Materials for the Engineering Technician-Lathe-Mill-OG

             Materials for the Engineering Technician

Raymond A. Higgins

Foreword                                                                                                                 v

Preface                                                                                                                   vii

1 Setting the Stage                                                                                                       1
A brief history of materials. Metallic and non-metallic materials.

Ferrous and non-ferrous metals.

2 The Crystal Structure of Metals                                                                            3
States of matter gas, liquid, and solid. Crystal patterns. Allotrophy.

 Dendritic solidification. The presence of impurities. Crystal size.

3 Casting Processes                                                                                                  12
Ingot-casting. Continuous casting. Sand-casting. Pressure and gravity

die-casting. Centrifugal casting. Shell-moulding. Investment-casting.

The full-mould process.

4 Mechanical Testing                                                                                               23
Fundamental properties-malleability, ductility, toughness.

The tensile test. Proof stress. Hardness tests-Brinell, diamond-pyramid,

Rockwell, and Shore. Impact tests. Creep. Fatigue. Other tests-Erichsen test,

bend tests, compression test.

5 Non-destructive Testing                                                                                      44
Detection of surface cracks penetrant and magnetic methods.

Detection of internal defects-X-rays, y-rays, and ultra-sonic methods.

6 Mechanical Deformation and Recrystallisation of Metals                            50
Elastic and plastic properties. Slip. Work-hardening. Annealing and

recrystallisation. Grain growth. Principles of cold-working and hot-working

processes. Grain flow and fibre. Macro-examination of forged structures.

7 The Mechanical Shaping of Metals                                                                   62
Hot-working processes. Forging. Drop-forging. Hot pressing.

Hot-rolling. Extrusion. Cold-working processes. Cold-rolling. Drawing.

Cold pressing and deep-drawing. Spinning. Stretch-forming. Coining and

embossing. Impact-extrusion. Powder-metallurgy.

8 Alloys                                                                                                                        77

Introduction. Eutectics. Solid solutions. Substitutional and interstitial

 solid solutions. Intermetallic compounds. Summary of properties.

9 Equilibrium Diagrams                                                                                          87

Construction of simple equilibrium diagrams. Types of equilibrium

diagram-solid solution, eutectic, and partial solubility. Pre­cipitation

from solid solutions. Ternary equilibrium diagrams.

10 Practical Microscopy                                                                                                                                          106

Selection of specimen. Grinding and polishing. Etching. The metallurgical

microscope. Use and care of the microscope. The electron microscope.

11 Iron and Steel                                                                                                         120

The manufacture of pig iron. Steel making-the open-hearth and

^`oxygen' processes. The composition of steel. The structure of plain-carbon

 steels. The iron-carbon diagram. The heat-treatment of steel-normalising and

annealing.

12 The Heat-treatment of Plain-carbon Steels                                                     137

Principles of hardening. Martensite. The hardening process. Tempering.

Mass effect and hardenability. Ruling section. The Jominy test.

13 Alloy Steels                                                                                                            149

General effects of alloying. Constructional steels-nickel steels, chromium steels,

nickel-chromium-molybdenum steels, manganese steels. Tool steels and die

steels-high-speed steels. Sintered tool materials. Stainless steels. Heat-resisting

steels. Summary of effects of alloying elements.

14 The Surface-hardening of Steels                                                                        165

Case-hardening-solid, liquid, and gaseous media. Heat-treatment.

Case-hardening steels. Nitriding. Carbonitriding. Flame-hardening.

Induction-hardening.

15 Cast Iron                                                                                                                  177

Effects of composition on structure. The influence of cooling-rate on structure. `

Growth^'. Engineering irons. High-duty irons. Spheroidal-graphite irons.

Malleable irons. Alloy cast irons.

16 Copper and its Alloys                                                                                                                                         189

Extraction and properties of copper. Commercial grades. The brasses.

Bronzes. Aluminium bronze. Copper-nickel alloys. Other copper alloys.

17 Aluminium and its Alloys                                                                                 204

Extraction and properties of aluminium. Alloys of aluminium. BS

specification system. Wrought alloys which are not heat-treated. Cast alloys

which are not heat-treated. Wrought alloys which are heat-treated.

Precipitation-hardening. Cast alloys which are heat-treated.

18 Nickel and its Alloys                                                                                         220

Extraction of nickel. Uses of nickel. High-temperature resistance alloys.

Corrosion-resistant alloys. High-temperature corrosion-resistant alloys.

Low-expansion alloys.

19 Other Non-ferrous Metals and Alloys                                                            226

Magnesium-base alloys. Zinc-base die-casting alloys. Lead-antimony alloys.

Type-metals. Fusible alloys. Bearing metals.

20 Some Metals of the Space Age                                                                        233

Beryllium. Germanium. Hafnium. Niobium (columbium). Tantalum.

Titanium. Zirconium. Uranium and plutonium.

21 The Machinability of Metals                                                                            241

Chip formation. Methods of improving machinability-the presence of a

constituent in the microstructure, heat-treatment, cold-working the material.

22 Corrosion                                                                                                             246

Chemical corrosion. Electrolytic corrosion. Examples of electrolytic corrosion.

The protection of metal surfaces. Painting. Stove-enamelling. Metal coatings.

Oxide coatings. Metals which are corrosion-resistant.

23 Plastics                                                                                                                 254

Types of plastics. General properties of plastics. Composition and structure.

Terms used in polymer technology. Some important plastics. Thermoplastic

materials-cellulosics, vinyls, fluorocarbons, polyamides, polyesters, and

acrylics. Thermo-setting materials phenolics, polyesters, polyurethanes,

epoxy resins, and silicones. Mechanical properties of plastics. Methods of

shaping plastics.

24 Wood and its Products                                                                                      280

Types of wood. The structure of timber. Moisture-content and seasoning.

Preservation of timber. Engineering uses of timber. Laminated wood.

Plywood, blockboard, and particleboard. Fibreboard.