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| موضوع: كتاب Handbook of Manufacturing Processes الأربعاء 02 مايو 2012, 11:40 pm | |
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تذكير بمساهمة فاتح الموضوع : أخواني في الله أحضرت لكم كتاب Handbook of Manufacturing Processes How Products, Components and Materials Are Made James G. Bralla With Contributions by a Distinguished Editorial Board
و المحتوى كما يلي :
TABLE OF CONTENTS IN BRIEF Editorial Board xxvii About the Author xxix Dedication xxxi Preface xxxii Acknowledgments xxxv How to use this Handbook xxxvii Section I - Manufacturing Processes xxxix Chapter 1 - Casting Processes 1 Chapter 2 - Metal Forming Processes 33 Chapter 3 - Machining Processes 87 Chapter 4 - Processes for Plastics 147 Chapter 5 - Glass and Ceramic Processes 211 Chapter 6 - Woodworking Processes 255 Chapter 7 - Assembly and Fusion (or Joining) Processes 295 Chapter 8 - Finishing Processes (including Heat Treating) 329 Chapter 9 - Paper, Fiber and Printing Processes 361 Chapter 10 - Textile Processes 385 Chapter 11 - Chemical Processes 417 Chapter 12 - Food Processes 483 Chapter 13 - Processes for Electronic Products 519 Chapter 14 - Advanced Manufacturing Methods 585 Section II - How Products, Components and Materials Are Made 613 Index 78 v Preface xxxii Section I-Manufacturing Processes Editorial Board xxvii About the Author xxix Dedication xxxi Preface xxxii Acknowledgments xxxv How to use this Handbook xxxvii Chapter 1-Casting Processes 1 A. Melting Metal for Casting 1 A1. cupola melting 1 A2. electric arc melting 1 A3. crucible melting 2 A4. air furnace (reverbatory) melting 2 A5. induction melting (high frequency and low frequency) 2 A6. open-hearth melting 4 A7. pouring 4 B. Sand-mold Casting 5 B1. green sand casting 6 B2. dry sand casting 6 B2a. skin-dried casting 6 B3. other sand-mold casting processes 6 B3a. shell mold casting 6 B3b. lost foam casting 8 B3c. magnetic molding 9 B3d. V-process casting (vacuum molding) 9 B3e. cement-sand molding 9 B3f. loam molding 9 B3g. flaskless mold casting 11 B3h. Antioch process 11 B4. core making 12 B4a. green sand cores 13 B4b. core blowing 13 B4c. core baking 13 B4d. oil-oxygen process 13 B4e. furan no-bake core process 13 B4f. carbon-dioxide process 14 B4g. shell process for cores 14 B5. sand mold methods 14 B5a. ramming 14 B5b. bench molding 14 B5c. floor molding 14 B5d. pit molding 14 B5e. machine methods 14 B5e1. jolt-squeeze methods 14 B5e2. sand slinging 15 B5e3. rap-jolt machines 15 B5e4. match-plate molding 15 B6. sand processing 16 B6a. sand mulling 16 B6b. reclamation of sand 16 B6b1. mechanical reclamation 16 B6b2. thermal reclamation 17 B6b3. wet reclamation 17 B6c. metal separation from sand 17 B6d. cooling of sand 17 B7. pattern making 18 B8. post-molding operations 18 B8a. shakeout 18 B8b. core knockout 18 B8c. blast cleaning 19 B8d. tumble cleaning 19 B8e. wire brush cleaning 20 B8f. gate, riser and fin removal 20 B8g. snagging 20 C. Other Expendable Mold Processes 20 C1. ceramic mold casting 20 C2. ceramic-shell process 21 C3. Shaw process 21 C4. Unicast process 21 C5. plaster mold casting 22 C5a. foamed plaster mold casting 22 D. Permanent Mold Processes 23 D1. permanent mold casting 23 D2. low pressure permanent mold casting 24 D3. slush casting 24 D4. pressed casting 24 D5. vacuum casting 24 E. Centrifugal Casting 24 E1. true centrifugal casting 25 E2. semicentrifugal casting 25 E3. centrifuged casting 25 DETAILED TABLE OF CONTENTSvi Table of Contents F. Die Casting 26 F1. hot-chamber die casting 26 F2. cold-chamber die casting 27 F3. trimming 28 F4. impregnation of die castings 28 G. Investment Casting (lost wax process) 29 G1. flask method 29 G2. shell method 29 H. Continuous Casting 32 Chapter 2-Metal Forming Processes 33 A. Hot and Warm Forming Methods 33 A1. hot rolling 33 A2. hot drawing or cupping 34 A3. extrusion 34 A3a. indirect extrusion 35 A3b. Sejournet process 35 A4. forging 35 A4a. open-die drop-hammer forging (hammer, flat-die or smith forging) 36 A4b. impression die forging (closed die forging) (die forging) 36 A4b1. drop forging 36 A4b2. precision forging 37 A4b3. flashless forging 37 A4c. press forging 37 A4d. upset forging 38 A4e. roll forging 38 A4f. isothermal forging 38 A4g. swaging 38 A4h. ring rolling (mandrel forging) 38 A5. piercing 39 A6. pipe welding 39 A7. hot spinning 39 A9. warm heading 39 B. Primary Cold-working Operations 39 B1. rolling 39 B2. cold drawing 40 C. Sheet Metal Cutting Operations 40 C1. shearing 40 C1a. squaring shears 41 C1b. alligator shears 41 C1c. rotary shears 42 C2. nibbling 42 C3. slitting 42 C4. blanking 42 C4a. steel rule die blanking 43 C4b. dinking 43 C4c. cutoff 44 C4d. parting 44 C4e. photochemical blanking 44 C5. punching 44 C5a. turret punching 44 C5b. notching 45 C6. trimming 46 C7. shaving 46 C8. lancing 46 C9. fineblanking 46 C9a. semi-piercing 48 D. Press Bending and Forming Operations of Sheet Metal 48 D1. bending 48 D1a. press brake bending 48 D1b. V-die bending 49 D1c. air bending 50 D1d. punch press (bending die) bending 50 D2. forming 50 D3. forming with rubber tooling 51 D3a. rubber tool forming (rubber pad forming) 51 D3b. Guerin process 51 D3c. Marform process 51 D3d. rubber diaphragm forming (hydroform process) (fluid forming) 52 D3e. Verson-Wheelon process 53 D4. drop hammer forming 53 D5. drawing (sheet metal parts) 54 D5a. shallow drawing 55 D5b. deep drawing 55 D5c. redrawing, direct and reverse 55 D6. coining 55 D6a. drop hammer coining 55 D7. embossing 56 D8. flanging 56 D9. beading 56 D10. hemming and seaming 56 D11. edge curling 57 D12. swaging 57 D13. sizing 57 D14. ironing 58 E. Multiple Die Stamping Press Operations 58 E1. progressive die operations 58 E2. transfer die (transfer press) operations 59 E3. compound die operations 60 F. Sheet Metal Operations Performed on Equipment Other Than Presses 61 F1. rotary swaging 61 F1a. stationary die swaging 62 F2. three-roll forming 62 F3. stretch forming 62 F3a. stretch draw forming 62 F3b. stretch wrapping (stretch wrap forming) 63 F3c. compression forming 63 F3d. radial-draw forming 64 F4. roll coining 64 F5. rotary embossing 64 F6. metal spinning 64 F6a. manual spinning 065 F6b. power spinning, “flow turning” or “shear spinning” 65 F7. roll forming (contour roll forming) 66 F7a. roll forming of tubing and pipe 66 G. Wire Forming Operations 67 G1. wire forming 67 G1a. manual forming of wire parts 67 G1b. wire forming in power presses and special machines 67 G2. forming in four-slide machines 67 Table of Contents vii G3. spring forming 68 G4. Turk’s-head rolling of wire 68 H. Tubing and Section Operations 68 H1. tube spinning 68 H1a. forward tube spinning 68 H1b. backward tube spinning 68 H2. tube and section bending 68 H2a. draw bending 68 H2b. compression bending 70 H2c. ram-and-press bending 70 H2d. stretch bending 71 H2e. wrinkle bending 71 H2f. roll bending 71 H2g. roll extrusion bending 72 H2h. bulging, mechanical 72 H2i. bulging, hydraulic 72 H2j. other methods of bulging tubing 73 I. Non-sheet Forming Operations 73 I1. shearing of bars and other non-flat shapes 73 I2. cold heading 73 I3. thread rolling 74 I4. impact/cold extrusion 74 I4a. backwards extrusion 74 I4b. forward extrusion 75 I4c. combined extrusion 75 J. High-energy-rate Forming Methods 75 J1. explosive forming 75 J2. combustible gas forming 75 J3. electromagnetic forming (EMF) (also known as magnetic pulse forming) 76 J4. spark-discharge forming (electrospark forming) 77 J5. electrohydraulic forming 77 J6. pneumatic-mechanical forming 78 J7. peen forming 78 K. Straightening 78 K1. manual straightening 78 K2. press straightening 79 K3. parallel roll straightening 79 K4. rotary straightening 79 K5. epicyclic straightening 