Table Of ContentNEW MATERIALS
PROCESSES, AND METHODS
TECHNOLOGY
© 2006 by Taylor & Francis Group, LLC
NEW MATERIALS
PROCESSES, AND METHODS
TECHNOLOGY
MEL SCHWARTZ
© 2006 by Taylor & Francis Group, LLC
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Library of Congress Cataloging-in-Publication Data
Schwartz, Mel M.
New materials, processes, and methods technology / by Mel Schwartz.
p. cm.
ISBN 0-8493-2053-4 (alk. paper)
1. Materials. I. Title.
TA403.S397 2005
620.1'1--dc22 2005049921
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Dedication
To Carolyn and Anne-Marie, my wife and daughter, whose courage and
strength are overwhelming and gratefully acknowledged
and whose inspiration guides my everyday life.
Additionally, Heather Pauline and David Andrew — the future.
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Preface
One of the most important requisites to the development and manufac-
ture of satisfactory products at minimum cost is making a sound eco-
nomic choice of engineering materials. This task is not an easy one. It
is fraught with many uncertainties. Often there is a lack of complete
facts on which to operate. Then, too, there are a vast number of materials
from which to ferret out the best ones for the job.
So, finding the optimum materials for an application requires a rig-
orous engineering approach. It is only in the past couple of decades that
material selection has been taken seriously and integrated into the meth-
odology of engineering development and manufacturing. Prior to this
time, materials selection was done rather casually. The general proce-
dure was to rely almost entirely on past experience and fit the design
of a product to the properties of the few materials with which the
engineer was familiar. Or, often, the product development program was
completed before any thought was given to materials. Under such cir-
cumstances, materials changes took place gradually and each change
usually provided only small improvements.
In recent years, the tremendous increase in the variety of materials,
coupled with the rise of new and more severe service requirements and
the demand for lower costs, have brought an end to this haphazard
approach. Today, materials selection is a complex process that operates
throughout the entire span of a product’s evolution, and usually
involves a number of different technicians and departments. Analytical
procedures have been developed to deal with the complex interaction
of requirements and performance properties. And materials engineering
departments and specialists who devote full time to materials selection
problems are now a common adjunct to engineering or manufacturing
departments.
Materials selection is not a simple function that is performed at one
certain time and place in the history of a product. When and where it
is done depends on a host of factors. Nevertheless, while each materials
selection decision has its own individual character and its own sequence
of events, there is a general pattern common to the materials selection
process.
The materials selection process operates in two distinctly different
areas of the engineering and manufacturing complex. First, it is an
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indispensable part of new product development projects. Second, it
plays an important role in the review and reevaluation of existing prod-
ucts. In the former case, materials selection is hardware oriented and,
therefore, has directed or assigned character about it. In the latter case,
it is not necessarily tied to a specific product and, therefore, often has
a less formal and, what might be termed, an unassigned character to it.
Both roles of the materials selection process are important.
This book covers many of the newly developed materials as well as
the processes that have come about in the past decade. The Materials
Age is here and will be with us for a long time to come. It is an age in
which the materials available to us are limitless in number and diversity.
It is an age in which the microscopic similarities of all materials are
more significant than their macroscopic differences. It is an age in which
most advanced mechanisms are critically dependent on materials. Yet,
it is an age in which new materials and processes still to come promise
almost unbelievable breakthroughs in the devices of automation, min-
iaturization, communication, space exploration, and the maximum uti-
lization of energy. “Engineering and technology lie at the heart of the
matter,” according to Robert M. White, former president, National
Academy of Engineering, on how the U.S. can prosper in the global
economy (The Bridge — 25th Anniversary Issue). The Materials Age is an
age made by people. It is an age that calls for people capable of grasping
and using the new science of materials, for people farseeing enough to
break down the conventional barriers of the various engineering disci-
plines. It is an age that requires us to reappraise our ways of doing
things. In education it has raised questions of how best to teach mate-
rials to engineers. In research and development it has raised questions
of how to most efficiently plan and administer the vast government-
sponsored programs. In industry it has raised questions of how best to
handle materials problems. In technical societies it has raised questions
of scope, stimulated reappraisals of programs, and spawned entirely
new societies. And in the information field it has created formidable
problems in collecting, evaluating, and disseminating data on materials.
Our progress in space flight, automation, electronics, and atomic energy
is dependent on the solution of crucial materials problems. Likewise,
in the less glamorous fields of industrial and consumer products, mate-
rials are now widely recognized as the critical factor that determines
cost, quality, and performance. Dr. W. O. Baker, former vice president
of research at Bell Labs, summed up the significance of materials in our
present age this way: “Materials as never before must be the means
through which man realizes his dreams of well being on earth, or, failing
that, liberation into space.”
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Not only has the number of materials increased, but the combinations
have increased as well. Clad metals, reinforced plastics, laminates, com-
posites, honeycomb sandwich, nanostructures and powders, layered
coatings (CVD, PVD, laser), FGMs, single crystals, fuel cells, and piezo-
electric materials have been introduced as well as the systems concept
to the materials user. Now we can construct materials in which the best
properties of two or more constituents will be used to advantage.
The tremendous increase in the number of materials, coupled with
the rise of new and more severe service requirements, is bringing about
many changes in our ways of applying materials. Traditionally, the point
of view of the user of materials was to fit the design or product to the
properties of a material. This attitude has changed. The major concern
now is finding and applying a material or materials with the right
combination of properties to meet the design and service conditions.
