, 547–568standard methods of, 546–547stress relaxation, 552, 554–555tensile tests, 547–548

melt index test for, 592, 594–596melting point determination for, 610, 612melt injection molding, 1022–1025molding processes for, 957–958pressure effects in, 1008–1009pressure-flow manufacturing processes, 996process as failure factor with, 776quiescent process, casting as, 995, 1032–

1033reaction injection molding, 990–991, 1025reinforced-plastic molding, 958reinforced plastics, 1430rheology for, 595–599rotational molding, 980–982, 997, 1032rotomolding, 957service conditions as failure factor with,

776shear-flow-dominated manufacturing

processes, 994–995, 1011–1019,1022–1025

calendering, 1018–1019extrusion, 1011–1016melt injection molding, 1022–1025reaction injection molding, 1025transfer molding, 1025wire coating, 1016–1018

sheet thermoforming, 975–977solubility test for, 612sources of momentum in, 996–997specific gravity test for, 613spectroscopy for, 607–609steady state manufacturing processes, 994for telecommunications device packaging,

1312–1313temperature effects in, 1007–1008

INDEX 1481

testing of, 545–589, 591–609accelerated weathering tests, 584–587arc resistance, 578–582brittleness temperature, 574, 575chemical / thermal analysis for polymer

identification, 613copper wire test, 613creep properties, 551–553dielectric constant and dissipation factor,

576–577dielectric strength, 575–576differential scanning calorimetry, 602–

604electrical resistance tests, 577–578elevated temperature performance tests,

568–574fatigue resistance, 564–566flexural properties, 549–551gel permeation chromatography, 599–601hardness tests, 566–568impact properties, 555–564material characterization tests, 591–609mechanical properties, 547–568melt index test, 592, 594–596melting point determination, 610, 612outdoor weathering, 587–589rheology, 595–599solubility test, 612specific gravity test, 613spectroscopy, 607–609standard methods of, 546–547stress relaxation, 552, 554–555tensile tests, 547–548thermal analysis techniques, 602–609thermogravimetric analysis, 604–605thermomechanical analysis, 605–606viscosity tests, 599

thermal analysis techniques for, 602–609thermal failure of, 778thermal properties tests for, 568–575

brittleness temperature, 574, 575elevated temperature performance tests,

568–574thermoforming, 958, 1027–1032thermogravimetric analysis for, 604–605thermomechanical analysis for, 605–606thermoplastics, 1424

commodity, 336–341engineering, 342–348fluorinated, 348–349, 352morphology of, 1427thermal behavior of, 1426

thermosets, 352–354alkyd resins, 353amino resins, 354diallyl phthalate (DAP), 353–354epoxy resins, 352–353

phenolic resins, 352unsaturated polyesters, 353

thermosetting resins, 1424glass transition temperature of, 1428thermal behavior of, 1426

transfer molding, 984, 985, 1025unsteady state manufacturing processes,

994viscosity tests for, 599weathering properties tests for, 582–589

accelerated weathering tests, 584–587outdoor weathering, 587–589

wire coating with, 1016–1018Plastic-clad optical fiber, 1320Plasticized PVC, 340Plasticizers, 1430Plastic optical fiber, 1320Plastic region, 253Plastics for Engineers (Domininghaus), 1433Plastics Technology Laboratories, Inc., 621Plastic strains, 713Plastic zone, 739Plunger transfer molding, 985P/M, see Powder metallurgyPMCs, see Polymer matrix compositesPMMA (poly(methyl methacrylate)), 341POD assessment, see Probability of detection

assessmentPoisson’s ratio, 376Pole vaulting, 1259–1260Polishing:

electrochemical, 912, 913electropolishing, 921, 922of metals, 963

Polyacetals, 343, 344Polyacrilonitrile-based (PAN) fibers, 361, 363,

366–367, 1134Polyamideimides (PAI), 347, 348Polyamides (nylon), 342, 343Poly(butylene terephthalate) (PBT), 342Polycarbonate /ABS alloys, 346Polycarbonates (PC), 345–346Poly(chlorotrifluoroethylene) (CTFE), 349Polycrystalline ceramics, see Transparent

ceramic materialsPolycrystalline diamonds, 861Polyesters, 342, 353, 1425Polyetherimides (PEI), 347, 348Poly(ethylene chlorotrifluoroethylene)

(ECTFE), 349, 352Polyethylene (PE), 336–337, 1424, 1425Polyethylene terephthalate (PET), 341, 1425Polyhedron Laboratories, Inc., 621Polyimides, 347, 348, 404–405, 1425Polymers, 1424–1429. See also Plastics

addition polymers, 1425amorphous, 1427

1482 INDEX

Polymers (continued )and Carothers equation, 1429chemical / thermal analysis for identification

of, 613crystalline, 1427definition of, 1424elastomers, 1424, 1426future of, 416–417glass transition /glass transition temperature

of, 1427–1429internal structure of, 1427liquid-crystal, 1427molecular weight /distributions of, 1425–

1426nylons, 1425piezoelectric, 404–407polyesters, 1425polyethylenes, 1424, 1425polyethylene terephthalate, 1425polyimides, 1425polymerization reactions, 1424–1425semicrystalline, 1427smart, 412–413, 415–416thermal analyses of, 1426–1427thermal behavior of, 1426thermoplastics, 1424, 1426, 1427thermosetting resins, 1424, 1426, 1428transparancy /opaqueness of, 1427ultrasonic properties of, 697–698viscoelastic regions of, 1427in wear applications, 1281

Polymerization process, 591–592Polymerization reactions, 1424–1425Polymer matrix composites (PMCs), 358,

1135–1136commingled thermoplastic matrix

composites, 1103–1106cure of thermosetting resins, 1049–1051glass mat thermoplastics, 1099–1101high-performance thermoplastic matrix

composites, 1101–1103injection-molded short-fiber-reinforced

thermoplastics, 1107–1110matrix materials used in, 368, 371mechanical properties of, 375–380physical properties of, 392–394SRIM of monomer precursor

thermoplastics, 1106–1107thermoplastic matrix systems, 1050, 1051thermoplastic resins in, 370, 371thermosetting resins in, 368, 370

Polymer melts:constitutive equations for, 1000–1007P–T–V relationships for, 1008–1009rheological properties of, 999–1000

Polymer morphology, 1427

Polymer precursors (ceramics manufacturing),1123

Polymer Solutions Inc., 622Poly(methyl methacrylate) (PMMA), 341Polyolefin-based materials:

for medical products, 1210–1213metallocene, 1211–1213, 1216–1218

Polyphenylene ether, modified, 347Polyphenylene sulfide (PPS), 344, 345Polypropylene (PP), 337, 338Polystyrene (PS), 337, 338Polysulfone, 346–347Poly(tetrafluoroethylene) (PTFE), 348–349Polythionic acid stress-corrosion cracking