80 K6. stretch straightening 80 L. Other Forming Processes 80 L1. powder metallurgy (P/M) processes 80 L1a. metal powder manufacture 80 L1b. powder blending and mixing 80 L1c. pressing (compacting) 81 L1d. sintering 81 L1e. repressing 83 L1f. secondary operations 83 L1g. powder metal forging 83 L2. electroforming 84 L3. metal injection molding (MIM) 84 Chapter 3-Machining Processes 87 A. Lathe and Other Turning Operations 87 A1. lathe operations (general description) 87 A1a. turning 87 A1b. form turning 87 A1c. tracer turning 87 A1d. facing 88 A1e. grooving 88 A1f. knurling 88 A1g. cutting off (parting) 89 A2. lathes and other turning machines 89 A2a. engine lathes 89 A2b. turret lathes 90 A2c. screw machines 90 A2c1. single spindle screw machines 91 A2c2. Swiss-type screw machines 91 A2c3. multiple spindle screw machines 91 A2d. chucking machines 92 A2e. turning centers 93 B. Round-hole-making Methods 93 B1. drilling 93 B2. counterboring 93 B3. countersinking 94 B4. reaming 94 B5. boring 94 B5a. jig boring 95 B5b. horizontal boring mills 95 B5c. vertical boring mills 95 B6. gun drilling 96 B7. trepanning 97 B8. multiple-spindle drilling 97 C. Grinding and Abrasive Machining 97 C1. cylindrical grinding 98 C1a. center-type cylindrical grinding 98 C1b. centerless grinding 99 C1b1. through-feed centerless grinding 99 C1b2. infeed centerless grinding 100 C1b3. end-feed centerless grinding 100 C2. internal grinding 100 C2a. internal centerless grinding 101 C3. surface grinding 101 C3a. horizontal spindle surface grinding 102 C3b. vertical spindle surface grinding 102 C3c. creep-feed grinding 102 C4. jig grinding 103 C4a. tool post grinding 103 C5. low-stress grinding 103 C6. plunge grinding 103 C7. disc grinding 103 C8. abrasive belt grinding 104 C9. abrasive jet machining 104 C10. abrasive flow machining (AFM) 104 C11. ultrasonic machining 105 C11a. rotary ultrasonic machining 105 D. Milling 106 D1. face milling 106 D2. peripheral milling 106 D3. end milling 106 D4. slab milling 106 D5. form milling 106 D6. gang milling 106 D7. straddle milling 106 D8. fly cutter milling 106 D9. pin routing 108 D10. spotfacing 109viii Table of Contents E. Screw Threads 109 E1. hand-die external threading 109 E2. internal thread tapping 109 E3. single-point screw-thread cutting 110 E4. thread cutting die heads 110 E5. thread milling 110 E6. thread grinding 111 E7. thread rolling 111 E8. cold-form tapping of internal threads 111 F. Broaching 112 F1. internal broaching 113 F2. external broaching 113 F3. pot broaching 113 G. Sawing 113 G1. circular sawing 113 G2. band sawing 113 G3. contour sawing 114 G4. hacksawing 114 G5. abrasive sawing 114 G6. diamond-edge sawing 114 G7. friction sawing 114 H. Flame Cutting (Thermal Cutting) 116 H1. oxy-fuel gas cutting (OFC) 116 H2. metal powder cutting (POC) 116 H3. chemical flux cutting (FOC) 117 H4. arc cutting 117 H4a. plasma-arc cutting (PAC) 117 H4b. air-carbon arc cutting and grooving 118 H4c. oxygen lance cutting (LOC) 118 H4d. gas metal arc cutting 118 H4e. gas tungsten arc cutting 118 H4f. shielded metal arc cutting 118 H4g. carbon arc cutting 118 H5. laser cutting 118 I. Electrical Machining Processes 119 I1. electrical discharge machining or EDM 119 I1a. ram EDM 119 I1b. wire EDM 120 I1c. electrical discharge grinding (EDG) 120 I2. electrochemical machining (ECM) 120 I2a. electrochemical grinding (ECG) 122 I2b. electrochemical turning (ECT) 122 I3. electrochemical discharge grinding (ECDG) 122 I4. electrochemical honing (ECH) 123 I5. electro etching 123 J. Finish Machining Operations 123 J1. honing 123 J2. lapping 124 J3. superfinishing 124 J4. burnishing 125 J5. roller burnishing 125 K. Deburring 126 K1. abrasive flow deburring 126 K2. abrasive jet deburring 127 K3. barrel tumbling 127 K4. chemical deburring 128 K5. electropolish deburring 128 K6. electrochemical deburring 128 K7. liquid hone deburring 128 K8. manual deburring 128 K9. thermal energy deburring 128 K10. ultrasonic deburring 128 K11. vibratory deburring 128 K12. water-jet deburring 129 K13. centrifugal barrel tumbling 129 K14. spindle finishing 129 K15. powered brush deburring 129 K16. abrasive belt sanding 129 K17. laser deburring 129 K18. plasma glow deburring 129 K19. skiving 130 K20. edge rolling 130 K21. burnish deburring 130 K22. edge coining 130 K23. robotic deburring 130 K24. CNC machining center deburring 130 K25. cryogenic deflashing 130 L. Filing 130 L1. burring (rotary filing) 131 M. Water Jet Machining (Hydrodynamic Machining) 131 M1. abrasive water jet machining (AWJ) 131 N. Electron Beam Machining (EBM) 132 O. Laser Beam Machining 133 O1. laser-assisted hot machining (LAM) 134 P. Shaping 134 Q. Planing 134 R. Slotting 135 S. Chemical Machining 135 S1. chemical milling 136 S2. chemical engraving 136 S3. chemical blanking 136 S4. photochemical blanking 136 T. Machining Centers 137 T1. turning centers 139 T2. multiple operation machines 139 U. Numerical and Computer Control 139 U1. NC, numerical control 140 U2. computer numerical control (CNC) 140 U2a. DNC (direct numerical control) 144 U3. programmable controllers 144 U4. CAD-CAM 144 U5. digital readouts in machining 145 U6. automatic tracing 145 U7. robots and robotic operations 145 V. Trimming 145 W. High-Speed Machining 145 X. Special Purpose Machines 145 Y. Transfer Lines 146 Chapter 4-Processes for Plastics 147 A. How Plastics Are Made 147 A1. definition - Plastics 147 A2. polymerization reactions 147 A2a. addition polymerization 147 A2b. condensation polymerization 148 A3. polymerization methods 148 A3a. bulk polymerization 148 A3b. solution polymerization 149 Table of Contents ix A3c. suspension polymerization 149 A3d. emulsion polymerization 149 A3e. gas-phase polymerization 149 A4. compounding plastics 149 A4a. mixing by tumbling 150 A4b. intensive dry mixing 150 A4c. internal intensive batch mixing 151 A4d. continuous mixing 151 A4e. single screw extruders 151 A4f. compounder-extruder mixing 151 A4g. twin screw extruder mixing 152 A5. pelletizing and dicing of plastics 152 A5a. mixing and dicing with two-roll mills 153 A5b. strand pelletizers 153 A5c. underwater pelletizing 153 B. Compression and Transfer Molding 153 B1. compression molding 153 B1a. automatic compression molding 155 B2. transfer molding 155 B2a. plunger molding 155 B2b. screw transfer molding 155 B3. cold molding 156 C. Injection Molding 156 C1. conventional injection molding 156 C1a. hot runner molding (heated runnerless molding) 157 C2. injection molding of thermosetting plastics 158 C3. structural foam molding processes 158 C3a. low-pressure injection molding of structural foam plastics 158 C3b. reaction injection molding 158 C3c. high-pressure injection molding of structural foam plastics 158 C3d. gas counterpressure molding 159 C3e. co-injection or sandwich molding 159 C3f. gas-assisted injection molding 160 C3g. casting of structural foam plastics 160 C3h. extrusion of structural foam plastics 160 C3i. slabstock foam process 161 C4. expanded polystyrene foam processes 161 C4a. pre-expansion of EPS beads 161 C4b. shape molding of EPS beads 161 C4c. block molding of EPS 162 C4d. expanded polyolefin foam process 162 C5. two-color injection molding 162 C6. insert molding 163 D. Thermoforming (Vacuum Forming) 163 D1. straight vacuum forming 163 D2. pressure forming 163 D3. drape vacuum forming 164 D4. plug-assist forming 164 D5. vacuum snap-back forming 165 D6. slip-ring forming (slip forming) 165 D7. matched mold forming 168 D8. pressure-bubble plug-assist forming (also called reverse-draw plug-assist forming, pressure-bubble plug-assist forming, billow-up plug-assist forming or reverse-draw with plug assist) 169 D9. pressure-bubble vacuum-snapback forming or billow-up vacuum snap-back