PRODUCTION TECHNOLOGY [MANUFACTURING PROCESS AND MATERIALS] by K.G. Aswani

Chapter 1 : MANUFACTURING TECHNOLOGY

Chapter 2 : MANUFACTURING MATERIALS

Part I : Ferrous metals

Part II : Non-ferrous metals and alloys

Part III : Ceramics

Part IV : Composites

Chapter 3 : PROPERTIES AND TESTING OF MATERIALS

Chapter 4 : PLASTIC FLOW AND MECHANICAL WORKING OF METALS

Chapter 5 : ROLLING AND EXTRUSION

Part I : Rolling

Part II : Extrusions

Chapter 6 : FORGING

Chapter 7 : SHEET METAL FORMING

Chapter 8 : SAND MOULDING PRACTICES AND METAL CASTING

Part I : Sand moulding and moulding processes

Part II : Metal casting

Part III : Cleaning and inspection of castings

Chapter 9 : MELTING FURNACES

Chapter 10 : WELDING AND OTHER JOINING PROCESSES

Chapter 11 : PLASTICS AND PLASTIC MOULDING

Chapter 12 : SURFACE FINISHING AND COATINGS

Chapter 1 : MANUFACTURING TECHNOLOGY

1-1	Introduction
	(1) (2) (3) (4) (5)	Metal cutting Metal forming Metal casting Fabrication Surface finish
1-2 1-3	Design considerations Factors affecting manufacturing processes
	(1) (2) (3)	Engineering requirements Manufacturing process Manufacturing cost
1-4	Types of materials
	(1) (2)	Metals (ferrous and non-ferrous) Non-metals
		(i) (ii) (iii)	Polymers Ceramics Composites
1-5	Manufacturing processes
	(1) (2) (3) (4)	Casting processes Forming processes Material removal processes Fabrication processes
1-6	Manufacturing cost
	(1) (2)	Fixed cost Variable cost
1-7 1-8	Break even point Reasons for cost estimates
	(1) (2) (3) (4) (5)	Cost control Fix selling price Make or buy decision Check supplier’s quotation Launching of new product
1-9 1-10	Factors affecting estimates Skills required for cost estimates
	(1) (2) (3) (4)	Estimating methods Education and training Experience Project management
	Exercise Top>>

Chapter 2 : MANUFACTURING MATERIALS

Part I Ferrous metals
2-1 2-2	Introduction Types of cast iron
	(1) (2) (3) (4)	Grey cast iron White cast iron Malleable cast iron Spheroidal graphite iron (nodular cast iron)
2-3     2-4	Iron–carbon equilibrium diagram Ferrite Austenite Cementite Pearlite Ledeburite Types of carbon steels
	(1) (2) (3)	Low carbon steel Medium carbon steel High carbon steel (tool steel)
2-5	Effect of residual elements on carbon steels
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Silicon Sulphur Phosphorus Manganese Nitrogen Oxygen Hydrogen Arsenic and antimony Tin
2-6	Alloy steels–classification
		(1) Low alloy steels (2) Medium alloy steels (3) High alloy steels
2-7	Alloying elements
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)	Chromium Nickel Tungsten Molybdenum Vanadium Cobalt Niobium Titanium Manganese Boron Silicon Aluminium
2-8	Properties of stainless steel and alloy steels
	(1)	Stainless steels
		(i) (ii) (iii)	Ferritic stainless steel Martensitic stainless steel Austenitic stainless steel
	(2)	Tool and die steels
		(i) (ii) (iii)	High-speed steels (h.s.s.) Cold worked tool steels Special purpose tool steels
	(3)	Heat resisting alloys steels
		(i) (ii) (iii) (iv)	Nickel base alloys Nimonic alloys Cobalt base alloys Ceramics and cermets
	(4) (5) (6) (7)	Hadfields manganese steel Spring steels High strength low alloy (hsla) steels High temperature bearing materials
2-9	Material coding (designation) system
	(1)	Coding system for castings
		(A) (B)	Plain castings Alloy castings
	(2) (3) (4) (5)	Coding system for ferrous metals Coding system for alloy steels Coding system for tool steels American iron and steel institute system
Part II Non-ferrous metals and alloys
2-10	Aluminium and aluminium alloys
	(1) (2)	Wrought alloys Cast alloys
		(i) (ii)	Heat treatable alloys Non-heat treatable alloys
2-11 2-12 2-13 2-14 2-15 2-16	Copper and copper alloys Magnesium and magnesium alloys Titanium alloys Zinc and zinc alloys Tin and tin alloys Bearing alloys
		(i) (ii) (iii)	white metal alloys bronze bearing alloys graphite bearings
2-17	Ceramics–constituents, structure and properties
	(1)	Structure of ceramics
		(i) (ii) (iii)	Crystalline ceramics Non-crystalline (amorphous) ceramics Bonded ceramics
	(2)	Properties of ceramics
		(i) (ii) (iii) (iv)	Thermal properties Mechanical properties Electrical properties Chemical properties
Part III Ceramics
2-18	Ceramic fibres
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Low thermal conductivity Light weight Thermal mass Thermal shock Mechanical shock Chemical attack Thermal expansion Acoustic properties Health and safety
2-19	Ceramic composites
Part IV Composites
2-20	Composites
	(1) (2) (3)	Fibre reinforced composites Particle reinforced composites (cermets) Dispersion reinforced composites
2-21	Materials for nuclear energy
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Uranium Thorium Plutonium Zirconium Beryllium Niobium Hafnium Cadmium Sodium Exercise Top>>

