MATERIALS PROCEESSING AND MANUFACTURING SCIENCEPDF电子书下载

1 Materials Behavior 1

Introduction 1

Process Innovation as Driver of Technological Growth 2

Single-Crystal Turbine Blades 2

Copper Interconnects for Microelectronic Packages 2

Tungsten Filament for Light Bulbs 3

Tailor-Welded Blanks 3

Atomic Bonding in Materials 4

Crystal Structure 6

Defects in Crystalline Solids 10

Annealing 14

Diffusion in Crystalline Solids 17

Mechanical Behavior 21

Strengthening of Metals 26

Fracture Mechanics 27

Fatigue 31

Creep 34

Deformation Processing 35

Heat Treatment 35

Precipitation Hardening 44

Thermal Properties 45

Electrical Properties 48

Dielectric and Magnetic Properties 50

Optical Properties 52

2 Casting and Solidification 57

Casting Techniques 57

Expendable-Mold Casting 58

Green Sand Casting 58

Thermal Considerations 65

Dry Sand and Skin-Dried Molds 69

Sodium Silicate-CO2 Process 69

Vacuum Molding 70

Shell-Molding 71

Investment Casting 72

Lost-Foam Casting 74

Other Expendable Mold Processes 75

Multiple-Use Mold Casting 75

Permanent Mold Casting 75

Die Casting and Semisolid Casting 77

Squeeze Casting 83

Centrifugal Casting 86

Continuous Casting 86

Single-Crystal Casting and Directionally Solidified Structure 86

Fluidity 95

Melt Treatments 98

Metallic Foams and Gasars 100

Melting Furnaces 102

Mold-Filling Time 102

Gate and Runner Area Calculation 105

Temperature Drop in Metal Flow 106

Riser Design 111

Naval Research Lab Method 113

Riser Size Estimation Using Chvorinov’s Rule 116

Solidification Rate 119

Sand Mold 119

Die Casting 122

Stages of Solidication—Nucleation and Growth 125

Nucleation 125

Homogeneous Nucleation 126

Heterogeneous Nucleation 130

Nucleation and Grain Refinement 133

Growth During Solidification 134

Atomic Structure at the Solidification Interface 134

Growth in Pure Metals 137

Growth of Single-Phase Alloys 139

Constitutional Supercooling and Interface Instability 142

Eutectic Solidification 146

Solidification of Industrial Castings： 149

Grain Structure 149

Segregation 151

Constrained Solidification in Small Regions 153

Rapid Solidification and Metallic Glass 157

Weld Solidification 158

Solidification Under Reduced Gravity 160

Interactions of Solidification Front with Insoluble Particles 162

3 Powder Metallurgy and Ceramic Forming 167

Crystalline Ceramics and Glasses 167

Powder Metallurgy 172

Powder Production 172

Solidification of Atomized Droplets 174

Other Methods of Powder Manufacture 176

Particle Size and Shape 177

Powder Mixing 179

Powder Compaction 180

Dynamics of Powder Densification 181

Isostatic Compaction and Hot Isostatic Compaction（HIP） 185

Analysis of Pressure Distribution in Uniaxial Compaction 185

Pressure Distribution in an Annular Cylinder 187

Powder Injection-Molding（PIM） 188

Rheological Considerations in Powder Injection-Molding 191

Settling and Segregation in Powder Injection-Molding Slurries 195

Sintering 197

Mechanism of Sintering 198

Other Considerations in Sintering 203

Homogenization 203

Coarsening 205

Ceramic Forming 207

Slip-Casting 207

Tape-Casting 213

Ceramic Extrusion 215

Electrolytic and Electrophoretic Deposition 216

Glass Forming 220

Pore Characterization 224

Properties of Ceramics 227

Mechanical Properties 227

Thermal Properties 232

Electrical and Electronic Properties 235

Oxidation and Corrosion Resistance 237

Bioceramics and Porous Ceramic Foams 240

Joining of Ceramics 241

4 Surface，Subsurface，and Interface Phenomena 247

Surface Forces 248

Electrostatic Forces 248

Van der Waals Forces 250

Contact Angle，Surface Tension，and Young’s Equation 251

Grain Boundaries in Polycrystals 254

Three-Phase Equilibrium 255