forming 169 D10. trapped sheet, contact heat, pressure forming 170 D11. air-slip forming 171 D12. free forming (free blowing) 171 D13. dual sheet forming (twin sheet forming) 171 D14. solid phase pressure forming 171 E. Rotational Molding 173 F. Blow Molding 173 F1. extrusion blow molding 173 F2. injection blow molding 173 F3. In stretch blow molding 174 F4. multilayer blow molding 175 F5. dip blow molding 175 F6. other blow molding processes 176 G. Processes for Reinforced Thermosetting Plastics 176 G1. hand lay-up 176 G2. spray-up 177 G3. vacuum-bag molding 177 G4. pressure-bag molding 177 G5. autoclave molding 177 G6. centrifugal casting 177 G7. Filament winding 178 G8. continuous laminating 178 G8a. continuous laminating with a thermosetting plastic 178 G8b. continuous laminating with a thermoplastic 178 G9. matched metal mold forming (cold stamping) 179 G10. matched metal mold forming of reinforced thermosetting material 179 G11. pultrusion 179 G12. pulforming 180 G13. resin transfer molding (RTM) (liquid resin molding) 181 G14. other processes for reinforced thermosetting plastics 181 H. Casting of Plastics 182 H1. casting of sheet 182 H1a. cell casting of sheet 182 H1b. continuous casting of sheet 182 H2. casting structural foam parts 183 H3. casting nylon parts 184 H4. casting acrylic parts 184 H5. encapsulation and potting 184 I. Plastics Extrusion 184 I1. profile extrusion 184 I2. coextrusion (dual extrusion) 185 I3. foam extrusion 185 I4. extrusion coating and laminating 186 I4a. wire coating 186 I5. extrusion of film and sheet 187 I5a. blown film extrusion 187 I5b. cast film extrusion 188 I6. operations after extruding 188 J. Calendering 188 K. Vinyl Dispersion Processes 189 K1. spread coating 189 K1a. knife coating (knife-over-roll coating) 189 K1b. roll coating 189 K2. dip coating (hot dipping) and dip molding 189 K2a. cold dipping 190x Table of Contents K3. slush molding 191 K4. cavity, in-place and low-pressure molding 191 K5. strand coating, using plastisols and organisols 191 K6. spray coating 191 K7. extrusion of plastisol 192 L. Welding and Adhesive Bonding of Plastics 192 L1. friction or spin welding 192 L2. hot plate welding 193 L3. vibration welding 193 L4. ultrasonic welding and sealing 194 L5. ultrasonic spot welding 194 L6. ultrasonic film and fabric welding 195 L7. adhesive bonding of plastics 195 L7a. solvent cementing of plastics 195 L7b. pretreatment of plastic surfaces for bonding 195 L7c. electromagnetic adhesive bonding 195 L8. induction welding 196 L9. radio frequency sealing (dielectric sealing) 196 L10. thermal sealing (heat sealing) of sheet 196 L11. hot gas welding 197 M. Surface Finishing and Decorating Processes for Plastics 197 M1. surface treatments for plastic parts 197 M1a. washing and cleaning 197 M1b. chemical etching 197 M1c. corona discharge 197 M1d. flame treatment 198 M1e. plasma treatment 198 M2. hot stamping 199 M2a. transfer coating (hot transfer coating) 199 M3. painting 199 M3a. spray and wipe 200 M3b. powder painting of plastics 200 M3c. manufacture of powder coatings 201 M3c1. dry blending 201 M3c2. melt mixing 201 M3c3. solution method 201 M4. decorating plastic parts with processes that are also common to non-plastics 201 M4a. electroplating of plastics 201 M5. in-mold decorating 201 M6. sheet and film embossing 202 N. Other Plastics Processes 203 N1. insert assembly 203 N1a. molding-in inserts 203 N1b. ultrasonic insertion 203 N1c. expansion installation 203 N1d. threaded hole installation 203 N1e. press insertion 203 N1f. self tapping 203 N1g. cemented installation 203 N1h. hot insertion 204 N2. other mechanical assembly of plastic parts 204 N3. granulating plastics 204 N4. coloring and blending of plastics 204 N5. drying of plastics 204 N6. machining of plastics 205 N7. trimming and die cutting of plastics 205 N8. radiation processing 206 N8a. non-ionizing radiation processing 206 N9. vacuum handling and loading of plastic materials 206 N10. robotic handling 207 N11. deflashing 207 N12. reel-to-reel molding (continuous strip molding) 207 O. Rubber and Elastomers 207 O1. natural rubber 207 O2. rubber, synthetic 208 O3. rubber compounding 209 O4. rubber fabrication methods 209 Chapter 5-Glass and Ceramics Processes 211 A. Glass Processes 211 A1. basic glassmaking 211 A1a. raw materials 211 A1a1. coloring materials 212 A1b. batching 212 A1c. melting 212 A2. primary forming processes 213 A2a. pressing 213 A2b. blowing 213 A2b1. manual blowing 213 A2b2. lampworking (lamp blowing, and scientific glass blowing) 215 A2b3. machine blowing 217 A2b3a. gob feeding machine 218 A2b3b. Owens bottle machine (the suck-blow process) 218 A2b3c. the blow-blow process 220 A2b3d. the press-blow process 222 A2b3e. the rotary-mold (paste mold) process 222 A2b3f. ribbon machine blowing process 222 A2c. glass tubing manufacture 222 A2d. centrifugal casting 224 A3. flat glass processes 224 A3a. manual methods 224 A3b. drawing sheet glass (the Fourcault process) 224 A3c. drawing sheet glass (the Colburn or Libby-Owens process) 225 A3d. drawing sheet glass (the Pittsburgh process) 225 A3e. plate glass manufacture 226 A3f. float glass process 227 A3g. rolling (casting) flat glass 228 A4. heat and chemical treating operations 229 A4a. annealing 229 A4b. tempering 230 A4c. chemical toughening 230 A5. secondary, finishing and decorating operations 231 A5a. bending and sagging 231 A5b. grinding 231 A5c. polishing 233 A5d. fusion sealing 233 A5e. grit blasting 234 Table of Contents xi A5f. acid etching 234 A5g. shrinking 234 A5h. staining 234 A5i. decorating with vitrifiable colors (vitreous enamels) 234 A5j. metallic coating 235 A5k. organic decorating 235 A5l. silk screening (screen printing) 235 A6. glass fiber manufacturing 235 A6a. mechanical drawing of continuous fibers 236 A6b. steam blowing 236 A6c. flame blowing (superfine process) 237 A6d. rotary wool forming process 237 A6e. methods for production of traditional optical glass fibers 237 A6f. methods for production of optical communications fibers 239 A7. manufacture of other types of glass 243 A7a. glass ceramics manufacture 243 A7b. photosensitive glass manufacture 243 A7c. cellular glass (foam glass) manufacture 243 A7d. glass microsphere manufacture 244 A8. powdered glass processes 244 A8a. dry pressing and sintering 244 A8b. slip casting of glass 244 A8c. fritted filter manufacture 244 B. Ceramics Processes 244 B1. the nature of ceramics 244 B2. ceramic materials 245 B3. ceramics operation sequence 245 B4. ceramic material preparation 245 B4a. material preparation for advanced ceramics 246 B5. pressing 246 B5a. isostatic pressing 247 B6. injection molding 247 B7. extruding 248 B8. slip casting of ceramics 248 B8a. pressure casting 248 B9. jiggering 249 B10. roll compaction 249 B11. tape casting 249 B12. throwing 249 B13. drying 249 B13a. partial in-process drying 250 B13b. final drying 251 B13c. microwave drying (also called dielectric or radio frequency drying) 251 B14. machining and grinding 251 B15. glazing 251 B16. sintering (firing) 251 B17. hot pressing 252 B17a. hot isostatic pressing (HIP) 252 Chapter 6-Woodworking Processes 255 A. Lumber Making Including Saw Mill Operations 255 A1. debarking 255 A2. headsaw operation (breakdown sawing) 256 A3. plain sawing of boards 257 A4. quarter sawing 257 A5. rift sawing 257 A6. edging 257 A7. trimming (cutting to length) 258 A8. inspecting and grading boards 258 A9. drying (seasoning) 258 A9a. air drying 259 A9b. kiln drying 259 A9c. radio frequency drying 259 B. Making Wooden Components 260 B1. cutting boards to size 260 B1a. ripping 260 B1b. cutting to length (crosscutting) 260 B2. surfacing with planers and jointers 260 B2a. planing (surfacing) 260 B2b. jointing 264 B3. contour (curved line) sawing 266 B4. turning 266 B5. drilling and boring 267 B6. shaping and routing 267 B7. other form, and special cutting and joint-making operations 270 B7a. computer-controlled routering 270 B7b. laser machining of wooden parts 271 B7c. dedicated special machines and multi-operation machines 271 B8. filing and sanding 271 C. Making Wood Joints 272 C1. butt joints 272 C2. rabbet joints 273 C3. dado and groove joints 273 C4. tongue-and-groove joints 274 C5. mortise and tenon joints 274 C6. dovetail joints 275 C7. dowelled and biscuit (joining plate) joints 276 C8. lap (halved and bridle), scarf and bevelled joints 278 D. Making Bent Wooden Components 279 D1. wet bending 279 D2. making curved laminations 279 D3. kerf bending 279 E. Assembly and Fastening Wood Products 280 E1. clamps and fixtures 281 E2. mechanical fastening 281 E3. adhesive bonding 282 E4. Assembling veneer and inlaid surfaces 282 F. Manufacture of Plywood and Other Panel Materials 284 F1. making veneer 284 F2. making plywood 284 F3. making wafer board (chipboard) 286 F4. making oriented strand board 286 F5. making particle board 286 F6. making fiberboard 287 F7. making engineered lumber, prefabricated wooden beams and joists 288 F8. making rigid plastic laminates (high pressure laminates) 289xii Table of Contents F9. making synthetic lumber (composite lumber) and components from plastics 289 G. Wood Finishing 290 G1. preparing the surface for finishing 290 G2. staining 290 G3. varnishing, lacquering and painting 290 G4. polishing 291 H. Upholstery 291 H1. installing webbing 292 H2. installing springs 292 H3. installing padding and cushioning 293 H4. installing covering 293 H5. cushions, channeling and tufting 293 Chapter 7-Assembly and Fusion (or Joining) Processes 295 A. Soldering and Brazing 295 A1. solder application methods 295 A1a. wire or rod soldering 295 A1b. preform soldering 296 A1b1. how solder preforms are made 296 A1c. solder paste soldering 296 A1d. Dip soldering (DS) 296 A1e. wave soldering 296 A1f. drag soldering 296 A1g. ultrasonic soldering 297 A2. workpiece heating methods: 297 A2a. with soldering iron (INS) 297 A2b. with gas torch 297 A2c. oven or furnace heating 297 A2d. selective infrared heating 297 A2e. vapor-phase heating 297 A2f. Resistance heating (RS) 297 A2g. laser heating 298 A2h. induction heating 298 A2i. hot gas 298 A3. fluxes 298 B. Brazing 299 B1. application of filler metal 299 B2. torch brazing 299 B3. furnace brazing 299 B4. induction brazing (IB) 300 B5. dip brazing 300 B6. salt bath brazing 300 B7. Resistance brazing (RB) 300 B8. diffusion brazing 301 C. Welding 301 C1. Arc welding 301 C1a. Shielded-Metal Arc (SMAW) or Stick Welding 301 C1b. Submerged Arc Welding (SAW) 302 C1c. Flux-cored arc welding (FCAW) 302 C1d. Gas-metal arc welding (GMAW) 302 C1e. Gas-tungsten arc welding GTAW) 304 C1f. Plasma arc welding (PAW) 304 C1g. Electroslag welding (ESW) 304 C2. induction welding (electromagnetic welding) 305 C3. Oxyfuel gas welding (OFW) 306 C4. Electron beam welding (EBW) 306 C5. Laser-beam welding (LBW) 306 C6. Resistance welding 306 C6a. Spot welding (RSW) 306 C6b. Seam welding (RSEW) 306 C6c. projection welding (RPW) 307 C7. stitch welding 308 C8. stud welding 308 C9. Friction welding (FRW) 308 C10. Flash welding (FW) 309 C11. percussive welding or percussion welding 309 C12. Thermit welding (TW) 310 C13. Solid-state welding, (SSW) 310 C13a. forge welding 310 C13b. forge-seam welding 310 C13c. cold welding 310 C13d. metal cladding 310 C13e. Roll welding (roll bonding) (ROW) 310 C13f. Explosive welding (EXW) 311 C13g. diffusion welding (diffusion bonding) 312 C13h. ultrasonic welding (of metals) 312 C13i. Friction stir welding (FSW) 312 D. Adhesive Bonding 313 D1. surface preparation methods for adhesive bonding 314 D1a. cleaning 314 D1b. surface roughening 314 D1c. surface ionization pretreatment 315 D2. adhesive application methods 315 D2a. brush, spray, dipping, roller or spatula application 315 D2b. dry film application 315 D2c. hot melt adhesives application 315 D2d. pressure sensitive and contact adhesive application 315 D2e. pump/pressure application of solid adhesives 316 D3. joint assembly methods 316 D4. curing methods 316 E. Welding of Plastics 317 F. Mechanical Assembly Processes 317 F1. bench assembly 317 F2. assembly lines 317 F3. automatic assembly 318 F3a. parts feeding equipment 320 F3b. high speed assembly with dedicated equipment 320 F3c. robotic assembly 321 F4. mechanical fastening methods 323 F4a. assembly with threaded fasteners 323 F4b. riveting 323 F4c. stitching/stapling 323 F4d. snap fit fastening 324 F4e. press and shrink fit fastening 326 F4f. staking, seaming and crimping 327 Table of Contents xiii Chapter 8-Finishing Processes (including Heat Treating) 329 A. Cleaning Processes 329 A1. mechanical cleaning processes 329 A1a. brushing 329 A1b. abrasive blasting 329 A1b1. wet blast cleaning 329 A1b2. dry blast cleaning 329 A1c. steam jet cleaning 329 A1d. tumbling 329 A2. chemical cleaning processes 330 A2a. solvent cleaning 330 A2a1. immersion cleaning 330 A2a2. spray degreasing 330 A2a3. vapor degreasing 330 A2b. ultrasonic cleaning 330 A2c. emulsion cleaning 331 A2d. alkaline cleaning 331 A2e. acid cleaning 331 A2f. pickling 331 A2g. salt bath cleaning 331 A3. electrochemical cleaning processes 332 A3a. electrolytic cleaning 332 A3b. electrolytic pickling 332 B. Polishing Processes 332 B1. conventional polishing 332 B1a. buffing 332 B2. barrel polishing (tumbling) 332 B3. electropolishing 332 B4. burnishing 332 C. Plating Processes 333 C1. conventional electroplating 333 C2. electroless plating 333 C3. barrel plating 333 C4. mechanical plating 333 C5. brush plating 333 C6. electroplating of plastics 334 D. Painting (Organic Finishing) 334 D1. brushing 334 D2. roller coating 334 D3. curtain coating 334 D4. dip painting 334 D5. flow coating 334 D6. spray painting 335 D6a. air atomized spray 335 D6b. airless spray 335 D7. electrostatic painting 335 D7a. with centrifugal spraying head 335 D8. powdered paint coating 335 D8a. electrostatic spray powder coating 335 D8b. fluidized bed powder coating 336 D8c. electrostatic fluidized bed powder coating 336 D8d. friction static spraying 337 D8e. flame spraying of powdered paint 337 D9. electrocoating (also referred to as electropainting, electrophoresis, electrophoretic coating or electrodeposition of paint) 337 D10. vinyl plastisol coatings 337 E. Chemical Surface Treatments 338 E1. anodizing 338 E1a. hardcoat anodizing 338 E2. phosphating 338 E3. chromate conversion coatings 338 E4. black oxide coating 339 F. Other Coatings 339 F1. porcelain enameling 339 F2. hot dip coating (galvanizing) 339 F3. vacuum metalizing 339 F3a. sputtering 340 F3b. chemical vapor deposition (CVD) 340 F3b1. plasma-enhanced (or plasma-assisted) chemical vapor deposition 341 F3c. physical vapor deposition (PVD) 341 F3d. ion implantation 341 F4. thermal spray coating 341 F4a. wire metalizing 341 F4a1. electric arc wire metalizing 342 F4b. powder spraying 342 F4c. detonation gun spraying 342 F4d. plasma arc spraying 343 F4d1. transferred plasma-arc spraying 344 F4e. high velocity oxy-flame coating (HVOF) 345 F5. clad metals 345 G. Heat Treating of Metals 345 G1. annealing 345 G2. annealing processes for steel 346 G2a. full annealing 346 G2b. isothermal annealing 347 G2c. spherodizing 347 G2d. stress relieving 347 G2e. normalizing 347 G2f. tempering 348 G2g. process annealing 348 G3. hardening processes for steel 348 G3a. surface hardening 348 G3a1. flame hardening 348 G3a2. induction hardening 348 G3a3. laser-beam hardening 349 G3a4. electron-beam hardening 349 G3a5. other surface heating methods for hardening 349 G3b. case hardening 349 G3b1. carburizing 