(PASSC), 73Polyurethane-based materials (for

encapsulation), 1240Polyvinyl chloride (PVC), 339–340

for medical products, 1211–1213, 1221metallocene-based polyolefins vs., 1211–

1213oxidative induction time of, 1201–1210yellowness index of, 1201, 1204–1206

Poly(vinyl fluoride), 352Poly(vinylidene chloride) (PVDC), 340–341Polyvinylidene fluoride (PVDF), 349Porosity (cast superalloys), 324Position-sensitive electronic assemblies,

1238–1239Pot transfer molding, 985Powder metallurgy (P /M), 959–960

and nickel alloys, 237and superalloys, 324–325in titanium alloy processing, 225

Power cable, 142PP, see PolypropylenePPS, see Polyphenylene sulfidePrecipitation hardening (stainless steels), 62Precipitation stainless steels, 49Precision-casting, 956Prefabricated composite laminates or shells,

1385, 1386Preimpregnated (prepreg) warp sheet, 1043

autoclave processing of, 1067–1076for construction repair applications, 1385processing options for, 1076

Prepreg, see Preimpregnated warp sheetPress forging (metals), 931Pressure:

in composite materials manufacturing,1048–1049

in plastics manufacturing, 1008–1009Pressure-flow manufacturing processes

(plastics), 996Prime surface, 1054Principle of conversion (wear control), 761Principle of diversion (wear control), 761

INDEX 1483

Principle of protective layers (wear control),761

Probabilistic design, 422Probability of detection (POD) assessment,

691–693ProceedingsFirst database, 456Processability, performance requirement

analysis for, 6Process annealing (recrystallization

annealing), 51Processing, see ManufacturingProcessing, intelligent, 1115Procurement of materials, 505–511

cost determination in, 509at General Electric, 510–511information sources

for purchasing, 507, 509for standards and specifications, 511–513

Producibility list (composites), 1363–1365Products. See also specific products

composites used in, 1344–1347ideal, 831medical, 1199–1213, 1219–1221product development team for, 1349–1350telecommunications, future of, 1337–1338

Product Data Exchange Specification (PDES),499–500

Product data management (PDM) systems,477–478

Proeutectoid ferrite, 36–37Professional organizations:

National Electrical ManufacturersAssociation, 617

National Fire Protection Association, 617–618

National Sanitation Foundation, 618Society of Plastics Engineers, 618–619Society of Plastics Industry, 619

Project team (database design /creation), 485Proof-test ratio, 812–813Properties of materials, see Materials

properties; specific materialsProtective layers, principle of (wear control),

761PS, see PolystyrenePTFE, see Poly(tetrafluoroethylene)P–T–V relationships (for polymer melts),

1008–1009Pugh decision matrix, 19Pultruded fiber-reinforced polymeric (PFRP)

composites, 1401–1416bridge applications, 1408, 1410–1416buildings applications, 1406, 1408–1410connections with, 1404–1405research and development of, 1402–1407

Pultrusion (composites), 1090–1095Punching, tool steels for, 62

Purchasing, see ProcurementPVC, see Polyvinyl chloridePVC copolymers, 340PVDC, see Poly(vinylidene chloride)PVDF (polyvinylidene fluoride), 349PZT, see Lead zirconate titanates

Q-Panel Lab Products, 622Quality assurance /control:

for composite applications, 1365–1367for databases /user interfaces, 492–493materials properties data for, 462

Quality (of information resources), 452–453Quantitative materials selection methods, 3–4

for comparing alternative solutions, 11–13digital logic method for, 11–13performance index in, 12–13weighted-properties method for, 11–13

for initial screening, 7–11Ashby’s material selection charts, 9, 10cost per unit property method, 8, 9Dargie’s method, 9–11limits on material properties, 7–8

Quasi-isotropic laminates, 376, 377, 379Quenching (steel), 50–52

Racetracking, 1082Rackets:

squash, 1264tennis, 1262–1264

Radiation:damage to metals by, 707, 712electron beam radiation effect, 1207–1210gamma radiation effect, 1201–1207

Radiation heat transfer, 1235–1236Radio frequency interface (RFI) shielding,

579–581Radiography testing (RT), 653, 663–672

and attenuation of X-radiation, 667, 668of ceramics, 646computed tomography, 671–672film-based, 668–669and generation /absorption of X-radiation,

664–666neutron radiography, 666–667penetrameters used in, 669–670real-time, 670–671

Rail and rail products:aluminum alloys in, 133specifications for, 53

Rake angles, 861Rapid solidification (RS) (magnesium alloys),

273, 285–287Rare earth elements (RE):

in alloy steels, 50in magnesium alloys, 261, 272–274, 282

Rattling, 962

1484 INDEX

Rayleigh angle, 660, 661RCF, see Rolling contact fatigueRE, see Rare earth elementsReaction bonding (ceramics), 1120Reaction (reactive) injection molding (RIM):

of composites, 1079of plastics, 990–991, 1025

Real-time radiography, 670–671Reciprocating power hacksaws, 892Recrystallization annealing (steels), 51Recyclability (aluminum alloys), 91Recycling, 513–515Red hardness, 859Reducing acids, 70Refining (superalloys), 319–323Reflectors, space, 1159–1162Refractory glass packages, 1312Reinforced concrete /masonry structure repair /

retrofit, 1388–1398axial load capacity upgrade, 1393–1398flexural capacity upgrade (concrete

members), 1388–1391minimum bond strength requirements, 1391shear and torsional strengths upgrade,

1392–1393Reinforced plastics, 958, 1430Reinforced reaction injection molding

(RRIM), 1079Reinforcements (in composite materials), 358,

359, 364–367, 375, 1134–1135. See alsospecific composite types

alumina-based fibers, 367aramid fibers, 367, 1134boron fibers, 367carbon (graphite) fibers, 366–367, 1134fiber–powder combinations, 1106fibers, 364–367glass fibers, 365, 366high-density polyethylene fibers, 367for press molding, 1065–1067silicon carbide-based fibers, 367

Reliability. See also Failure analysisof brittle materials, 809–810performance requirement analysis for, 6

Relief angles, 861Remotely queried embedded microsensors

(RQEM), 1147Repair and retrofit infrastructure systems,

1371–1399automated machine lamination, 1385, 1387design considerations for (FRP

composites), 1385, 1387–1388design philosophy for (FRP composites),

1388–1398durability and long-term performance of,

1398–1399

prefabricated composite laminates or shells,1385, 1386

preimpregnated (prepreg) compositesystems, 1385

reinforced concrete and masonry structures,1388–1398

wet /hand lay-up method, 1375–1376,1379, 1381–1385

Repeaters (regenerators), 1329Rephosphorized steels, 47, 53, 54Residual elements (alloy steels), 50Resins:

alkyd, 353amino, 354for contact molding, 1059–1061epoxy, 352–353glass transition temperature of, 1428phenolic, 352for press molding, 1065–1067styrene emissions from, 1061thermosetting, 1424

cure of, 1049–1051thermal behavior of, 1426

Resin film infiltration, 1077–1078Resin transfer molding (RTM), 1078–1086

high-pressure, 1084low-pressure, ambient cure, 1083–1084manufacture of preforms for, 1084–1086