Microscopic Angles and Precursor Film 257

Roughness and Chemical Inhomogeneity 257

Dynamic Contact Angles 260

Immersion of Solids in Liquids 264

Gas-Solid Attachment and Gas Stabilization 268

Agglomeration 268

Capillary Flow 273

Capillary Pressure 273

Capillary Rise 275

Wettability and Capillary Rise at High Temperatures 280

Effect of Oxide on Liquid 280

Alloying and Surface Coatings 282

Reactive Infiltration 283

Reactive Penetration 285

Capillary Flow with Unsteady Contact Angle and Pore Size 286

Joining 289

Adhesion 296

Capillarity in Miscellaneous Other Processes 298

Wear，Friction，and Lubrication 301

Corrosion 307

5 Coatings and Surface Engineering 313

Design and Development of Coatings 313

Surface Pretreatments 314

Coating Techniques 316

Vapor-Phase Deposition 316

Nucleation and Growth in Vapor Condensation 320

Ion-Nitriding 324

Thermal Spray-Coating 325

Physical Considerations in Thermal Spraying 326

Structure，Properties，and Applications of Thermal Spray Coatings 332

Electroplating 338

Physical Considerations 338

Plating Practice 339

Electroless Plating 343

Anodizing 345

Coatings on Powders and Fibers 348

Organic Coatings—Paints and Powders 348

Powder Coatings 351

Electrostatic Powder Spray 351

Electrocoating 352

Conversion Coatings 353

Vitreous Ceramic Coatings 353

Surface Hardening 355

Selective Hardening 355

Diffusion Hardening 357

Laser Surface-Engineering 361

Laser-Materials Interaction 361

Types of Lasers 362

Lasers as Surface-Engineering Tools 363

Characteristics of Laser Surface Engineering 364

Laser Surface Heating 368

Laser Surface Melting 372

Solidification Structure 374

Laser Surface Alloying 377

Laser-Induced Ceramic Coating 381

Laser-Cladding 382

Laser-Induced Combustion Synthesis 387

Laser Surface-Vaporization 387

Laser Surface-Texturing 388

Laser Surface Cleaning 390

Laser Surface-Marking 391

Laser Surface-Shocking 391

Miscellaneous Laser Processes 391

Residual Stress State of Laser-Treated Surface 392

Promise of Lasers in Surface-Engineering 394

6 Composite Materials 397

Definition and Classification 397

Fibers 398

Glass 399

Boron 399

Carbon Fiber 400

Organic Fibers 402

Metallic Fibers 402

Ceramic Fibers 403

Interface 406

Fiber Strengthening 409

Polymer-Matrix Composites 410

Matrix 410

Properties of Polymeric Matrices 414

Polymer Composites 414

Ceramic-Matrix Composites 418

Carbon-Carbon Composites 423

Chemical Vapor Infiltration 425

Metal-Matrix Composites 429

Heat-Resistant Composites 429

Dispersion-Strengthened Composites 429

In Situ Composites 433

Particulate and Fiber-Reinforced High-Temperature Alloys 436

Fabrication of Metal-Matrix Composites 439

Solid-State Fabrication 440

Liquid-State Fabrication 445

Infiltration 445

Reactive Infiltration 448

Stirring Techniques 453

Low-Cost Composites by Casting 455

Other Liquid-Phase Techniques 457

Wettability and Bonding 458

Ni-Base Composites 458

Properties 460

Interface Strength 460

Fiber Strength 467

Stiffness，Strength，and Ductility 469

Fatigue and Fracture Toughness 475

Other Properties 476

Creep 476

Vibration Damping 477

Wear and Friction 477

Thermal Properties 480

Thermal Fatigue 482

Oxidation Resistance 483

7 Semiconductor Manufacturing 485

Introduction 485

Integrated Circuit Applications and Market 485

Feature Size and Wafer Size 486

Technology Trends 489

Fundamentals of Semiconductors 489

Crystal Structure of Silicon 489

Energy Band Theory 493

The Fermi Level 495

Intrinsic Semiconductor 495

Extrinsic Semiconductor 497

Dopant Concentration and Conductivity 498

Diodes 498

Bipolar Junction Transistors（BJT） 500

Metal Oxide Field Effect Transistors（MOSFET） 503