Chapter 3 : PROPERTIES AND TESTING OF MATERIALS

3-1	Properties of materials
Mechanical properties
3-2 3-3	Elastic and plastic behaviour Stress and strain
		Stress Strain
		(i) (ii)	Elastic strain Plastic strain
	(3) (4) (5) (6)	Hook’s law Poisson’s ratio Limit of proportionally Elastic limit
3-4 3-5	Stress–strain diagram for carbon steel Yield and tensile strength
	(1) (2)	Yield strength Tensile strength
3-6 3-7 3-8 3-9 3-10 3-11	Compressive, shear and torsional strengths Ductility Malleability Brittleness Hardness Hardenability
	(1)	Factors affecting hardenability
		(i) (ii) (iii) (iv)	Carbon content Structure of steel i.e., grain size, homogeneity and size of specimen Medium and process of quenching Shape of parts
	(2)	Jominy test
3-12 3-13 3-14 3-15 3-16	Toughness Stiffness Tenacity Resilience Factors affecting mechanical properties
	(1) (2) (3)	Grain size Temperature Carbon content
3-17	Impact strength
Impact test
		(i) (ii)	Izod test Charpy test
3-18	Hardness tests
	(1) (2) (3)	Brinell’s hardness test Application of brinell’s hardmess test Vickers hardness test Rock well hardness test
3-19	Fracture
	(1) (2)	Ductile fracture Brittle fracture
3-20	Factors affecting fracture
	(1) (2) (3)	Stress concentration Speed of loading Temperature
3-21 3-22 3-23	Fracture failure prevention Fracture toughness Factors affecting fracture toughness
	(1) (2) (3) (4)	Material thickness Composition of the material Heat treatment Service conditions
3-24 3-25	Fatigue Factors affecting fatigue properties
	(1) (2) (3) (4) (5) (6)	Microstructure of the material Stress concentration Residual stresses Surface finish Temperature Heat treatment
3-26	Fatigue test
	(1) (2) (3)	Bending stress test Alternate tension fatigue test Torsional fatigue test
3-27 3-28	Creep Factors affecting creep
	(1) (2) (3) (4)	(1) Temperature (2) Stress (3) Grain size (4) Composition
3-29 3-30	Mechanism of creep Creep resisting materials
	(1) (2) (3) (4)	Low alloy ferritic steels High alloy ferritic steels Ni-base supper alloys Refractory oxides and carbides
3-31	Non destructive testing (ndt)
	(1) (2) (3) (4) (5) (6)	Radiography Magnetic particle test Eddy current testing Liquid penetration test Spark test Ultrasonic inspection
3-32	X-rays properties and applications Properties of x-rays Application of x-rays Exercise Top>>

Chapter 4 : PLASTIC FLOW AND MECHANICAL WORKING OF METALS

4-1 4-2	Introduction Variables in metal working
	(1) (2) (3) (4)	Micro structure of metals Chemical composition Bonding forces Thermal changes
4-3 4-4	Wrought versus cast metals Plastic deformation
	(1) (2)	Deformation by slip Deformation by twinning
4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12	Mechanical working processes Cold working Warm working of metals Hot working of metals Work (strain) hardening Annealing of cold worked metals Recovery (stress relieving) Re-crystallisation
	(1) (2) (3) (4)	Re-crystallization temperature Alloying The grain size Cold work
4-13 4-14	Grain growth Grain size measurement Questions Top>>