349 G3b1a. pack carburization 349 G3b1b. liquid carburization 350 G3b1c. gas carburization 350 G3b2. carbonitriding 350 G3b3. cyanidizing 351 G3b4. nitriding 351 G3b5. liquid nitriding 351 G3c. through hardening 351 G3d. martempering 351 G3e. austempering 351 G4. solution treating/precipitation hardening (aging or age hardening) 352xiv Table of Contents G5. heat treating processes for non-ferrous metals 352 G5a. Aluminum alloys 352 G5b. copper and copper alloys 353 G5c. magnesium alloys 354 G5d. nickel and nickel alloys 354 G5e. titanium and titanium alloys 355 H. Shot Peening 355 I. Product Marking Methods 356 I1. manual marking 356 I2. stamp indented marking 356 I3. etching (chemical etching) 356 I4. engraving 356 I4a. pantograph engraving 356 I5. laser marking and engraving 356 I6. stenciling 357 I7. printing 357 I7a. pad printing 357 I7b. screen printing (silk screening) 357 I8. branding 357 I9. decal marking 357 I10. casting and molding 358 I11. embossing and coining 358 I12. nameplates, labels and tags 358 I13. hot stamping 359 I14. dyeing 359 I15. flocking 359 Chapter 9-Paper, Fiber and Printing Processes 361 A. Definition, Paper 361 B. Paper-making Processes 361 B1. raw materials 361 B2. paper making from wood (by machine) 361 B2a. debarking of wood logs 363 B2b. pulping of wood 363 B2b1. mechanical pulping of wood 363 B2b2. chemical pulping of wood 363 B2b3. semi-chemical pulping of wood 363 B2c. refining 364 B2d. removing foreign material 364 B2e. bleaching and washing 364 B2f. beating 364 B2g. making paper from pulp 364 B2g1. Fourdrinier and cylindrical paper-making machines 365 B2h. finishing (converting) 366 B2h1. extrusion coating and laminating of paper 366 B2h2. water dispersion coating 366 B2h3. sizing 366 B2h4. filling 366 B3. paper making from rags and other textile fibers 367 B4. paper making from synthetic fibers 367 B5. paper making from waste paper (paper recycling) 367 B5a. waste paper processed with de-inking 367 B5b. waste paper processed without de-inking 367 C. Manufacture of Various Paper Grades 367 C1. bond paper 368 C2. newsprint 368 C3. paperboard 368 C4. sanitary papers 368 C5. kraft paper 368 C6. vulcanized fiber 369 D. Printing 369 D1. relief or letterpress printing 369 D1a. typesetting for letterpress printing 369 D1b. flexographic printing 371 D2. planographic printing 371 D2a. lithography and offset lithography 371 D2b. collotype (collography) 372 D3. intaglio printing 373 D3a. gravure printing 373 D3b. making gravure plates 374 D4. stencil and screen printing (porous printing) 376 D4a. stencil printing 376 D4b. screen printing (serigraphy) (silk screening) 376 D5. electronic printing methods 377 D5a. laser printing 377 D5b. copy machine printing 378 D5b1. electrophotographic printing systems 378 D5c. ink-jet printing 379 D5d. magnetographic printing 380 D5e. ion or electron deposition printing (ionography) 380 D5f. microcapsule printing 380 D5g. thermal sublimation, dye sublimation, thermal wax and wax transfer printing 380 D5h. dot-matrix printing 380 D6. sheet and web printing 380 D7. color printing 382 D8. halftone screens 382 D9. pad printing 383 Chapter 10-Textile Processes 385 A. Textile Fibers 385 A1. natural fibers 385 A2. manufactured and synthetic fibers 386 B. Yarn Making (Spinning) 387 B1. picking (including opening and blending) 387 B2. carding 389 B3. combing 389 B4. drawing (drafting), (re-blending) 390 B5. spinning (twisting) 390 B6. spinning synthetic fibers 391 C. Weaving 392 C1. Jacquard loom weaving 393 C2. automatic bobbin changing 393 C3. shuttle-less looms 394 C4. pile weaving 394 D. Knitting 394 D1. weft or filling knitting 396 D2. warp knitting 396 Table of Contents xv E. Non-woven Fabrics 398 F. Finishing 398 F1. preparation 398 F2. bleaching 399 F3. finishing to improve appearance 399 F3a. napping 399 F3b. shearing 400 F3c. brushing 400 F3d. beetling 400 F3e. decating 400 F3f. calendering 400 F3g. creping 400 F3h. embossing 400 F3i. optical brightening 401 F3j. tentering 401 F3k. crabbing 401 F3l. flocking 401 F4. finishing to improve feel (tactile properties) of the fabric 401 F4a. sizing (stiffening) 401 F4b. weighting 401 F4c. fulling, (felting or milling) 402 F4d. softening 402 F5. finishing to improve performance 402 F5a. anti-shrinkage treatment 402 F5b. durable press (permanent press) (wash and wear) 402 F5c. antistatic treatment 402 F5d. treatment for soil and stain release properties 402 F5e. water repelling and water proofing treatments 403 F5f. other treatments 403 G. Coloring 403 G1. dyeing 403 G1a. stock dyeing 404 G1b. top dyeing 404 G1c. yarn dyeing 404 G1d. piece dyeing 404 G1e. cross dyeing 404 G1f. solution pigmenting (dope dyeing) 404 G2. printing 404 G2a. block printing 405 G2b. engraved printing (intaglio printing) 405 G2b1. duplex printing 405 G2c. discharge printing 405 G2d. heat-transfer printing 405 G2e. stencil and screen printing 405 G2f. resist printing 406 G2g. warp printing 406 G2h. pigment printing 406 H. Manufacture of Clothing and Other Sewn Products (“Needle Trades”) 406 H1. spreading/stacking 406 H2. marking 407 H3. cutting (chopping or knifing) 407 H4. sewing 409 H4a. stitch-less joining (seam bonding) (heat sealing) 411 H5. pressing 411 H6. folding, labeling, wrapping/packing 411 I. Rug and Carpet Making 412 I1. weaving rugs and carpets 412 I2. tufting rugs 413 I3. making knitted rugs 413 I4. making needlepunch carpets 413 I5. making hooked rugs 413 I6. making braided rugs 413 I7. making oriental rugs 415 I8. making needlepoint rugs 415 Chapter 11-Chemical Processes 417 A. Batch Processes in General 417 B. Continuous Processes in General 417 C. Separation Processes 418 C1. distillation 418 C1a. fractional distillation (rectification, fractionation or enrichment) 418 C1b. vacuum distillation 421 C1c. flash distillation (equilibrium distillation) 421 C1d. multiple-effect distillation (multistage flash evaporation) 422 C1e. steam distillation 422 C1f. sublimation 422 C1g. destructive distillation 422 C2. absorption-stripping 422 C3. extraction and leaching 424 C4. expression 426 C5. crystallization 427 C6. precipitation 428 C7. fluid-particle separation 429 C7a. filtration 429 C7b. types of filters 430 C7c. membrane separation (including ultra filtration) 432 C7d. sedimentation 435 C7e. centrifugation 435 C7e1. cyclone separation, cycloning 438 C7f. bag filtering 439 C7g. evaporation 439 C7h. scrubbers - or wet collectors 441 C8. separation of solids 443 C8a. screening (sieving) 443 C8b. flotation 444 C8c. dense-media separation 445 C8d. magnetic separation 446 C8e. electrostatic separation 446 C9. adsorption and ion exchange 448 C10. electrolytic processes (electrolysis) 449 C11. electro thermal processes 449 C12. drying 449 C12a. spray drying liquid materials 453 C12b. freeze drying 454 D. Size Reduction 454 D1. crushing 454xvi Table of Contents D2. secondary crushing 455 D3. pulverizing 455 E. Size Enlargement 458 F. Fermentation 458 G. Mixing Methods 458 G1. mixing gases with gases 459 G2. mixing gases with liquids 459 G3. mixing liquids with liquids 460 G4. liquids-solids mixing 461 G5. solids mixing 461 H. Petroleum Refining and Petrochemicals 465 H1. separation 465 H1a. fractional distillation of crude petroleum 465 H1b. vacuum distillation of petroleum fractions 465 H1c. absorption/stripping of petroleum factions 466 H1d. solvent extraction 466 H1e. crystallization of petroleum fraction contaminants 466 H2. conversion 466 H2a. cracking 466 H2a1. thermal cracking 466 H2a2. catalytic cracking 466 H2b. polymerization 467 H2c. alkylation 467 H2d. reforming 467 H3. chemical and other treatments 467 H3a. sulfur removal (hydrogen treatment) 467 H3b. additive addition 468 H3c. blending 468 I. Chemical Reactions 468 