Crystal Growth and Wafer Preparation 504

Czokhralski Method 505

Floating-Zone Method 506

Defects 507

Wafer Preparation 510

Initial Steps 510

Wafer Slicing 510

Postslicing Polishing and Cleaning 511

Oxidation 512

Properties of Silicon Dioxide 512

Oxidation Techniques 512

Oxidation Furnaces and Factors Affecting Oxide Growth 514

Characterization of Oxide Films 515

Simulation 517

Diffusion 517

Fick’s Diffusion Equations 518

Constant Source Diffusion 519

Limited Source Diffusion 519

Diffusion Coefficient 520

Concentration-Dependent Diffusion 520

Lateral Diffusion 521

Junction Depth 521

Sheet Resistance 521

Simulation 522

Ion Implantation 522

Ion Implanter 522

Channeling 523

Implantation Damage 524

Annealing 524

Rapid Thermal Annealing 524

Photolithography 524

Introduction 524

Optical Lithography 526

The Clean Room 526

The Pattern Transfer Process 527

Exposure Systems 530

Masks and Resists 532

Thin Film Deposition 532

Vacuum Deposition Techniques 532

Physical Vapor Deposition 532

Evaporation 533

Sputtering 534

Reactive Sputtering 535

Radio Frequency（RF）Sputtering 535

Magnetron Sputtering 535

Collimated Sputtering 535

Ionized Magnetron Sputtering 536

Chemical Vapor Deposition 536

Epitaxy 537

Molecular Beam Epitaxy 537

Nonvacuum Deposition Techniques 537

Chemical Bath Deposition 537

Spin-On Deposition 538

Etching 538

Introduction 538

Etching Types 538

Wet Etching 538

Dry Etching 539

Ion Beam Milling 539

Plasma Etching 540

Reactive Ion Etching 540

Metallization 540

Ohmic Contacts 540

Metals and Alloys 541

Junction Spiking 541

Electromigration 542

Copper Metallization 542

Damascene Technology 543

Chemical Mechanical Polishing（CMP） 544

Silicide 544

Packaging 546

Traditional Packaging 546

Advanced Packaging 547

Yield and Reliability 548

Yield 548

Processing Effects 548

Circuit Sensitivities 548

Point Defects 549

Reliability 549

8 Nanomaterials and Nanomanufacturing 551

Introduction 551

Nanotubes，Nanoparticles，and Nanowires 552

Methods Using Solid Precursors 554

Inert Gas Condensation 554

Pulsed Laser Ablation 555

Ion Sputtering 557

Methods Using Liquid or Vapor Precursor 557

Chemical Vapor Synthesis 557

Laser Pyrolysis 557

Synthesis of Nanopaicles by a Chemical Methods 557

Nanoparticles：Biomedical Applications 558

Tissue Engineering 560

Manipulation of Cells and Biomolecules 561

Protein Detection 562

Cancer Therapy 562

Semiconductor Nanowires 563

General Synthetic Strategies 563

Fabrication of Semiconductor Nanowires 565

Fabrication of Metal Nanowires 569

Electrochemical Fabrication of Metal Nanowires 571

Negative Template Methods 571

Anodic porous Alumina 572

Fabrication of Metal Nanowires 573

Positive Template Method 575

Carbon Nanotube Template 575

DNA Template 575

Polymer Templates 576

Applications of the Nanowires 579

Magnetic Materials and Devices 579

Optical Applications 580

Biological Assays 580

Chemical Sensors 581

Carbon Nanotubes 581

Structure of the Carbon Nanotube 583

Synthesis of Carbon Nanotubes 585

Growth Mechanisms of Carbon Nanotubes 587

Carbon Nanotube Composite Materials 588

Polymer NanoComposites 590

Ceramic NanoComposites 591

Ceramic Nanotube Composite Systems 593

Ceramic-Coated MWNTs and SWNTs 594

Conductive Ceramics 595

Nanostructured Metals and Metal Composites 595

Solid-State Powder-Based Processing 596

Liquid-Phase Processing 597

Surface，Interface，Nucleation and Reactivity 599

Agglomeration，Dispersion and Sedimentation 601

Properties 602

Strength and Modulus 602

Nanotribology 603

Carbon Nanotubes：Biosensor Applications 603

FET-Based Biosensors 604

Aligned Nanoelectrode Array-Based Electronic Chips 605

Index 615