Chapter 5 : MANUFACTURING TECHNOLOGY

Part I Rolling
5-1	Introduction
	(1) (2) (3)	Blooms Billets Slabs
5-2 5-3	Principles of rolling Methods of rolling
	(1) (2)	cold rolling Hot rolling
		(i) (ii) (iii)	Pack rolling Shape rolling Contour rolling
5-4	Classification of rolling mills
	(1) (2) (3) (4) (5) (6)	Two–high rolling mills Three–high rolling mills Roll design Four–high rolling mills Continuous roll mills Cluster mills Universal mills
5-5	Roll passes
	(1) (2) (3)	Break down pass Roughing pass Finishing pass
5-6	Break down passes
	(1) (2) (3)	Box pass series Diamond square series Oval square series
5-7 5-8	Draught Roll materials
	(1) (2) (3) (4)	Soft rolls Semi hard rolls Hard rolls Extra hard rolls
5-9 5-10	Tube (roll) piercing Defects in rolled products
Part II Extrusions
5-11 5-12 5-13	Principle of extrusion Design considerations and limitations Types of extrusions
	(1) (2)	Hot extrusion Cold extrusion
5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26	Forward hot extrusion Backward hot extrusion Hydrostatic (forward cold) extrusion Impact (backward cold) extrusion Cold extrusion forging Advantages of extrusion Extrusion blow moulding Extrusion pressure Wire drawing Tube drawing Bar drawing Rotary swaging Straightening Exercise Top>>

Chapter 6 : FORGING

6-1	Introduction
	(1) (2) (3) (4)	Drawing out Upsetting Shaping in a closed impression dies Shaping without closed impression dies
6-2	Drop forging impressions
	(1) (2) (3) (4) (5)	Fullering Edging Bending Blocking Finishing and trimming
6-3	Methods of forging
	(1) (2)	Cold forging Hot forging
6-4	Forging processes
	(1) (2) (3) (4)	Smith forging Drop (closed die) forging Press forging Machine (upset) forging
6-5	Smith forging
	(1) (2)	Steam hammers Hydraulic presses
6-6	Drop (die) forging
Drop hammers
	(1) (2) (3) (4)	Steam drop hammers board drop hammers Air/steam lift drop hammers Counter blow steam hammers
6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14	Press forging Machine (upset) forging High energy rate forging Roll forging Forge welding Forging materials Dies for drop forging Dies for upset forging
Location of cavities
6-15	Forging design
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)	Fillet and corner radii Parting line Draft angle Flash Gutter Flash land Direction of flow lines Fillets and curvatures Pockets and recesses Ribs Section size
6-16 6-17	Design guidelines for dies and punches Allowances on forgings
	(1) (2) (3) (4)	Shrinkage allowance Finish allowance Draft allowance Die wear allowance
6-18	Forging defects
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)	Cold shut Die shift Scale pits Unfilled areas Faulty grain flow Flakes Fins and rags Inaccurate dimensions Overheated or burnt metal Structural faults
6-19 6-20 6-21	General considerations Operations before and after forging Forged vis-à-vis cast parts Questions Top>>

Chapter 7 : SHEET METAL FORMING

7-1 7-2	Sheet metal forming processes Shearing operations
	(1) (2)	General shearing process Die shearing process
7-3	Shearing with dies
	(1) (2) (3)	Blanking Piercing Combined blanking and piercing layout
		(i) (ii) (iii) (iv)	Strip width Economy of material Direction of material grain Arrangement of tools (dies)
	(4) (5) (6) (7) (8) (9)	Trimming Shaving Nibbling Notching Punching Cutting
7-4 7-5 7-6 7-7 7-8 7-9 7-10	Angular clearance for dies Clearances for punch and die Minimum diameter for piercing Design requirements for punch press parts Shearing force and work done Stripping force Drawing
	(1) (2)	Redrawing Ironing
7-11 7-12 7-13 7-14 7-15 7-16	Deep drawing Blank size Punch (drawing) force Lubrication Punch (drawing) speed Forming (bending)
		Designing parts for bending
7-17	Forming (bending) methods
	(1) (2)	Cold roll forming Roll bending
			Types of dies for bending
7-18 7-19 7-20 7-21	Bend length Bending load Work done during bending Power required
	(1) (2)	Power required-hydraulic press Power required by horizontal plate bending machine
7-22 7-23 7-24	Stretch forming Bulging Coining, embossing and stamping
	(1) (2) (3)	Coining Embossing Stamping
7-25	Tests on sheet metals
	(1)	Bend tests
		(i) (ii)	Single bend test Reveres bend test
	(2)	Cupping test
7-26 7-27 7-28	Spinning Power press construction Types of power presses
	(1) (2)	Hydraulic power press Mechanical power press
		(i) (ii)	Single action press Double action presses
	(3) (4) (5)	Hand operated press (fly press) Foot press Screw press
7-29	Safety devices for power press Exercise Top>>