Resistance to service conditions, performancerequirement analysis for, 6–7

Resonators, RF, 1328–1329bulk, 1328, 1329thin-film, 1328–1329

Resulfurized steels, 53, 54Retained austenite, 44Retirement for cause (RFC), 688, 689Retrofits, see Repair and retrofit infrastructure

systemsRFC, see Retirement for causeRFI shielding, see Radio frequency interface

shieldingRF resonators, see Microwave radio-frequency

resonatorsRheology (plastics), 595–599Rhodium (electronic packaging), 1245Rigid deployable space structures, 1152Rigid PVC, 339RIM, see Reaction (reactive) injection

moldingRiveting (metals), 941Rocketdyne Division of Boeing North

America, 477Rockwell Hardness test, 567, 1229Rods, copper, 185Roll bending (metals), 943, 944Roller leveling, 944Roll forging (metals), 932

INDEX 1485

Rolling, 927–929, 962Rolling contact fatigue (RCF), 424, 425Roll straightening, 944Rotational molding (plastics), 980–982, 997,

1032Rotational rheometer, 597Rotomolding (plastics), 957Roughness (diamond films), 1295–1296RQEM (remotely queried embedded

microsensors), 1147RRIM (reinforced reaction injection molding),

1079RS, see Rapid solidificationRT, see Radiography testingRTM, see Resin transfer moldingRunning shoes, 1256–1259Rupture strengths (superalloys), 308–310, 317Rupture stress (nickel and nickel alloys), 241Rutherford Research Corp., 622

SAE, see Society of Automotive EngineersSAE/AISI numbering system, 52–64SAE Materials Standards Manual, 53Safe-life design, 684, 687Safety (medical products), 1196Salem Avenue Bridge (Ohio), 1410, 1411SAN, see Styrene /acrylonitrile copolymerSand casting:

of magnesium and magnesium alloys, 261,262

of metals, 949–952Sand molds, 950Sandwich panels (composite), 1353, 1357–

1358Sawing:

electrical discharge, 917–918of metals, 892–893

Scatter of lifetime (ceramics), 797, 798Scatter of strength (ceramics), 794–797SCC, see Stress corrosion crackingSchuyler Heim steel lift bridge (California),

1412–1414Science Citation Index, 455–456Scientific Process and Research, Inc., 622SCRIMP, see Seeman composites infusion

molding processSealing adhesives, 1251Seaming (metals), 944Secondary manufacturing processes, 838Seeman composites infusion molding process

(SCRIMP), 1080, 1081Seismic repair and rehabilitation, 1370, 1371,

1373–1380Seizure failure, 707, 711, 757Selecting optimum solution (as materials

selection step), 13, 15–19

Selection of materials, see Materials selection;specific materials

Selective leaching, 709, 767Selenium (in alloy steels), 50Self-propagating high-temperature synthesis

(SHS), 1118Semicrystalline polymers, 336, 1427Service conditions:

as factor in failureof ceramics, 803–807of plastics, 776

resistance to, 6–7SFF, see Solid freeform fabricationSFTRPs, see Short-fiber-reinforced

thermoplasticsSGML (standard generalized markup

language), 501SGS U.S. Testing Co., Inc., 622Shannon’s equation, 1304Shapes, copper, 185Shaped-tube electrolytic machining (STEMT),

914, 915Shape memory alloys, 414–415Shaping (of metals), 854, 888, 891–892Sharpening, electrochemical, 912, 913Shaving (metals), 946Shear, 595Shear angle (metal cutting), 851Shear-flow-dominated manufacturing

processes (for plastic parts), 994–995,1011–1019, 1022–1025

calendering, 1018–1019extrusion, 1011–1016melt injection molding, 1022–1025reaction injection molding, 1025transfer molding, 1025wire coating, 1016–1018

Shear flows, 994Shearing:

maximum shearing stress theory, 714–715of metals, 892–893, 944–947tool steels for, 62

Shear rate, 596, 994Shear strength:

of high-nickel alloys, 254, 255in reinforced concrete /masonry structure

repair / retrofit, 1392–1393Sheet molding compound (SMC), 353, 373,

374, 1044, 1095–1099Sheet thermoforming, see ThermoformingShell drawing (metals), 947–948Shielding:

electromagnetic, 1228, 1234–1235electromagnetic interference, 579–582,

1140–1141in electronic packaging applications

electromagnetic, 1228

1486 INDEX

Shielding (continued )electrostatic, 1228–1229magnetic, 1229

electrostatic, 1228–1229, 1234–1235magnetic, 1229, 1234–1235stress (in total hip arthroplasty), 1169–1171

Shielding gases (for carbon vs. stainlesssteels), 83–84

Ships, specifications for, 53Short discontinuous fibers (in composites),

1038Short-fiber-reinforced thermoplastics

(SFRTPs), 1107–1110Shot peening, 962SHPB testing, see Split Hopkinson pressure

bar testingSHS (self-propagating high-temperature

synthesis), 1118Shushing compounds, 965SiC/SiC, see Silicon carbide fiber-reinforced

silicon carbideSilicon:

in alloy steels, 47in magnesium alloys, 283in materials for encapsulation, 1240in stainless steels, 69–70

Silicon carbide, fibers based on (in compositematerials), 367

Silicon carbide abrasives, 894Silicon carbide fiber-reinforced silicon carbide

(SiC/SiC), 385, 397Silicon carbide particle-reinforced aluminum,

382, 383Silicon carbide particle-reinforced MMCs,

395Silver (in electronic packaging), 1244–1245Simple shear, 994Single-crystal ceramics, see Transparent

ceramic materialsSingle-crystal diamonds, 860–861Single screw extruders, 1011–1015Size effect (composite materials), 365, 373Sizing (metals), 940Skeist Inc., 622Skis, 1269, 1270Skin effect, 673Sleeve bearings, cast copper / alloys in, 199Slotting (metals), 888, 891–892Small-scale yielding, 718Smart catalysts, 414Smart (intelligent) gels (hydrogels), 413–414Smart materials, 401–436

definition of, 401elastorestrictive materials, 409electrorheological materials, 409–410electrostrictive materials, 407–408features of, 401–402

fullerenes, 415light-sensitive materials, 412magnetic gels, 415magnetorestrictive materials, 408–409magnetorheological materials, 410–411pH-sensitive materials, 411–412piezoelectric materials, 403–407shape memory alloys, 414–415smart catalysts, 414smart (intelligent) gels (hydrogels), 413–

414and smart polymers, 412–413, 415–416in smart structures, 402technical applications of, 402–403thermoresponsive materials, 411versatility of, 416and water, 415

Smart polymers, 412–413, 415–416Smart structures, 402SMC, see Sheet molding compoundSME (Society of Manufacturing Engineers),