I1. gas-phase reactions 469 I2. gas/liquid reactions 469 I3. liquid/liquid reactions 470 I4. gas/liquid/solid reactions 472 I5. solids/solids and solids/gas reactions 472 I6. reactions with catalysts 474 J. Heat-transfer Methods 474 J1. heat exchange for solid materials 476 J2. cooling with air 476 K. Extracting and Recovering Metals from Ores 478 K1. recovery/refining processes 478 K1a. hydro metallurgy 479 K1a1. precipitation in hydro metallurgy 479 K1b. pyrometallurgy processes 479 K1b1. roasting 479 K1b2. smelting 480 K1c. electrometallurgy 480 K1c1. electrowinning (electrolytic deposition) 480 K1c2. electrorefinning 480 K2. other chemical processes 480 K3. alloying processes 480 L. Esterification 481 Chapter 12-Food Processes 483 A. Cleaning Raw Food Materials 483 B. Sorting and Grading of Foods 484 C. Size Reduction 485 C1. roll crushing 487 C2. hammer milling 487 C3. ball milling (tumble milling) 487 C4. disc attrition milling 487 C5. milling grain 487 C5a. post-milling treatments 488 C5a1. altering protein content 488 C5a2. bleaching flour 488 C5a3. enriching flour 488 D. Mixing 489 E. Separation Processes 490 E1. filtration 490 E2. expression 490 E3. centrifugation 492 E4. crystallization 492 E5. extraction 494 F. Concentration 495 F1. evaporation 495 F2. freeze concentration 496 F3. reverse osmosis and ultrafiltration 496 G. Thermal Processing of Foods 497 G1. blanching 497 G2. pasteurization 498 G3. heat sterilization 498 G4. canning 498 G5. aseptic processing 499 G6. cooking 500 G7. baking 501 H. Dehydration and Drying 501 H1. vacuum drying 503 H2. spray drying 503 H3. drum drying 503 H4. fluidized-bed drying 503 H5. freeze drying (freeze dehydration) 503 I. Cooling for Preservation 505 I1. freezing food 505 I1a. freezing with refrigerated air 505 I1b. freezing with a liquid medium 505 I1c. indirect-contact freezing 506 I2. dehydrofreezing 506 J. Other Operations 506 J1. irradiation 506 J2. homogenization 506 J3. hydrogenation 507 J4. fermentation 507 J5. extrusion of foods 507 J6. food additives 508 J7. pickling 508 J8. salting 510 J9. sugar curing/sugar addition 510 J10. candying and glazing 510 J11. high-intensity pulsed electric field processing (PEF) 510 J13. high pressure processing (or ultra-high pressure processing) 511 K. Meat Packing 511 K1. stunning 512 K2. slaughtering 512 K3. butchering 512 L. Bottling 513 M. Other Packaging 515 Table of Contents xvii N. Storage 515 O. Food Equipment Cleaning and Sanitizing 515 O1. equipment rinsing 516 O2. equipment cleaning 516 O3. equipment sanitizing 516 O4. other factors 516 Chapter 13-Processes for Electronic Products 519 A. Printed Circuit Boards (PCBs) 519 A1. making bare printed circuit boards 519 A1a. resists and photoresists 520 A1b. subtractive process for making wiring patterns on the board 521 A1c. additive method 522 A1d. making photo masters and masks 522 A1e. screen printing the masks 523 A1f. stripping resists from printed circuit boards 524 A2. other board operations 524 A2a. hole making in boards 524 A2b. contact finger plating 524 A2c. solder fusing 524 A2d. solder masks 524 A2e. separating boards (depanelling) 525 A2f. silkscreen identification 525 A3. multilayer boards 525 A4. making flexible printed circuit boards 527 B. Wiring and Populating Boards 527 B1. populating boards with through-hole connections 527 B2. assembling surface mounted components 528 B2a. dispensing adhesives 530 B2b. using solder paste 530 B2b1. syringe dispensing of solder paste (pressure dispensing) 530 B2b2. pin transfer dispensing of solder paste 531 B2b3. screen printing of solder paste 531 B2b4. stencil dispensing of solder paste 532 B2b5. submerged disk dispensing of solder paste 532 B2b6. dip coating of solder paste 532 B2b7. roller coating of solder paste 533 B2c. using solder preforms 533 B3. cleaning prior to soldering 533 B4. prebaking before soldering 533 C. Soldering Processes 534 C1. flux application 534 C1a. dip fluxing 534 C1b. brush application of flux 534 C1c. foam flux application 534 C1d. spray application of flux 534 C1e. wave fluxing 534 C1f. roller fluxing 535 C1g. cored solder fluxing 535 C1g1. making flux cored wire solder 535 C2. preheating 535 C3. dip soldering 536 C4. drag soldering 536 C5. wave soldering 537 C6. reflow methods 538 C6a. oven heating for reflow 538 C6b. vapor-phase soldering 539 C6c. laser soldering 540 C7. hot gas soldering 541 C8. soldering iron soldering 541 C9. using lead-free solders 541 D. Cleaning After Soldering 541 D1. solvent cleaning 542 D2. water washing 542 D3. semi-aqueous cleaning 543 E. Making Solder Paste 544 E1. making solder powder by gas atomization 544 E2. spinning disk powder making 545 E3. ultrasonic method of powder making 546 E4. screen classification of powder 546 E5. air classification of powder 547 E6. inspection of powder 547 E7. mixing solder paste 547 E8. inspection of paste 547 F. Ball Grid Arrays 549 G. Fluxes for Electronics 549 H. Tinning 550 I. Quality Control and Inspection Operations 550 I1. visual inspection of joints 550 I2. incoming inspection 550 I3. solderability testing 550 J. Repair and Touch-up 551 K. Integrated Circuits (ICs) (Microcircuits or Chips) 551 K1. material preparation - making ultra-pure silicon 551 K2. making a single crystal of silicon 552 K2a. slicing into wafers 553 K2b. polishing the wafers 553 K2c. other wafer preparation operations 554 K3. wafer fab 554 K3a. layering 555 K3a1. oxidation of silicon 556 K3a2. nitridation 556 K3a3. chemical vapor deposition (CVD) 556 K3a3a. epitaxy 557 K3a4. vacuum deposition 557 K3a5. sputtering 557 K3a6. adding thick films 557 K3a7. adding protective layers 558 K3b. patterning 558 K3b1. lithography 558 K3b1a. making masks 560 K3b1b. applying resist (photoresist film) 560 K3b1c. expose and develop the resist 562 K3b2. etching 563 K3b2a. wet etching with liquid etchants (wet chemical etching) 563xviii Table of Contents K3b2b. dry etching 564 K3b2b1. plasma etching 564 K3b2b2. ion beam etching (sputter etching or ion milling) 564 K3b2b3. reactive ion etching (RIE) 565 K3b3. stripping photoresist from wafers 565 K3c. doping (dopant defusion) 566 K3d. heat treating 568 K3d1. annealing 568 K3d2. alloying 568 K4. wafer testing and sorting 568 K5. packaging (assembly) of chips 569 K5a. backside preparation 570 K5b. dicing (die separation) 570 K5c. chip insertion and fastening to the package 570 K5d. wire bonding 570 K5e. closing and sealing the package 571 K5f. lead plating and trimming 571 K5g. marking and final testing 571 K6. other methods of connecting the integrated circuit to the board 573 K6a. chip on board (COB) technology 573 K6b. conductive adhesive connections 573 K6c. tape automated bonding (TAB) 573 K6d. flip-chips 574 L. Making Discrete Devices 575 L1. making resistors 575 L2. making capacitors 576 L3. making inductors (chokes, choke coils) 578 L4. making transformers 578 L5. making discrete transistors and diodes 582 M. Conformal Coatings 582 N. Other Chip Configurations 582 N1. multiple integrated circuit packages (multichip devices, assemblies, modules [MCM], system in a package (SIP) or packages) 582 Chapter 14-Advanced Manufacturing Methods 585 A. Rapid Prototyping (RP) Methods 585 A1. initial step: computer aided design (CAD) 586 A2. the STL file 586 A3. the SLI file 586 A4. liquid-based rapid prototyping systems 586 A4a. the stereolithography (SLA) system 586 A4b. QuickCast 587 A4c. solid ground curing (SGC) 588 A4d. solid creation system (SCS) 589 A4e. solid object ultraviolet-laser printer (SOUP) 589 A4f. soliform System 589 A4g. MEIKO system 589 A4h. E-Darts system 589 A5. solid-based systems 590 A5a. laminated object manufacturing (LOM) 590 A5b. fused deposition modeling (FDM) 591 A5c. paper lamination technology (PLT) 591 A5d. multi-jet modeling (MJM) 592 A5e. ModelMaker and PatternMaster 592 A5f. slicing solid manufacturing (SSM), melted extrusion modeling (MEM) and multi-functional RPM systems (M-RPM) 592 A6. powder-based systems 592 A6a. selective laser sintering (SLS) 592 A6b. EOSINT 594 A6c. three dimensional printing (3DP) 594 B. Rapid Tooling 594 B1. direct shell production casting (DSPC) 596 B2. Prometal 3D printing process 596 B3. RapidTool 596 B4. laminated metal tooling 597 B5. direct AIM 597 B6. SL composite tooling 597 B7. 