Chapter 8 : SAND MOULDING PRACTICES AND METAL CASTING

Part I Sand moulding and moulding processes
8-1	Introduction
	(1) (2) (3) (4)	Liquid stage Musy stage Plastic stage Solid stage
8-2	Basic steps in sand moulding
	(1) (2) (3) (4) (5) (6) (7)	Pattern making Core making Moulding Gating system Melting and pouring Solidification Cleaning
8-3 8-4	Sand mould preparation Pattern materials and types
	(1) (2)	Pattern materials Pattern types
		(i) (ii) (iii) (iv) (v) (vi) (vii) (viii)	Single piece pattern Split pattern Cope and drag pattern Match plate patterns Gated pattern Master pattern Sweep pattern Loose (piece) patterns
8-5	Pattern allowances
	(1) (2) (3) (4)	Shrinkage Distortion Machine finish Draft
8-6 8-6-1	Moulding processes and materials Processes based upon type of sand used
	(1) (2) (3) (4)	Dry sand moulds Green sand moulds Skin dried mould Loam mould
8-6-2	Processes based upon machine used
	(1) (2) (3) (4)	Jolt moulding machine Jolt squeeze machine Sand slinging Core moulding
8-6-3	Special moulding processes
	(1) (2) (3) (4) (5) (6) (7) (8)	Plaster moulding Shell moulding process CO2 moulding process Antioch moulding process Cement sand moulding Shaw moulding process Graphite moulds Ceramic moulding
			Advantages Limitations
	(9) (10)	Hot and cold box moulding process Investment moulding process
8-6-4	Methods used
	(1) (2)	Full moulding process Pit moulding
8-7	Types of moulding sand
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Green sand Dry sand Natural bonded sand Synthetically bonded sand Facing sand Loan sand Mould washes Backing sand Parting sand
8-8	Properties of moulding sand
	(1) (2)	Grain size Clay and water
		(i) (ii)	Kaolinite or fine clay Bentonite
	(3) (4) (5) (6) (7)	Chemical inertness Permeability Green strength Dry and hot strength Refractoriness
8-9	Sand tests
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)	Grain fineness Permeability Moisture content Clay content Green compressive strength (gcs) Compactability Refractoriness Methylene blue (mb) (active) clay Volatile matter Loss on ignition
8-10 8-11	Mould and core materials Core making
	(1)	Properties of cores
		(i) (ii) (iii) (iv) (v) (vi) (vii) (viii)	Dry strength Green strength Permeability Refractoriness Smoothness Low gas emission Collapsibility Friability
	(2)	Types of cores
		(i) (ii)	Dry sand cores Green sand cores
	(3)	Materials for cores
8-12 8-13 8-14 8-15 8-16	Core boxes and core plates Core dryers Chaplets Core prints Core sands and binders
		Core binders
8-17	Core making machines
	(1) (2) (3) (4)	Core blowers Screw feed machines Core ovens Core dryers
8-18 8-18-1	Gating system Components of gating system
	(1) (2) (3) (4) (5) (6) (7)	Pouring basin Sprue Sprue base well Runners Riser Gates Gating ratio
8-18-2	Types of gating
	(1) (2) (3) (4) (5) (6)	Parting line system Bottom gating Side gating system Top gating system Pencil gates Wedge gate
8-19 8-20 8-21	Gating design Pouring time Fluidity of molten metal and fluidity test
	(1) (2)	Fluidity of molten metal Fluidity test
8-22	Terminology
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18)	Moulding sand Facing sand Backing sand Pattern Core Mould Drag and cope Runner Sprue Pouring basin Gate Chills Riser Chaplets Bottom board Flask Dump box Parting line
Part II Metal casting
8-23 8-24	Solidification of metals Design for sound castings
	(1) (2) (3) (4) (5) (6) (7) (8)	Minimum section thickness Sharp corners Different section thickness Changes in section thickness Sharp inside corners Bosses on casting surfaces Residual stresses Joint design
8-25	Types of casting processes
	(1) (2) (3) (4)	Permanent mould castings Expandable mould and pattern castings Permanent pattern castings Newly developed casting processes – continuous casting
8-26	Permanent mould castings
		Advantages Limitations
		(i) (ii) (iii) (iv)	Pressure die-castings Gravity die castings Vacuum die casting Centrifugal casting
			(a) (b) (c)	True centrifugal casting Semi centrifugal casting Centrifuging
8-27 8-27-1	Expandable mould and pattern castings Investment or precision castings
	(1) (2)	Preparation of wax pattern Preparation of dies
8-27-2 8-27-3 8-27-4	Plaster mould casting Ceramic mould castings Antioch casting
		Advantages
8-28	Permanent pattern casting
	(1)	Shell moulding casting
			Advantages Limitations
	(2)	Sand mould castings
			Advantages Limitations
8-29	Newly developed casting process
		Continuous casting
Part III Cleaning and inspection of castings
8-30	Cleaning and finishing of castings
	(1) (2) (3) (4) (5) (6)	Surface cleaning Hydraulic cleaning Removal of cores and gates Removal of gating and risers Removal of fins and other unwanted projections Flame gouging Grinding
8-31	Casting defects and remedies
	(1)	Entrainment of air and gas defects
		(i) (ii) (iii)	(i) Blow holes (ii) Internal air pockets (iii) Pin holes porosity
	(2)	Design defects
		(i) (ii) (iii) (iv) (v)	Hot tears (cracks) Cold shuts Mis runs Fins Warping
	(3)	Metal pouring defects
		(i) (ii) (iii) (iv)	Pour short Metal penetration Sponginess and honey combing Slag inclusions
	(4)	Moulding defects
		(i) (ii) (iii) (iv) (v) (vi)	Run out Fusion Rat tails Swell Drop Cuts
	(5)	Shrinkage defects
		(i) (ii) (iii) (iv) (v)	(i) Cold cracks (ii) Metal contraction during solidification (iii) Shrinkage cavity (iv) Hot spots (v) Chills
8-32 8-33	Precautions to avoid defects Inspection of castings
	(1)	Non-destructive testing
		(i) (ii) (iii) (iv) (v) (vi) (vii)	Visual inspection Dimensional inspection Process inspection Pressure tests Radiography Penetrant tests Magnetic particle test
	(2)	Destructive test
8-34	Casting yield Exercise Top>>