863SM PAN fibers, see Standard modulus PAN

fibersS–N curve, see Stress–strain curveSnell’s law, 660–662S–N–P curves, 727–733Society of Automotive Engineers (SAE), 52,

53, 863Society of Manufacturing Engineers (SME),

863Society of Plastics Engineers (SPE), 618–619Society of Plastics Industry (SPI), 619, 1417Soda-lime glasses, 1250Softball bats, 1267Sol-gel processing (ceramics), 1123–1127Solid freeform fabrication (SFF), 1122–1123Solid-state semiconductor lasers, 1314–1317Solid-state sintering, 1113Solubility:

of plastics, 612in steel manufacture, 32

Solution-phase technology, 1121Solution viscosities, 1425SONET (synchronous optical network), 1308Sound:

reflection / transmission of, 657–660refraction of, 660–662wave characteristics of, 657

Sources of information, see Informationsources

Sources of momentum (plasticsmanufacturing), 996–997

Spacecraft, advanced composite materials in,1131–1162

for all-composite mirrors, 1161–1162for antennas, 1159–1160

INDEX 1487

coefficient of thermal expansion of, 1137–1138

for deployable structures, 1152–1153for electronics enclosures, 1153–1157EMI shielding and electrical characteristics

of, 1140–1141environmental durability of, 1141–1142examples of, 1149–1162FORTE, 1150high specific stiffness / strength of, 1138,

1139for hybrid composite mirrors, 1160–1161for inflatable structures, 1153isogrid structures, 1145joints, 1145manufacturing methods used with, 1146–

1149material properties for, 1137–1142Midcourse Space Experiment, 1151–1152for mirrors, 1159–1162for optical benches and instrument

structures, 1157–1159for primary bus /chassis structure, 1150–

1152properties / characteristics of, 1137–1142qualities of advanced composites used in,

1132–1136for reflectors, 1159–1162sandwich structures, 1143–1144solid laminate construction of, 1142–1143standard structural forms of, 1142–1145thermal conductivity of, 1139–1140truss structures, 1144

Space-filling biomaterials, 1188–1191biocompatibility of, 1188–1191capsule formation with, 1188–1190carcinogenesis / immunological

complications with, 1190–1191functioning of, 1188material selection for, 1191

Space Infrared Imaging Telescope III (SPIRITIII), 1151

Spade drills, 876, 877Spalling failure (metals), 707, 711–712SPDM (Structural Plastics Design Manual),

1417SPE, see Society of Plastics EngineersSpecialty Testing and Equipment, Inc., 622Specifications. See also Standards

for alloy steels, 55–64for carbon steels, 53–55directories of / cross references to, 511–513for electrical wire products, 142for higher alloy steels, 58–64from Information Handling Services, 507for low-alloy steels, 56–58for low-carbon steels, 54–55

militaryMil-Handbook 17, 500MIL-HDBK-5, 460–461for ultrasonic testing, 656

for stainless steels, 77for steel products, 52–64

alloy steels, 55–64carbon steels, 53–55higher alloy steels, 58–64low-alloy steels, 56–58low-carbon steels, 54–55

Specific gravity test (plastics), 613, 1228Spectra polypropylene fibers, 1346Spectroscopy (plastics), 607–609Speed (metal cutting), 852, 862, 863, 865Spelling, variations in, 445Spheriodizing (steel production), 51, 52SPI, see Society of Plastics IndustrySpinning:

cold, 947fiber spinning, 1019–1020hot, 935, 937of metals, 935, 937

cold, 947hot, 935, 937tube spinning, 937, 938

of plastic parts, 1019–1020tube spinning, 937, 938

SPIRIT III (Space Infrared ImagingTelescope), 1151

Split Hopkinson pressure bar (SHPB) testing,633–634

Sports equipment applications, 1253–1272baseball bats, 1266, 1267bicycles, 1260–1262boats, 1267–1268cricket bats, 1264ethical considerations in, 1270–1272golf clubs, 1264–1266hockey sticks, 1270javelins, 1268, 1269for optimum design, 1255–1256for performance enhancement, 1256–1270running shoes, 1256–1259skis, 1269, 1270softball bats, 1267squash rackets, 1264surfboards, 1267–1268tennis rackets, 1262–1264vaulting poles, 1259–1260watercraft, 1267–1268wheelchairs, athletic, 1264, 1265wind surfing fins, 1267–1268

Springborn Laboratories, Inc., 622Sputtering (deposition technique), 1330Squash rackets, 1264Squeezing processes (metals), 940–941

1488 INDEX

SRIM, see Structural reaction injectionmolding

Stainless steels, 58–62, 67–87age-hardening martensitic, 67, 80alloying elements in, 68–71argon–oxygen decarburization process for,

77austenitic, 49, 50, 59–60, 67, 80–82

alloying elements in, 44nickel in, 48

availability of grades of, 78carbon levels in, 76–77chemistry control for, 78classification of, 58–62, 67corrosion resistance of, 71–76

to crevice corrosion, 74to galvanic corrosion, 75–76to general corrosion, 71–72to intergranular corrosion, 75to pitting corrosion, 74, 75to stress-corrosion cracking, 72–73

dual certification of, 77duplex, 61duplex austenitic–ferritic, 61, 67, 80ferritic, 49, 50, 60–61, 67, 78–79‘‘L’’ grades of, 76–77martensitic, 50, 61–62, 67, 79martensitic age hardening, 67nickel alloys, 80–82nickel-base steels vs., 67pitting resistance of, 75precipitation, 49precipitation hardening, 62specifications for, 59–62sulfur levels in, 77–78superaustenitics, 67, 73, 78welding of, 82–87

austenitic, 85–86carbon vs. stainless steels, 82–85duplex, 86–87high-molybdenum, 87

Staking (metals), 941Standards. See also Specifications

ASTM, 520. See also ASTM standardsfor ceramic materials, 434–435for characterizing material attributes, 487for composites in construction applications,

1416–1419directories of / cross references to, 511–513for identifying /qualifying test methods, 487Japanese Industrial Standards, 53. See also

JIS standardsfor materials data, 497–502

ASTM Committee E 49, 498IGES/PDES, 498–499ISO/STEP, 499–500from materials consortia, 500

and XML applications, 500–502for materials data exchange, 497–498for materials test data, 497in MIL-HDBK-5, 460organizations developing

American National Standards Institute,615–616

American Society for Testing andMaterials, 616

Food and Drug Administration, 616–617National Bureau of Standards and

Technology, 617National Electrical Manufacturers

Association, 617National Fire Protection Association,

617–618National Sanitation Foundation, 618Society of Plastics Industry, 619

for plastics testing, 546–547for superalloys, 297testing, 520

Standard generalized markup language(SGML), 501

Standard modulus (SM) PAN fibers, 366–367State Street Bridge (Utah), 1373Static fatigue, 792, 814Steady state manufacturing processes