Thus, the new attitude is end-service-oriented. The next logical step, of
course, is tailor-made materials. As we will read in this book, definite
progress in this direction has been and will be made in the future.
No longer do scientists, researchers, and technologists accept the
atomic arrangements nature gives us. Such, for example, is the case with
high polymers — those aggregates of giant, chain-like molecules. High
polymers that nature gave us, such as wood, leather, and glue, have
been used as engineering materials for centuries. But only during the
past couple of decades have we acquired sufficient understanding of
their molecular structure to improve on nature. Now, by varying the
chain length and degree of branching or cross-linking, materials can be
produced with combinations of properties to meet specific application
requirements.
In many of the materials and processes described there is the solid
state approach. The impact of solid state science on engineering mate-
rials is reflected on three distinct levels. It has made possible:
1. Discovery of completely new and perhaps novel materials.
2. Major or minor improvements in existing materials that come
only with a more complete understanding of the nature of the
materials and their properties.
3. Understanding the ultimate theoretical limits to the properties
of materials before they have been attained practically.
Finally, most of the common materials being used today have been
developed over the centuries by pure art, and the early effort of solid
state science was directed at trying to rationalize, in terms of the new
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theoretical concepts, facts and properties that were already well-known
to the technologist and the engineer.
Many of the important developments in the fields of new metals,
semiconductors, magnetic materials, dielectrics, and ceramics have been
the result of trial-and-error or “statistical” methods of research with
little benefit from the advancing science of the solid state.
On the other hand, it should be emphasized that not only has solid-
state sciences advanced the various materials sciences but also that
many important fundamental advances in solid state would have been
impossible without the aid of the rapidly advancing technology of
materials which has its scientific foundations, for the most part, in
classical thermodynamics and classical inorganic chemistry. The prep-
aration of ultra pure materials, the controlled addition of minute con-
centrations of impurities, and the growth of nearly perfect single crystals
have been among the indispensable techniques of progress.
The lesson in this catalog of new materials is that for years the engi-
neer relied on certain old standbys such as the steels in structural
designs or on iron-silicon alloys in magnetic designs. Rare or hard-to-
find metallic elements remained scientific curiosities. Now, suddenly, a
host of new materials has appeared on the scene with too many com-
binations to enable all possibilities to be exhausted purely by trial-and-
error, a fruitful avenue of progress in the past. Trial-and-error will
always be the ultimate arbiter, but more basic principles are needed to
guide us on what to try, and how to proceed from preliminary success
to further improvements.
At the other end of the scale from metals are materials that the phys-
icist would like to ignore, but which the engineer cannot afford to: the
complex synthetic materials and organic materials. The pattern of
progress in these fields is more difficult to forecast or generalize; how-
ever, several chapters will have a discussion on these synthetic materials.
With these more complex materials, the problems are immeasurably
more difficult and will take all the resources of modern techniques to
solve and produce.
The solid-state science has left its mark and will leave its mark in
some of the aforementioned fields but solid state is a basic science
showing no signs of running out of motivation for discovery within
itself. If there is one challenge for the years ahead, it is the challenge to
the engineering scientist to modify the traditions in his training and
practice to allow more room for the approach of the physicist in the
practically infinite spectrum of materials problems.
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The Author
Mel Schwartz has degrees
in metallurgy and engineer-
ing management and has
studied law, metallurgical
engineering, and education.
His professional experience
extends over 51 years serv-
ing as a metallurgist in the
U.S. Bureau of Mines; met-
allurgist and producibility
engineer, U.S. Chemical
Corps; technical manufac-
turing manager, chief R&D
Lab, research manufacturing
engineering, and senior staff
engineer, Martin-Marietta
Corporation for 16 years; program director, manager and director of
manufacturing for R&D, and chief metals researcher, Rohr Corp for
8 years; staff engineer and specification specialist, chief metals and metals
processes, and manager of manufacturing technology, Sikorsky Aircraft
for 21 years. While retired Mel has been a consultant for many compa-
nies including Intel and Foster Wheeler, and is currently editor for
SAMPE Journal of Advanced Materials.
Mel’s professional awards and honors include: Inventor Achievement
Awards and Inventor of the Year at Martin-Marietta; C. Adams Award
& Lecture and R.D. Thomas Memorial Award from AWS; first recipient
of the G. Lubin Award and an elected Fellow from SAMPE; an elected
Fellow and Engineer of the Year in CT from ASM; and Jud Hall Award
from SME.
Mel’s other professional activities involve his appointment to ASM
Technical Committees (Joining, Composites and Technical Books;
Ceramics); manuscript board of review, Journal of Metals Engineering as
peer reviewer; the Institute of Metals as peer reviewer as well as Welding
Journal; U.S. Leader of IIW (International Institute of Welding) Commis-
sion I (Brazing & Related Processes) for 20 years and leader of IIW
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Commission IV (Electron Beam/Laser and Other Specialized Processes)
for 18 years.
Mel’s considerable patent activity has resulted in the issuance of five
patents especially aluminum dip brazing paste commercially sold as
Alumibraze.
Mel has authored 16 books and over 100 technical papers and articles.
Internationally known as a lecturer in Europe, the Far East, and Canada,
Mel has taught in U.S. colleges (San Diego State, Yale University), ASM
Institutes, McGraw-Hill Seminars, and in-house company courses.
© 2006 by Taylor & Francis Group, LLC