Chapter 9 : MELTING FURNACES

9-1 9-2 9-3	Melting furnaces Types of furnaces Cupola: Melting furnace for ferrous metals
	(1) (2)	Construction Zones of a cupola
		(i) (ii) (iii) (iv) (v) (vi)	Charging and stack zone Preheating zone Melting zone Reducing zone Oxidising or combustion zone Crucible zone
9-4 9-5	Cupola operation Metallurgical control Combustion air supply and control Cupola charging
	(1)	Raw materials
		(i) (ii) (iii) (iv)	Pig iron Hard coke Ferro alloys Lime stone
	(2)	Coke bed
		(i) (ii) (iii) (iv)	Ignition Addition Consolidation Height of bed coke
	(3) (4) (5) (6)	Precautions during charging Hot blast cupola Cupola shut down Sizing of cupola
9-6	Cupola efficiency and heat balance
		Heat input Heat output
9-7 9-8 9-9 9-10	Gas and/or liquid fuel furnaces Open hearth (reverberatory) furnace Air furnace Crucible furnace: For melting non-ferrous metals
	(1) (2)	Tilting type Pit type
9-11 9-12 9-13 9-14	Non-crucible furnaces Rotary melting furnaces Bessemer converter Ladles
	(1) (2) (3) (4) (5)	Hand ladle Shank ladles Tea pot ladle Bottom pour ladle Ladle handler
9-15	Electric furnaces
	(1) (2) (3)	Direct arc furnace Indirect arc furnace Induction furnaces
		(i) (ii)	Core type induction (low frequency) furnace Core less type induction furnace
	(4)	Electric resistance furnace
9-16	Temperature measurement
	(1) (2) (3)	Thermocouple pyrometers Optical pyrometers Radiation pyrometers
	Exercise Top>>