(plastics), 994Steels, 27–64. See also Stainless steels;

specific typesalloying elements in, 27–28, 44–50alloy steels, 55–64

classification of, 55–64dual-phase steels, 57–58heat-resistant steels, 63higher alloy steels, 58–64high-performance steels, 58low-alloy steels, 55–58microalloyed (high-strength, low-alloy)

steels, 57specifications for, 55–64stainless steels, 58–62tool steels, 62trip steels, 58ultrahigh-strength steel, 63–64wear-resistant steels (austenitic

manganese steels), 63aluminum–silicon deoxidized (killed), 48annealing (full annealing) of, 51austenitic manganese, 47bake-hardening, 55carbon steels

classification of, 53–55high manganese, 53, 54nonresulfurized, 53–54rephosphorized and resulfurized, 53, 54specifications for, 53–55

INDEX 1489

welding of stainless steels vs., 82–85classification and specifications of, 52–64

alloy steels, 55–64carbon steels, 53–55higher alloy steels, 58–64low-alloy steels, 56–58low-carbon steels, 54–55

composition of, 27continuous casting of, 29controlling microstructure of, 29–43

continuous-cooling transformationdiagram for, 41

hardenability concept in, 41–43iron-carbon equilibrium diagrams for

principles of, 30–37isothermal transformation diagram for,

38–40under real world conditions, 37–38time–temperature transformation

diagrams for, 38–41creep in, 48drawability of, 54–55drawing-quality special-killed, 48–49dual-phase, 57–58ductility of, 37, 39, 49, 51electrical, 55enameling steel, 55fine-grain, 48finishes for, in electronic packaging, 1237–

1238forging of, 29free-machining, 47Hadfield manganese, 47heat-resistant, 63heat treatment of, 50–52

annealing (full annealing), 51normalizing, 51process annealing (recrystallization

annealing), 51quenching, 52spheriodizing, 51, 52stress relieving, 51tempering, 52

higher alloy, 58–64high-performance, 58hypereutectoid, 37hypoeutectoid, 36, 37insterstitial-free (IF), 49interstitial alloying elements in, 32ironmaking, 28low-alloy, 56–58machinability of, 47, 50, 56manufacture of, 28–29maraging steel, 63–64microalloyed (high-strength, low-alloy), 57for motor lamination, 55in music wire, 64

normalizing of, 51process annealing (recrystallization

annealing) of, 51quenching of, 52rephosphorized, 47rolling of, 29spheriodizing of, 51, 52steelmaking, 28–29stress relieving for, 51substitutional alloying elements in, 32temper embrittlement in, 48tempering of, 52titanium carbide particle-reinforced, 382,

383tool, 62trip, 58ultrahigh-strength, 63–64

maraging steel, 63–64music wire, 64

wear-resistant, 63weathering steels, 47

Steel bars, 29Steelmaking, 28–29STEMT, see Shaped-tube electrolytic

machiningSTEP, see ISO 10303Sterile delivery (of medical products), 1198Sterilization (of medical products), 1200Stiffness:

in advanced composites, 1138–1139cost per unit stiffness, 8, 9of diamond films, 1298localized, in commercial fiberglass

structures, 1362–1363STN International, materials properties data

from, 469–470Stone (as wear materials), 1281Storage temperature ranges (electronic

packaging), 1227–1228Straightening (metals), 944Strain gauge stress analysis (plastics), 782Strain hardening (high-nickel alloys), 253–

255Strain (metal cutting), 851Strand casting, 29Strength. See also Tensile strength

of aluminum alloys, 91of brittle materials

indented inert strength measurements,816, 824

initial strength distribution, 811–813tests for, 821–823

of ceramicscompressive strength measurement of,

798–799predicting, 792scatter of strength, 794–796

1490 INDEX

Strength (continued )of composites, 373–375compressive strength measurement, 798–

799converting hardness of steels to, 42–43cost per unit strength, 8in electronic packaging applications, 1228of hip implant, 1168–1169of iron, 44–45prediction of (for ceramics), 792of superalloys, 316–317of titanium and titanium alloys, 203, 204and type of loading, 9, 10

Strengthening:of superalloys, 294–296of titanium alloys, 211

Strength /weight ratios:of aluminum alloys, 90of titanium alloys, 203

Stress. See also Failure analysiscombined stress theory, 714with hip implants, 1169–1171maximum normal stress theory, 715–716in plastics, 780–783in steels, 51

Stress corrosion, 92, 708, 709, 712, 769–770Stress corrosion cracking (SCC):

in magnesium and magnesium alloys, 276of metals, 769–770resistance of stainless steels to, 72–73

Stress fields, 718Stress relaxation testing:

for metallic materials, 528for plastics, 552, 554–555

Stress rupture, 740, 741in heat-resistant steels, 63of metals, 707, 711, 740–746

creep under uniaxial state of stress, 743–746

prediction of long-term creep behavior,742–743

Stress–strain (S–N) curve:for ceramics, 793for metals, 727for plastics, 787

Stress-time patterns, 723–726Stretcher leveling, 944Stretch forming (metals), 947Structural adhesives, 1251Structural bonding (composites), 1358, 1360–

1361Structural Design Manual on Pultruded

Composite Joints (ASCE), 1418Structural integrity, 683–687Structural Plastics Design Manual (SPDM),

1417

Structural reaction injection molding (SRIM),1079–1080

Styrene /acrylonitrile copolymer (SAN), 338,339

Sublimation (electronic packaging), 1230–1231

Substitutional alloying elements, 32Substitution of materials, see Materials

substitutionSubstrate selection (wear materials), 1280Sulfur:

in alloy steels, 46, 47in carbon steels, 53–54nickel alloys exposed to, 255in stainless steels, 77–78

Sun Bank Building (Florida), 1406, 1408Superalloys, 293–334

alloying elements in, 295–296cast, 323–324

effect of temperature on mechanicalproperties of, 306–307

for high-temperature applications, 332–333

nominal compositions of, 301physical properties of, 302–303rupture strengths of, 310

chemistry control with, 318–319corrosion of, 329–330cracking of, 312definition of, 294effect of temperature on mechanical

properties of, 304–307environmental properties of, 314–316evolution of, 318–319forging of, 324at high temperatures, 312–314, 332–333for hot-corrosion resistance, 330information sources for, 296–297, 325–326,

328–329for intermediate-temperature applications,

330–332joining of, 325manufacturing with, 295, 296, 319–329

casting, 323–324forging, 324joining, 325melting / remelting, 319–323powder metallurgy, 324–325refining, 319–323sources of information on, 325–326,

328–329mechanical properties of, 316–318melting / remelting of, 319–323nominal compositions of, 298–301physical properties of, 302–303, 314–316powder metallurgy, 324–325protective coatings for, 329–330