3D Keltool 597 B8. direct metal laser sintering (DMLS) 597 C. Manufacturing Cells (Group Technology) (Family of Parts Concept) 597 D. Advanced Inspection Devices 599 D1. coordinate measuring machines (CMMs) 599 D2. machine vision 599 D3. laser scanning 601 E. Automatic Guided Vehicle (AGV) Systems 602 F. Automated Storage/Retrieval (AS/R) Systems 603 G. Use of Robots in Manufacturing Operations 605 G1. areas of robot applicability 605 G2. robots in foundries 606 G2a. in die casting 606 G2b. in sand-mold casting 606 G2c. in investment casting 606 G3. robots in forging 606 G4. robots in metal stamping 606 G5. robots in injection molding and other plastics molding 606 G6. robots in welding 607 G7. robots in painting, sealing, coating 608 G8. robots in material handling 608 G9. robots in mechanical assembly 608 G10. robots in electronics 608 G11. robots in quality control 609 G12. robots in machining 609 G13. robots in heat treatment 610 G14. robots in some specific industries 610 G14a. in automobile assembly 610 G14b. in appliances 610 G14c. in the food industry 610 G14d. in glass making 610 G14e. in chemical industries 611 G14f. in woodworking 611 G14g. in other industries 611 Table of Contents xix Section II-How Products, Components and Materials Are Made 613 (listed in alphabetical order) A 615 abrasives 615 ABS plastics 615 acetal plastics 615 acetate fibers and fabrics - See chapter 10, particularly section 10A2. 616 acetone 616 acrylic plastics 616 adhesives 616 advanced ceramic materials, (high technology ceramics), (modern ceramics), (fine ceramics) - See 5B4a. 617 air bags (for automotive passenger protection) 617 air conditioners 618 aircraft, (airplanes) 619 alcohol, denatured 623 alcohol, ethyl (ethanol) 623 alcoholic beverages 624 alcohol, isopropyl, (isopropanol or rubbing alcohol) 624 alcohol, methyl 624 ale 624 alloys 625 aluminum 625 aluminum foil 627 aluminum oxide - See abrasives. 627 ammonia 627 antifreeze 627 antimony 627 anti-shrink fabrics (cloth) - See 10F5a. 627 apple sauce 627 argon 627 asbestos / asbestos board 628 asphalt 628 aspirin 628 athletic shoes - See shoes, athletic. 628 automobile engines 628 automobile bodies 629 automobile chassis 629 automobiles 629 automobile windshields 630 B 632 bacon 632 bags, paper 632 bags, plastic 632 baking powder 632 ball bearings 632 ball grid arrays - See 13F. 632 ballpoint pens 632 balls, athletic 633 banknotes - See paper money. 633 bar codes 633 baseballs 633 bathtubs, cast iron 634 bathtubs, plastic 634 bathtubs, steel 634 bats, baseball 634 batteries, flashlight (dry cells) 634 bauxite - See aluminum. 636 beams, plastic, reinforced 636 beer 636 bells 638 bent wood components - See 6D. 638 bicycles 638 bills, dollar, and other paper money - See paper money. 638 bleach 638 blue jeans 639 boats, small, plastic 639 boats, fiberglass 639 bolts (machine screws, cap screws, set screws) 639 books 639 bond paper 639 bottled drinks - See 12L and soft drinks. 640 bottles, glass 640 bottles, plastic 640 bowling balls 640 bowls, glass 640 boxes, corrugated - See cartons, corrugated. 640 brake linings 640 brandy 640 brass 640 bread 641 breakfast cereal - See cereals, breakfast. 642 bricks 642 bronze 642 brushes 642 bulbs, light - See light bulbs. 643 bulletproof glass 643 bullet-proof vests 643 bullets (small arms ammunition or cartridges) 643 bungee cords 644 burlap 644 butter 644 buttons 645 C 646 cabinets, wood - See chapt. 6. 646 cams 646 candied fruit - See 12J10. 646 candy 646 canned food - See 12G4. 647 cans, metal 647 capacitors, electronic - See 13L2. 649 carbon, activated 649 carbon black 649 carbon fibers 649 carpets 649 carrying cases, power tools and instruments 649xx Table of Contents cars - See automobiles. 649 cast iron 649 CDs - See compact discs. 649 cellophane 649 cellular glass - See 5A7c. 650 cellulose acetate plastics 650 cement, portland 650 ceramic materials, advanced, (high technology ceramics), (modern ceramics), (fine ceramics) - See 5B4a. 650 ceramics - See 5B. 650 cereals, breakfast 650 chairs, upholstered - See 6H. 652 chairs, wooden - See chapt. 6. 652 charcoal 652 cheese 652 cheese, Swiss 652 chewing gum 653 chinaware 653 chipboard (wafer board) - See 6F3. 654 chips, electronic - See 13K. 654 chlorine 654 chocolate 654 chokes, choke coils, inductors (electronic) - See 13L3. 654 chromium 654 cider 655 clad metals - See 7C13d. 655 cloth, anti-shrink - See 10F5a. 655 cloth, knitted - See 10A, 10B and 10D. 655 cloth, non-woven - See 10A, 10B and 10E. 655 cloth, woven - See 10A, 10B and 10C. 655 clothing - See 10H. 655 coal gas - See gas, manufactured. 655 coffee 655 coffee, decaffeinated 655 coffee, instant 655 coils, electrical - See 13L3. 655 coins 655 combs 656 compact discs 656 composite structural lumber - See 6F7. 656 concrete blocks 656 condensers, electronic - See 13L2 and 13K3a6. 656 confectioner’s glaze - See candy. 656 contact lenses - See lenses, contact. 656 containers, plastic 656 cooking utensils 656 copper 657 corn flakes - See cereals, breakfast. 659 corn, frozen - See 12I1. 659 corn oil 659 corrugated cartons 659 cotton fabric 660 cottonseed oil - See margarine. 660 crayons (wax) 660 crepe fabric - See 10F3g. 660 crystal, lead glass - See 5A1. 660 cups, plastic, disposable 660 cups, paper - See drinking cups, paper. 660 cut glass - See 5A5b. 660 D 661 denim 661 detergents 661 diamonds, synthetic 661 diesel fuel - See fuel, diesel. 662 digital video discs (DVDs) 662 dinner plates - See chinaware. 663 diodes and transistors - See 13L5 and Fig. 13L5. 663 dishes, china - See chinaware. 663 dishes, glass 663 dishes, plastic 663 distilled spirits (distilled liquors) 663 downspouts, roof 663 drill bits 664 drinking cups, foam plastic 664 drinking glasses 665 drive screws - See screws. 665 drums, 55 gallon 665 dry cells - See batteries, flashlight. 665 dry ice 665 ductwork, steel 665 ductwork, plastic 665 DVD’s - See digital video discs. 665 dyed fabrics - See 10G1. 665 dyes 665 dynamite 665 E 666 edible oils - See oils, edible. 666 elastomers 666 electrical wire - See wire, electrical. 666 electricity 666 electric light bulbs - See light bulbs and lights, fluorescent. 666 electric motors - See motors, electrical. 666 electric transformers - See 13L4. 666 electrical wire - See wire, electrical. 666 enamel, vitreous (porcelain enamel) 666 enclosures, shower 666 engineered lumber - See 6F7. 666 engine blocks 666 envelopes 667 epoxy 668 essential oils - See oils, essential. 668 etched glass - See 5A5f. 668 ethanol - See alcohol. 668 ethylene (ethene) 668 explosives - See dynamite. 668 eyeglasses 668 F 669 fabrics, anti-shrink - See 10F5a 669 fabrics, dyed - See 10G1. 669 fabrics, knitted - See 10A, 10B and 10D. 669 fabrics, flocked - See 10F3l. 669 Table of Contents xxi fabrics, non-woven - See 10A, 10B and 10E. 669 fabrics, permanent press (wash and wear) - See 10F5b. 669 fabrics, printed - See 10G2. 669 fabrics, stain release - See 10F5d. 669 fabrics, woven - See 10A, 10B and 10C. 669 felt 669 felt-tip marking pens - See marking pens, felt tipped. 669 fertilizer 669 fiberboard, low density (insulation board) - See 6F6. 669 fiberboard, medium density - See 6F6. 