Chapter 10 : WELDING AND OTHER JOINING PROCESSES

10-1 10-2	Joining processes Welding process
		Edge preparation of joints
		(i) (ii) (iii) (iv) (v)	Butt joint T-joint Corner joint Lap joint Spot weld
10-3	Types of welding processes
	(1) (2) (3) (4) (5)	Fusion or gas welding Plastic or arc welding Resistance welding Solid state welding Thermit welding
10-4	Oxy-acetylene gas welding
	(1) (2)	Process Types of flames
		(i) (ii) (iii)	Neutral flame Reducing flame Oxidizing flame
	(3)	Equipment for oxy-acetylene welding
		(i) (ii) (iii) (vi) (v) (vi)	Welding torch with tip Pressure regulator Gas cylinders (oxygen and acetylene) Hose pipe and hose fittings Safety goggles and hand gloves Spark lighter
10-5	Gas welding techniques
	(1) (2) (3)	Forehand or leftward welding Backhand or rightward welding Vertical welding
10-6	Arc welding
	(1) (2) (3) (4)	Process of arc welding Equipments for arc welding Arc welding electrodes Power supply of arc welding machines
		(i) (ii)	Alternating current (a.c.) power supply Direct current (d.c.) power supply
	(5)	Types of arc welding machines
		(i) (ii)	constant current or drooping curve welding machines Constant voltage welding machines
	(6)	Types of welding processes
10-7	Shielded metal arc welding (smaw)
		Arc energy Arc length
10-8 10-9 10-10 10-11 10-12	Flux cored arc welding (fcaw) Submerged arc welding (saw) Gas metal arc welding (gmaw) Tungsten inert-gas (tig) welding Plasma arc welding (paw)
	(1) (2)	Transferred arc mode Non-transferred arc mode
			Advantages Stud welding
10-13	Resistance welding
	(1) (2) (3) (4)	Resistance spot welding Resistance seam welding Projection welding Upset welding
Heat consumed and melting efficiency
10-14	Solid state welding
	(1) (2) (3) (4)	Friction welding Ultrasonic welding Explosive welding Diffusion welding
10-15 10-16 10-17 10-18 10-19 10-20 10-21	Thermit welding Electron beam welding (EBW) Laser beam welding (LBW) Electro-slag welding (ESW) Atomic hydrogen welding (AHW) Robotic arc welding (RAW) Types of weld joints
	(1) (2) (3)	Fillet weld (lap joint) Groove weld (butt joint) Plug and slot welds
10-22 10-23	Electrode classification Soldering
	(1) (2) (3)	Soldering iron Dip soldering Wave soldering
10-24 10-25	Brazing Braze welding
Distinction between soldering, brazing and braze welding
10-26 10-27	Metallizing Welding of various metals
	(1)	Carbon steels
		(i) (ii) (iii) (iv)	Low carbon steels Medium carbon steels Higher carbon steels Low alloy steels
	(2)	stainless steels
		(i) (ii) (iii)	Ferritic stainless steels Martensitic stainless steels Austenitic stainless steels
			(a) (b)	Sensitization Hot cracking
		(iv) (v)	Precipitation – hardening stainless steels Duplex stainless steels
	(3) (4) (5)	Cast iron Aluminium and aluminium alloys Copper and copper alloys
10-28	Welding defects
	(1) (2) (3) (4) (5) (6) (7) (8)	Distortions Incomplete fusion Porosity Slag inclusion Hot cracking Cold cracking Under cut Lamellar tearing
10-29	Thermal cutting
	(1) (2) (3) (4)	Oxy fuel cutting Plasma arc cutting (pac) Plasma arc gouging Air arc gouging (aag)
10-29	Mechanical fasteners
	(1) (2) (3) (4) (5)	Bolted assemblies Cap screws Self-tapping screws Self-locking plates Riveting and staking
10-31 10-32	Adhesive bonding Types of adhesives
	(1) (2) (3) (4)	Epoxies Anaerobic Cyanoacrylate Toughened adhesives
10-33	Terminology
	(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)	Arc cutting Back hand welding Backing weld Braze weld Buildup Buttering Butt joint Butt weld Carbon arc Caulk weld (seal weld) Crater Fish-eye Flash back Flux Fillet weld Fusion weld MIG welding Neutral flame Nugget Oxidising flame Stress crack Sweating Tack weld Tig Undercut Wagon tracks Weld metal
	Exercise Top>>