INDEX 1491

refining of, 319–323rupture strengths of, 308–310strengthening of, 294–296thermal barrier coatings for, 330wrought

effect of temperature on mechanicalproperties of, 304–305

for intermediate-temperature applications,330–332

nominal compositions of, 298–300rupture strengths of, 308–309

Superaustenitic stainless steels, 67, 73, 78Superfinishing, 899Superplastic forging (isothermal forging), 324Superplastic forming, 229Surface characteristics:

of CVD diamond films, 1295–1296of materials for vascular prostheses, 1185

Surface fatigue, 708–709Surface fatigue wear, 710, 761Surface finishing, 899Surface modifications:

for magnesium alloys, 288in wear materials, 1280

Surface treatment:for carbon vs. stainless steels, 82–83hardness of material and, 1229–1230of metals, 960–967

chemical conversions, 966–967cleaning processes, 960–963coatings, 963–966

Surfboards, 1267–1268Swaging (metals):

cold, 940hot, 932

Switches (telecommunications), 1329Synchronous optical network (SONET), 1308

TA, see Thermal analysisTack, 1043TAM, see Thermally assisted machiningTantalum (in alloy steels), 49TBCs (thermal barrier coatings), 330TCM (thermochemical machining), 923TDMA (time division multiple access), 1308TEA-21 (Transportation Equity Act), 1419Technological momentum, 1255Telecommunications applications, 1303–1338

antireflection coatings for, 1324cable networks, 1304–1306deposition processes for, 1330, 1334–1337

chemical vapor deposition, 1334–1335crystal growth, 1336electroplating, 1337epitaxy, 1335–1336evaporation, 1330, 1334–1335sputtering, 1330

electro-optical materials, 1323–1324future possibilities for, 1337–1338isolators incorporating Faraday rotators,

1325materials selection for, 1303–1338

antireflection coatings, 1324cable networks, 1304–1306and chemical vapor deposition, 1334–

1335and crystal growth, 1336data transmission, 1309and deposition methods, 1330, 1334–

1337electro-optical materials, 1323–1324and epitaxy, 1335–1336and evaporation, 1330, 1334–1335and future communication components,

1337–1338isolators incorporating Faraday rotators,

1325microelectromechanical systems, 1325–

1328microwave radio-frequency resonators,

1328–1329multilayer ceramic integrated circuits,

1329–1330for networks, 1304–1308optical fiber, 1318–1323optical filters, 1324optical networks, 1306–1308packaging, 1311–1314photodetectors, 1317, 1318and plating, 1337repeaters, 1329solid-state semiconductor lasers, 1314–

1317for specific components, 1309–1311,

1330–1333and sputtering, 1330switches, 1329for transmission, 1309voice transmission, 1309wireless networks, 1308

microelectromechanical systems, 1325–1328

microwave radio-frequency resonators,1328–1329

multilayer ceramic integrated circuits,1329–1330

networks, 1304–1308cable, 1304–1306optical fiber, 1306–1308wireless, 1308

optical fiber, 1318–1323device fabrication with, 1322–1323fabrication of, 1320–1322in fiber-optic cables, 1322

1492 INDEX

Telecommunications applications (continued )glass, 1319–1320plastic, 1320plastic-clad, 1320

optical fiber networks, 1306–1308optical filters, 1324packaging, 1311–1314photodetectors, 1317, 1318repeaters, 1329solid-state semiconductor lasers, 1314–

1317switches, 1329transmission

data, 1309voice, 1309

wireless networks, 1308Temperature. See also High temperatures

dependence of polymer properties on, 376in electronic packaging applications, 1235–

1236and grinding processes, 898and mechanical properties of superalloys,

304–307and oxidation of magnesium and

magnesium alloys, 268–274in plastics manufacturing, 1007–1008superalloys for intermediate-temperature

applications, 330–332and thermoresponsive materials, 411and titanium/ titanium alloy capabilities,

202Temper designations:

for aluminum alloys, 98, 100for copper and copper alloys, 137–139

Tempering (steels), 51, 52Template machining (gears), 883–884Temporary corrosion protection (metals),

965–966TEM (thermal energy method), 923TEM (transmission electron microscopy)

analysis, 170Tennis rackets, 1262–1264Tensile creep testing:

for ceramics, 630for plastics, 551–553

Tensile fatigue test (plastics), 566Tensile strength:

of iron, 44–46of steels, 54of superalloys, 316–317of titanium alloys, 220

Tensile testing:for ceramics, 625–626for metallic materials, 524–526for plastics, 547–548

Terminology, changes in, 445–446

Testing, 545–546. See also Failure analysis;Nondestructive inspection /evaluation

of ceramics, 623–648electrical, 646–648mechanical, 624–638nondestructive, 644–646radiography, 646thermal, 638–644ultrasonic, 645–646

of metals, 519–542adhesion / friction /wear of surfaces, 540ASTM standards for, 520bending strength, 540creep, 526–528environmental considerations in, 540–

542fatigue, 535–540fracture toughness, 531–535hardness, 528–529high strain rate, 540impact tests, 530–531sensors / instrumentation for, 522–524stress relaxation, 528tensile (compressive) test, 524–526test machine (loading frame) for, 520–

522thermomechanical fatigue, 543

of new medical products, 1195–1198organizations involved in

American Society for Testing andMaterials, 616

costs for services of, 620independent testing laboratories, 621–

622Society of Plastics Industry, 619Underwriters Laboratories, 619–620

of plastics, 545–589, 591–609accelerated weathering tests, 584–587arc resistance, 578–582brittleness temperature, 574, 575creep properties, 551–553dielectric constant and dissipation factor,

576–577dielectric strength, 575–576electrical resistance tests, 577–578elevated temperature performance tests,

568–574fatigue resistance, 564–566flexural properties, 549–551hardness tests, 566–568impact properties, 555–564material characterization tests, 591–609mechanical properties, 547–568outdoor weathering, 587–589standard methods of, 546–547stress relaxation, 552, 554–555tensile tests, 547–548

INDEX 1493

standard methods for, 546Test machines, 520–522Textual databases, 463–464, 1040TFM (total form machining), 906TGA, see Thermogravimetric analysisThermal analysis (TA):

of plastics, 602–609, 784of polymers, 1426–1427

Thermal barrier coatings (TBCs), 330Thermal behavior (polymers), 1426Thermal conductivity:

of aluminum alloys, 90of ceramics, 640–643of composite materials, 363, 386–391of composites, 1139–1140of diamond, 1290–1291of diamond film, 1293, 1295in electronic packaging applications, 1225

Thermal cycle-induced microcracking, 1142Thermal deburring, 923Thermal diffusivity, 642Thermal emissivity (in electronic packaging),

1225Thermal energy method (TEM), 923Thermal expansion. See also Coefficient of

thermal expansionof ceramics, 638–640of diamond film and substrates, 1298in electronic packaging applications, 1225–

1226Thermal failure (plastics), 778Thermal fatigue, 708Thermal index (UL temperature index), 571–

574Thermally assisted machining (TAM), 901,

905, 906Thermal mechanical analysis (TMA), 1427Thermal-mechanical fatigue (TMF), 312Thermal paints, 679Thermal properties tests (plastics), 568–575

brittleness temperature, 574, 575elevated temperature performance tests,

568–574Thermal relaxation failure (metals), 707, 711Thermal shock:

ceramic failure under, 803–805ceramic resistance to, 428–429metal failure under, 707, 711