669 fiberglass insulation 669 fibers, glass 669 fibers, textile - See 10A. 669 fibers, optical - See 5A6, 5A6e and 5A6f. 669 fibers, synthetic - See 10A2 and 10B6. 669 fiber, vulcanized - See 9C6. 669 film, photographic 669 film plastic - (See section 4I5.) 670 filters 670 finger-jointed lumber - See 6F7. 670 fireworks 670 fishing rods (poles) 671 flashlights 673 flatware (tableware)(silverware) 673 flexible printed circuit boards - See 13A4. 674 flocked fabrics - See 10F3l. 674 floor covering, vinyl - See vinyl flooring. 674 flour 674 flour, bleached - See entry 12C5a2. 674 flour, enriched - See entry 12C5a3. 674 fluorescent lights 674 flux-cored wire solder - See 13C1g1. 675 foam plastics - See 4C3. 675 food wrap, (“saran wrap”) - See saran. 675 footballs 675 footwear - See shoes. 675 Formica(r), Micarta(r) (rigid plastic laminates) - See 6F8 and fig 6F8. 675 fragrances (perfumes) 675 freeze dried food - See 12H5. 675 frozen food - See 12I1, 12I1a, 12I1b, 12I1c and 12I2. 676 fuel, diesel 676 fuel, jet 676 furniture, upholstered - See 6H. 676 furniture, wooden - See chapt. 6. 676 G 677 garlic - See spices. 677 garments (clothing) 677 gaskets, packings and seals 677 gas, manufactured 677 gas, liquified petroleum (LPG) 677 gasoline 678 gears 678 Gemstones - See Jewelry. 684 gin - See distilled spirits. 684 ginger - See spices. 684 girders, steel 684 glass - See 5A 684 glass bottles - are made by glass blowing (5A2b). 684 glass, bulletproof (bullet resistant) 684 glass, cellular (foam glass) - See 5A7c. 684 glass ceramics - See 5A7a. 684 glass containers - See 5A2b1 and 5A2b3. 684 glass, cut - See 5A5b. 684 glasses, drinking - See drinking glasses. 684 glasses, eye - See eyeglasses. 684 glass, etched - See 5A5f. 684 glass, pyrex - See cooking utensils. 684 glass fibers 684 glass filters - See 5A8c 684 glass, foam (cellular glass) - See 5A7c. 684 glass jars 684 glass lenses - See lenses. 684 glass microspheres - See 5A7d. 684 glass, photosensitive - See 5A7b. 684 glass pitchers - See 5A2b1 684 glass, plate - See 5A3e. 684 glass, safety - See safety glass. 684 glass thermometers - See thermometers, glass. 684 glass tubing - See 5A2 684 glassware, laboratory (scientific) - See 5A2b1, 5A2b2, 5A5h and 5A5i. 684 glass vases - See 5A2b1 684 glass, window - See flat glass processes, 5A3. 684 glass wool - See glass fibers. 684 glazing compound - See putty. 684 glove compartments, automotive 684 gloves 684 glue - See adhesives. 684 glued-laminate lumber (“glulam”) - See 6F7. 684 gold 684 golf balls 685 golf clubs 685 graphite 686 gravure printing plates - See 9D3b. 686 grease, lubricating 686 grinding wheels 686 guitars, acoustic 687 gum, chewing - See chewing gum. 687 guns (firearms) 687 gutters, roof 689 gypsum plaster 689 gypsum board - See plasterboard. 689 H 690 ham 690 hammers 690 handles, cooking utensils 690 handles, tool 690 hand tools - See hammers, pliers, wrenches, screwdrivers and handles, tool. 690 hardboard (including tempered hardboard) - See 6Fc. 690 helium 690 herbicides 691 high-density polyethylene - See polyethylene, high-density. 691xxii Table of Contents hosiery (stockings and socks) 691 houses, prefabricated (modular houses) 691 housings, appliance 692 housings, business machine 692 hydraulic fluid 693 hydrochloric acid (HCl) 693 hydrogen 693 I 694 I-joists, wooden - See 6F7 and Fig. 6F7-1. 694 ice, dry - See dry ice. 694 ice cream 694 ice skates 694 inductors (chokes, choke coils) - See 13L3. 694 ink 694 in-line skates 695 insecticides (pesticides) 695 instant coffee - See coffee, instant. 696 insulation board (low-density fiberboard) - See 6F6. 696 integrated circuits - See 13K. 696 iron 696 isopropyl alcohol (isopropanol or rubbing alcohol) - See alcohol, isopropyl. 697 J 698 jars, glass - See 5A2b3. 698 jelly 698 jelly beans 698 jet engines (gas turbines) 698 jet fuel 701 jewelry 701 K 703 kerosene 703 Kevlar 703 keyboards, computer 703 keys 703 keys for computer keyboards 704 kidskin 704 knit fabrics 704 kraft paper - See 9C5, 9B and 9B2b. 704 L 705 lace 705 lacquer 705 ladders 705 lasers 705 latex 706 lawn mowers 707 lead 707 lead glass (lead crystal) 707 leather 707 leather goods 708 lenses 709 lenses, contact 710 licorice 711 light bulbs, incandescent 711 lights, fluorescent - See fluorescent lights. 712 linen 712 liquid crystal displays (LCDs) 712 locks, combination 713 low-density fiberboard - See 6F6. 714 lubricating grease - See grease, lubricating. 714 lumber 714 lumber, pressure treated 714 M 715 magnesium 715 magnets 715 manganese 716 maple syrup 716 marbles 716 margarine 716 marking pens, felt tipped 717 matches 717 meat - See 12K. 717 meat tenderizer 717 melamine plastic - See urea and melamine plastic. 717 mercury 717 medium density fiberboard - See 6F6. 717 metal cans - See cans, metal. 717 metal powders - See powders, metal. 717 methane 717 microcircuits - See 13K. 718 microspheres, glass - See 5A7d. 718 milk, condensed 718 milk, powdered 718 milk, skim 718 mineral wool (rock wool) - See 5A6d. 718 mirrors 718 molybdenum 718 monuments 718 motors, electric 719 multiple chip packages (electronic) - See 13N1. 720 musical instruments 720 musical instruments, brass 720 N 722 nail polish 722 nails 722 nameplates - See 8I12, 8I2, 8I4, 8I4a, 8I5, 8I7 and other items under 8I (Product Marking). 722 naphtha - See 11H1a and 11H2a1. 722 napkins, paper - See 9C4 and 9B5. 722 napped fabrics - See 10F3a 722 natural gas 722 natural rubber - See 4O1. 723 needlepoint carpets - See 10I8. 723 needlepunch carpets - See 10I4. 723 neon signs 723 neoprene - See 4O2. 723 newspapers 723 Table of Contents xxiii newsprint - See 9C2 723 nickel 723 nitrile rubber - See 4O2. 724 nitrogen 724 no-clean solder flux - See 13G 724 non-woven fabric - See 10E. 724 nuclear power - See electricity and Fig. E1. 724 numerical controls - See 3U and 3U1. 724 nutmeg - See spices. 724 nuts, screw 724 nylon 724 O 726 oils, edible 726 oils, essential 726 oil, fuel (furnace oil) 726 oil, lubricating 726 oils, vegetable - See oils, edible; olive oil; oils, essential 726 olive oil 727 olives, green 727 optical glass fibers - See 5A6, 5A6e and 5a6f. 727 optical lenses - See lenses. 728 orange juice 728 oriented strand board (OSB) - See 6F5. 728 o-rings 728 Orlon 728 oxygen 728 P 729 packages, blister 729 paint 729 paint brushes - See brushes. 730 paint removers (paint strippers) 730 pallets, plastic 730 pallets, wood 730 pans, cooking - See cooking utensils. 730 paper - See 9A and 9B. 730 paperboard 730 paper, bond - See 9B and 9C1. 730 paper clips 730 paper hankerchiefs - See 9C4. 730 paper, kraft - See 9B, 9B2b2 and 9C5. 730 paper money 730 paper, rag (rag bond) - See 9B and 9B3. 730 paper, sanitary - See 9B and 9C4. 730 paper towels - See 9C4. 730 particle board - See 6F5. 730 partition glass - See 5A3g. 730 pasta 731 patterns for casting - See 1B7. 731 peanut butter 731 pencils, lead 731 pens, ball point - See ballpoint pens. 731 pepper - See spices. 731 perfume 731 permanent press fabrics - See 10F5b. 732 pesticides - See insecticides. 732 petrochemicals - See 11H. 732 petroleum 732 petroleum jelly (petrolatum, Vaseline) 732 pewter 732 phenolic plastics 732 photographic film - See film, photographic. 732 pickles - See 12J. 732 pig iron 732 pile rugs (tufted rugs) - See 10I2. 732 pipe, plastic - See tubing, plastic. 732 pipe and tubing,metal 732 pipe, cast - See 1E1. 733 pipe, welded - See pipe and tubing, metal above. 733 plaster - See gypsum plaster. 733 plasterboard, gypsum board, wallboard and drywall 734 plastics 734 plastic film - See 4I5. 734 plastic laminates, rigid (“Formica” or “Micarta”) - See 6F8. 734 plastic wood, wood filler 734 plate glass - See 5A3e. 734 platinum 734 playground equipment 734 plexiglas 735 pliers
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