Chapter 11 : PLASTICS AND PLASTIC MOULDING

11-1 11-2 11-3	Introduction Characteristics of plastics Thermoplastic polymers
	(1) (2) (3) (4) (5) (6)	Acrylic resin Nylon Polypropylene Polystyrene Polyvinyl chloride (pvc) Polyethylene resins
11-4	Thermosetting polymers
	(1) (2) (3) (4)	Epoxy resins Amines Phenolic resins (bakelite) Silicones
11-5	Additives
	(1) (2) (3) (4) (5) (6) (7) (8) (9)	Antioxidants (stabilizers) Blowing agents Fillers Foaming agents Hardeners (cross-linking agents or catalyst) Initiators Pigments (dyes and pigments) Plasticizers Reinforcing fillers
11-6 11-7 11-8 11-9	Moulding processes Compression moulding Process characteristics Transfer moulding Injection moulding
	(1) (2) (3)	Process equipments Process characteristics Application
11-11 11-12 11-3	Design requirements for injection moulding Jet blowing Plastic extrusion process Process equipments Blow moulding
	(1) (2)	Extrusion type blow moulding Injection type blow moulding
11-14 11-15 11-16	Rotational moulding Process equipment Calendering Thermo-forming (vacuum forming)
	(1) (2) (3)	Vacuum forming Drape vacuum forming Vacuum snap back forming
11-17 11-18	Blown film process Casting
	(1) (2) (3)	Shell moulding Slush moulding Centrifugal casting
11-19	Design of plastic moulds
	(1) (2) (3) (4) (5) (6)	Selection of process Selection of resin material Design of mould cavity Feed system Material of construction General requirements
11-20 11-21	Machining of plastics Laminates
	(1) (2) (3) (4)	Low pressure laminates High pressure laminates Contact lap method Rubber bag method
11-22 11-23 11-24	Foamed plastics Summary of plastic moulding processes Joining of plastics
	(1) (2) (3) (4) (5) (6)	Mechanical fasteners Hot gas welding Hot platen welding Dielectric welding Solvent bonding Ultrasonic welding
11-25	Plastics in packaging Exercise Top>>

Chapter 12 : SURFACE FINISHING AND COATINGS

12-1 12-2 12-3	Introduction Cleaning and finishing Chemical cleaning
	(1)	Vapour (solvent) degreasing
		(i) (ii)	Water cleaning Petroleum solvents
	(2) (3) (4) (5)	Acid pickling Alkaline cleaning Emulsified solvent cleaning Ultrasonic cleaning
	12-4. Mechanical cleaning
	(1) (2)	Shot blasting Polishing and buffing
		(i) (ii)	Grease base Grease less
	(3) (4) (5) (6)	Belt grinding Barrel finishing and tumbling Liquid honing Power brushing
12-5 12-6 12-7 12-8 12-9 12-10	Thermal–explosive debarring Electro-polishing/forming Surface coating Properties of coatings Types of coatings Metallic coatings
	(1)	Metal spraying or metallizing
		(i) (ii)	Use of metal in powder form Use of metal wire instead of powder
	(2) (3)	Vacuum coating Hot dip plating
		(i) (ii) (iii)	Galvanizing Tin coating Aluminizing (Calorizing)
	(4)	Electroplating
12-11	Organic coatings
	(1) (2) (3) (4) (5) (6)	Primers Paints Varnishes Lacquers Enamels Rubber base coatings
		(i) (ii) (iii)	Chlorinated rubber Neoprene rubber Hypolan
12-11-1	Constituents and application of paints
	(1)	Constituents of paints
		(i) (ii) (iii) (iv)	Binders or vehicles Pigments Solvents and thinners Additives
	(2)	Application of paints
		(i) (ii)	Spray painting Electrostatic painting
12-12	Inorganic coatings
	(1) (2) (3)	Vitreous enamelling Ceramic coatings Composite coatings
		(i) (ii) (iii) (iv) (v)	Fibre-reinforced metal composites Particle dispersed metal composites Laminated composites Electroless composites Optical composites
12-13	Chemical conversions
	(1) (2) (3) (4)	Anodizing Chromate coating Phosphate coating Chemical oxide coating
12-14	Plastic coating
	(1) (2) (3) (4) (5)	Liquid plastisol Fine powder dipping Electrostatic spraying Vacuum coating Flame spraying
12-15	Electron beam coating Exercise Top>>