Thermal testing:of ceramics, 638–644

calorimetry (heat capacity), 644differential scanning calorimetry (heat

capacity), 644dilatometry (thermal expansion), 639,

640guarded hot plate (thermal conductivity),

641–642

heat capacity, 643–644laser flash (thermal conductivity), 642–

643thermal conductivity, 640–643thermal expansion, 638–640

nondestructive inspection methods, 678–680

infrared cameras, 679thermal paints, 679thermal testing, 679–680

Thermal thinning, 1008Thermochemical machining (TCM), 923Thermoforming (sheet thermoforming):

of plastic parts, 975–977, 1027–1032of plastics, 958

Thermogravimetric analysis (TGA):of plastics, 604–605of polymers, 1426

Thermomechanical analysis (TMA), 605–606Thermomechanical fatigue (TMF), 543Thermoplastics, 1424

classifications of, 336commodity, 336–341

ABS, 339impact polystyrene (IPS), 338polyethylene (PE), 336–337poly(ethylene terephthalate) (PET), 341poly(methyl methacrylate) (PMMA), 341polypropylene (PP), 337, 338polystyrene (PS), 337, 338polyvinyl chloride (PVC), 339–340poly(vinylidene chloride) (PVDC), 340–

341styrene /acrylonitrile copolymer (SAN),

338, 339in electronic packaging applications, 1246,

1247engineering, 342–348

modified polyphenylene ether, 347polyacetals, 343, 344polyamides (nylon), 342, 343poly(butylene terephthalate) (PBT), 342polycarbonates, 345–346polyesters, 342polyimides, 347, 348polyphenylene sulfide, 344, 345polysulfone, 346–347

fluorinated, 348–349, 352fluorinated ethylene–propylene (FEP),

349poly(chlorotrifluoroethylene) (CTFE),

349poly(ethylene chlorotrifluoroethylene)

(ECTFE), 349, 352poly(tetrafluoroethylene) (PTFE), 348–

349poly(vinyl fluoride), 352

1494 INDEX

Thermoplastics (continued )polyvinylidene fluoride (PVDF), 349

glass mat, 1099–1101monomer precursor, 1106–1107morphology of, 1427short-fiber-reinforced thermoplastics, 1107–

1110thermal behavior of, 1426viscosity measurement for, 599

Thermoplastic matrix systems, 1044–1045commingles, 1103–1106high-performance, 1101–1103processing with, 1050, 1051

Thermoplastic polymers, 1424Thermoresponsive materials, 411Thermosetting matrices, precompounded

reinforcements with, 1042–1044Thermosetting plastics (thermosets), 336,

352–354alkyd resins, 353amino resins, 354diallyl phthalate, 353–354in electronic packaging applications, 1246–

1249epoxy resins, 352–353phenolic resins, 352unsaturated polyesters, 353viscosity measurement for, 599

Thermosetting resins, 1424cure of, 1049–1051glass transition temperature of, 1428thermal behavior of, 1426

Thermostructural applications (ceramicmaterials), 427–429

Thin-film resonators, 1328–1329Thixomolding, 260–261, 284Thread cutting and forming (metals

manufacturing), 884–886Thread rolling (metals), 886, 941Time division multiple access (TDMA), 1308Time–temperature transformation (TTT)

diagrams, 38–41continuous-cooling transformation diagram

as, 41isothermal transformation diagram as, 38–

40for steels, 38–41

TiN, see Titanium nitridesTin, 50, 1245Tin bronzes, 199Titanium, 81

in alloy steels, 49in electronic packaging applications, 1245

Titanium alloys, 201–233alpha alloys, 205, 208, 209, 216alpha-beta alloys, 209, 216, 218, 224beta alloys, 205, 208, 210, 218–219

biomedical applications of, 231–232corrosion resistance of, 203, 231cryogenic applications of, 232effect of alloy elements, 211–225

in alpha alloys, 216in alpha–beta alloys, 216, 218in beta alloys, 218–219in cast alloys, 224–225and effects of processing, 214hydrogen, 214–215on intermediate compounds / secondary

phases, 211–212on mechanical and physical properties,

212–225nitrogen, 215oxygen, 215on physical properties, 212–214in wrought alloys, 219–224

grades of, 208–210at high temperatures, 205–207manufacturing processes for, 225–231

forging, 227–229investment casting, 229joining, 230–231machining, 229–230vacuum arc melting, 226–227

metallurgy of, 204–205microstructure and properties of, 208–211sources of information on, 203, 204, 233strengthening of alloys, 211strength of, 203, 204temperature capability of, 202titanium aluminides, 208vacuum arc melting of, 226–227

Titanium carbide particle-reinforced steel,382, 383

Titanium nitrides (TiN), 1277–1278TLP (transient liquid-phase) bonding, 325TMA (thermal mechanical analysis), 1427TMA (thermomechanical analysis), 605–606TMF (thermal-mechanical fatigue), 312TMF (thermomechanical fatigue), 543Tool life (metals manufacturing), 855–857Tool steels, 48, 62Torque rheometer, 597Torsional strength (reinforced concrete /

masonry structure repair / retrofit), 1392–1393

Toss factor, 557Total form machining (TFM), 906Total hip arthroplasty, 1166–1180

biocompatibility, 1174–1178corrosion, 1174–1177frictional forces, 1171–1172function of hip implant, 1167–1173joint motion with, 1171–1173leaching and absorption with, 1177–1178

INDEX 1495

material selection for, 1178–1180strength of implant, 1168–1169stress shielding, 1169–1171wear, 1172–1173wear debris from, 1178

Total shear, 995Tow placement (composite processing), 1085–

1086, 1090Tramp elements (steel), 50Trampoline effect (golf), 1265–1266Transducer materials, 1327Transfer molding (plastics), 984, 985, 1025Transformers, electrical steels for, 55Transient liquid-phase (TLP) bonding, 325Transmission electron microscopy (TEM)

analysis, 170Transparent ceramic materials, 432, 433Transportation Equity Act (TEA-21), 1419Traveling wire EDM, 918Trepanning, 876Tresca criterion, see Maximum shearing stress

theoryTrimming:

of composites, 1358of metals, 947

Trip steels, 58Truss structures (sandwich panels), 1144TTT diagrams, see Time–temperature

transformation diagramsTubes and fittings, copper and copper alloys

in, 183–185Tube spinning (metals), 937, 938Tumbling, 962Tungsten:

in alloy steels, 48in stainless steels, 69

Turbines, superalloys for, 331–333Turbine blades, 841–842Turning:

alignment charts for, 866–868break-even point with, 869cutting horsepowers for, 854electrochemical, 913, 914lathe size for, 866primary factors involved in, 863–866tool wear factors in, 855

