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1 General Introduction 1

1.1 What are Material Forming and Manufacturing? 1

1.2 Examples of Manufactured Products 3

1.2.1 Paper clips 3

1.2.2 Incandescent light bulbs 4

1.3 The Design Process and Concurrent Engineering 5

1.4 Design for Manufacture and Assembly 8

1.5 Selecting Materials 10

1.6 Selecting Manufacturing Processes 10

1.7 Computer Integrated Manufacturing 11

1.7.1 Machine control systems 12

1.7.2 Computer technology 12

1.8 Quality Assurance and Total Quality Management 14

1.9 Organization for Manufacture 15

1.10 Summary 16

Questions 17

Note 17

2 The Structure of Metals 18

2.1 The Crystal Structure of Metals 18

2.2 Deformation and Strength of Single Crystals 20

2.3 Imperfections in the Crystal Structure of Metals 22

2.3.1 Dislocations 23

2.3.2 Work hardening(strain hardening) 23

2.4 Grains and Grain Boundaries 23

2.4.1 Grain size 24

2.4.2 Influence of grain boundaries 24

2.4.3 Grain boundary embrittlement 25

2.5 Plastic Deformation of Polycrystalline Metals 25

2.6 Recovery,Recrystallization and Grain Growth 25

Questions 27

Note 27

3 Metal Alloys:Their Structure and Strengthening by Heat Treatment 29

3.1 Introduction 29

3.2 Structure of Alloys 29

3.2.1 Solid solutions 30

3.2.2 Intermetallic compounds 30

3.2.3 Two phase systems 31

3.3 Structure of Alloys 32

3.4 The Iron Carbon System 33

3.4.1 Ferrite 33

3.4.2 Austenite 34

3.4.3 Cementite 34

3.5 Heat Treatment of Nonferrous Alloys and Stainless Steels 35

3.5.1 Solution treatment 35

3.5.2 Precipitation hardening 35

3.6 Annealing 36

3.7 Summary 37

Questions 37

Note 37

4 Metal Casting Process 38

4.1 Introduction 38

4.2 Solidification of Metals 39

4.2.1 Pure metals 39

4.2.2 Alloys 40

4.2.3 Structure property relationships 43

4.3 Fluid Flow and Heat Transfer 44

4.3.1 Fluid flow 44

4.3.2 Fluidity of molten metal 45

4.3.3 Heat transfer 45

4.3.4 Shrinkage 46

4.3.5 Defects 47

4.4 Summary 50

Questions 50

Note 50

5 Rolling 52

5.1 Introduction 52

5.2 Flat Rolling 53

5.2.1 Frictional forces 54

5.2.2 Roll force and power requirement 54

5.3 Flat Rolling Practice 56

5.4 Defects in Rolled Plates and Sheets 57

5.5 Rolling Mills 59

5.6 Shape Rolling Operations 60

5.7 Production of Seamless Tubing and Pipe 62

5.8 Summary 63

Questions 63

Note 64

6 Forging Process 65

6.1 Introduction 65

6.2 Open Die Forging 66

6.3 Impression Die and Closed Die Forging 67

6.4 Precision Forging 68

6.5 Coining 68

6.6 Heading 69

6.7 Piercing 70

6.8 Other Operations 70

6.9 Die Materials and Lubrication 71

6.10 Forgeability 72

6.11 Forging Defects 72

6.12 Summary 73

Questions 73

Note 73

7 The Metallurgy of Welding 74

7.1 Introduction 74

7.2 The Welded Joint 74

7.2.1 Solidification of the weld metal 75

7.2.2 Heat affected zone 76

7.3 Weld Quality 77

7.3.1 Porosity 77

7.3.2 Slag inclusions 77

7.3.3 Incomplete fusion and penetration 77

7.3.4 Cracks 78

7.3.5 Lamellar tears 79

7.3.6 Su rface damage 79

7.3.7 Residual stresses 79

7.4 Weldability 80

7.5 Weld Design and Process Selection 81

7.6 Summary 81

Questions 82

Note 82

8 Quality Assurance,Testing and Inspection 83

8.1 Introduction 83

8.2 Product Quality 84

8.3 Quality Assurance 85

8.4 Total Quality Management 86

8.4.1 Quality engineering as a philosophy 86

8.4.2 The ISO 9000 standard 88

8.5 Statistical Methods of Quality Control 90

8.6 Statistical Process Control 92

8.7 Acceptance Sampling and Control 92

8.8 Reliability 93

8.9 Destructive Testing 94

8.10 Automated Inspection 94

8.11 Summary 95

Questions 96

Note 96

Appendix 97

References 171