Turning machines, 863–869Twin screw extruders, 1015–1016

UHM PAN fibers, see Ultrahigh modulusPAN fibers

UHMWPE (ultrahigh-molecular-weightpolyethylene), 337

UHS PAN fibers, see Ultrahigh strength PANfibers

UL, see Underwriters LaboratoriesUL temperature index, 571–574

Ultrahigh modulus (UHM) PAN fibers, 366–367

Ultrahigh-molecular-weight polyethylene(UHMWPE), 337

Ultrahigh-strength steels, 63–64maraging steel, 63–64music wire, 64

Ultrahigh strength (UHS) PAN fibers, 366–367

Ultrasonic machining (USM), 898–899, 907Ultrasonic properties of materials, 694–698

ceramics, 697liquids, 694metals, 695–696polymers, 697–698

Ultrasonic testing (UT), 653, 656–663of ceramics, 645–646inspection process with, 662–663and reflection / transmission of sound, 657–

660and refraction of sound, 660–662and sound wave characteristics, 657

Ultraviolet (UV) radiation, effect on plasticof, 583–586

Underwriters Laboratories (UL), 619–620,622

Unidirectional composites, 376, 381, 387, 388UNI (Ente Nazionale Italiano di Unificazione)

standards, 53Unified Numbering System (UNS) (steels), 52United Kingdom, steel standards in, 53United States:

copper production in, 136–137cost of corrosion in, 248

University of Massachusetts Lowell, Inst.Plastics Innov., 622

Unsaturated polyesters, 353Unsteady state manufacturing processes

(plastics), 994UNS (Unified Numbering System) steels, 52Upper bainite, 38Upset forging (metals), 931, 932U.S. Corps of Engineers, 1419User interface (databases), 492USM, see Ultrasonic machiningUT, see Ultrasonic testingUV radiation, see Ultraviolet radiation

Vacuum arc melting (VAR):of superalloys, 319, 321–323of titanium and titanium alloys, 226–227

Vacuum-assisted resin injection (VARI), 1080Vacuum-assisted resin transfer molding

(VARTM), 1080Vacuum-induced outgassing, 1142Vacuum induction melting (VIM), 319–321,

323

1496 INDEX

Vacuum melting (superalloys), 318Vacuum metallizing, 965Vanadium (in alloy steels), 48Vapor baths (metals), 960–962Vapor phase technology, 1121VAR, see Vacuum arc meltingVARI (vacuum-assisted resin injection), 1080Varnishes (metals), 964VARTM (vacuum-assisted resin transfer

molding), 1080Vascular prostheses, 1180–1188

biocompatibility of, 1183–1186blood transport by, 1181–1183coagulation with, 1184–1186functioning of, 1181–1183hemolysis with, 1184hemostasis with, 1184material selection for, 1186–1188neointima formation with, 1183–1184property degradation with, 1186

Vaulting poles, 1259–1260Venting (of composite core gasses), 1143Very low density polyethylene (VLDPE), 337Vickers hardness test, 43, 631, 632VIM, see Vacuum induction meltingViscoelastic regions (polymers), 1427Viscosity, 595

dynamic (absolute), 599kinematic, 599of plastics, 599of polymers, 1425–1426

Viscous heating, 1007–1008Visual examination (plastics failure analysis),

778–779Vitreous enamels (metals), 964–965VLDPE (very low density polyethylene), 337Voice transmission, 1309Von Mises criterion, see Distortion energy

theory of failureVTEC Laboratories, Inc., 622

Wafer level packaging, 1314Water:

exposure of plastics to light and, 586–587used in smart applications, 415

Water bottles, polymers in, 1425Watercraft, 1267–1268Water-jet machining (WJM), 907, 908Wavelength division multiplexing (WDM),

1307–1308WDM, see Wavelength division multiplexingWear:

abrasive, 758, 760adhesive, 710, 756–759corrosive, 710elastic deformation failure, 710fretting, 711

and hardness, 1230of hip implants, 1172–1173impact, 710surface fatigue, 710of surfaces, 540

Wear applications:bearings, 424, 425ceramic materials in, 423–427cutting tool inserts, 425, 426

Wear debris (hip implants), 1178Wear failure (metals), 707, 709–710, 746–

747, 756–761Wear materials, 1275–1281

applications of, 1281film thickness for, 1280–1281information resources on, 1279–1280manufacturing process selection for, 1278–

1279materials selection process for, 1276–1278properties of, 1276substrate selection for, 1280surface modifications in, 1280

Wear resistance:in electronic packaging applications, 1230of steels, 48

Wear-resistant steels (austenitic manganesesteels), 63

Weathering properties tests (plastics), 582–589

accelerated weathering tests, 584–587outdoor weathering, 587–589

Weathering steels, 47Weibull statistics:

for brittle materials, 422, 811–812, 818–821

for ceramics, 794–803Weighted-properties values, 11–13

digital logic method, 11–12performance index in, 12–13

Weld decay, 766–767Welding:

of austenitic stainless and nickel alloys, 80,81

of carbon vs. stainless steels, 82–85intergranular corrosion from, 75of magnesium and magnesium alloys, 262,

263martensitic stainless steels for, 79of metals, 937, 938of nickel and nickel alloys, 256–257pipe welding, 937, 938for repair of metal products, 844–845of stainless steels, 82–87

austenitic, 85–86carbon steels vs., 82–85duplex, 86–87high-molybdenum, 87

INDEX 1497

of superalloys, 295, 325, 326of titanium and titanium alloys, 230–231

Western Europe, copper production in, 136Wet corrosion, 249Wet /hand lay-up method (composite repair),

1375–1376, 1379, 1381–1385Wheels, bicycle, 1262Wheelchairs, athletic, 1264, 1265Window frames, 840–841Wind surfing, 1267–1268Wire, copper, 185Wire brushing (metals), 962Wire coating (plastics), 1016–1018Wire cutting (electrical discharge), 918Wireless networks, 1308Wire products (copper and copper alloys),

142–143WJM, see Water-jet machiningWorkability (aluminum alloys), 90–91World Wide Web Consortium (W3C), 501Woven fabrics, 1041, 1042, 1104–1105W3C (World Wide Web Consortium), 501

Xenon arc-type light, exposure of plastics to,586–587

XML (extensible markup language), 501X-rays:

attenuation of, 667, 668

computed tomography, 646, 671–672diffraction of (ceramics testing), 640generation /absorption of, 664–666microradiography, 646

X-Rite, Inc., 622

Yasuda model, generalized, 1001–1002Yellowness index (YI):

of medical PP, 1217–1219of PVC, 1201, 1204–1206

Yielding, small-scale, 718Yielding failure (metals), 708, 713–715Yield strength:

of iron, 44, 45of nickel and nickel alloys, 252–253of steels

in annealed condition, 54silicon and, 47

of superalloys, 317Yttrium (in magnesium alloys), 261

Zero mean cyclic stresses, 729Zinc:

in electronic packaging applications, 1244in magnesium alloys, 271, 282–283

Zirconium:in alloy steels, 49in magnesium alloys, 261, 267, 268, 279,

283