Joining of materials and structures: from pragmatic process to enabling technology

Robert W. Messler0750677570, 9780750677578, 9781417544363

Joining of Materials and Structures is the first and only complete and highly readable treatment of the options for joining conventional materials and the structures they comprise in conventional and unconventional ways, and for joining emerging materials and structures in novel ways. Joining by mechanical fasteners, integral designed-or formed-in features, adhesives, welding, brazing, soldering, thermal spraying, and hybrid processes are addressed as processes and technologies, as are issues associated with the joining of metals, ceramics (including cement and concrete) glass, plastics, and composites (including wood), as well as, for the first time anywhere, living tissue. While focused on materials issues, issues related to joint design, production processing, quality assurance, process economics, and joint performance in service are not ignored. The book is written for engineers, from an in-training student to a seasoned practitioner by an engineer who chose to teach after years of practice. By reading and referring to this book, the solutions to joining problems will be within one’s grasp. Key Features: ?·

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Table of contents :
Cover……Page 1
Half Title Page……Page 2
Title Page……Page 4
Copyright……Page 5
Contents……Page 6
Preface……Page 22
PART I: Joining Processes & Technologies……Page 26
1.1 JOINING DEFINED……Page 28
1.2 REASONS FOR JOINING MATERIALS AND STRUCTURES……Page 30
1.3 CHALLENGES FOR JOINING MATERIALS……Page 38
1.5 HOW JOINING IS CHANGING OR MUST CHANGE……Page 40
1.6 JOINING OPTIONS……Page 47
1.7 SOME KEY CONCEPTS RELATING TO JOINTS……Page 57
SUMMARY……Page 65
QUESTIONS AND PROBLEMS……Page 66
BIBLIOGRAPHY……Page 68
2.1 INTRODUCTION……Page 70
2.2 MECHANICAL JOINING AS AN ASSEMBLY PROCESS……Page 71
2.3 SOURCES AND TYPES OF JOINT LOADING……Page 75
2.4 SHEAR-LOADED FASTENED JOINTS……Page 79
2.5 TENSION-LOADED FASTENED JOINTS……Page 100
2.6 FATIGUE LOADING OF FASTENED JOINTS……Page 110
2.7 OTHER FACTORS AFFECTING FASTENERS AND FASTENED JOINTS……Page 114
2.8 INTEGRALLY ATTACHED JOINTS……Page 118
SUMMARY……Page 122
QUESTIONS AND PROBLEMS……Page 124
CITED REFERENCES……Page 128
BIBLIOGRAPHY……Page 129
3.1 INTRODUCTION……Page 130
3.2 FASTENERS VERSUS INTEGRAL ATTACHMENTS OR INTERLOCKS……Page 134
3.3 THREADED FASTENERS……Page 143
3.4 UNTHREADED FASTENERS……Page 159
3.5 INTEGRAL MECHANICAL ATTACHMENTS……Page 183
3.6 OTHER MECHANICAL JOINING METHODS……Page 192
SUMMARY……Page 198
QUESTIONS AND PROBLEMS……Page 199
CITED REFERENCES……Page 200
BIBLIOGRAPHY……Page 201
4.1 INTRODUCTION……Page 202
4.2 ADHESIVE BONDING AS A JOINING PROCESS……Page 204
4.3 MECHANISMS OF ADHESION……Page 212
4.4 FAILURE IN ADHESIVE-BONDED JOINTS……Page 220
4.5 KEY REQUIREMENTS FOR QUALITY ADHESIVE BONDING……Page 222
4.6 ADHESIVE JOINT DESIGNS, DESIGN CRITERIA, AND ANALYSIS……Page 228
4.7 CEMENT AND MORTAR JOINING AND JOINTS……Page 243
SUMMARY……Page 247
QUESTIONS AND PROBLEMS……Page 248
BIBLIOGRAPHY……Page 251
5.1 INTRODUCTION TO ADHESIVES, CEMENTS, MORTARS, AND THE BONDING PROCESS……Page 252
5.2 THE CONSTITUENTS OF ADHESIVES……Page 253
5.3 CLASSIFICATION SCHEMES FOR ADHESIVES……Page 256
5.4 IMPORTANT ORGANIC STRUCTURAL ADHESIVES……Page 270
5.5 IMPORTANT INORGANIC ADHESIVES, CEMENTS, AND MORTARS……Page 275
5.6 THE ADHESIVE BONDING PROCESS: STEPS AND EQUIPMENT……Page 281
5.7 ADHESIVE-BONDED JOINT PERFORMANCE……Page 286
5.8 APPLICATIONS OF ADHESIVES, CEMENTS, AND MORTARS……Page 303
SUMMARY……Page 304
QUESTIONS AND PROBLEMS……Page 305
BIBLIOGRAPHY……Page 308
6.1 INTRODUCTION TO THE PROCESS OF WELDING……Page 310
6.2 JOINING MATERIALS BY NATURAL PHYSICAL FORCES: WELDING……Page 313
6.3 CLASSIFICATION SCHEMES FOR WELDING PROCESSES……Page 319
6.4 FUSION WELDING PROCESSES……Page 330
6.5 NON-FUSION WELDING PROCESSES……Page 357
6.6 WELD JOINT DESIGN……Page 363
SUMMARY……Page 368
QUESTIONS AND PROBLEMS……Page 369
BIBLIOGRAPHY……Page 373
7.1 INTRODUCTION TO THE PROCESS OF BRAZING……Page 374
7.2 BRAZING AS A SUBCLASSIFICATION OF WELDING……Page 376
7.3 PRINCIPLES OF BRAZE PROCESS OPERATION……Page 380
7.4 BRAZING PROCESSES……Page 381
7.5 BRAZING FILLER MATERIALS……Page 389
7.6 BRAZING FLUXES AND ATMOSPHERES……Page 399
7.7 BRAZE JOINT DESIGN……Page 403
SUMMARY……Page 408
QUESTIONS AND PROBLEMS……Page 410
BIBLIOGRAPHY……Page 412
8.1 INTRODUCTION TO THE PROCESS OF SOLDERING……Page 414
8.2 SOLDERING AS A JOINING PROCESS AND SUBSET OF BRAZING……Page 416
8.3 SOLDERING PROCESS CONSIDERATIONS……Page 420
8.4 SOLDERING PROCESSES……Page 427
8.5 SOLDERS AND BASIC SOLDER ALLOY METALLURGY……Page 432
8.6 FLUXES AND ATMOSPHERES FOR SOLDERING……Page 452
8.7 JOINT DESIGNS AND JOINT PROPERTIES FOR SOLDERING……Page 457
8.8 SOLDERABILITY TESTING……Page 462
SUMMARY……Page 468
QUESTIONS AND PROBLEMS……Page 469
BIBLIOGRAPHY……Page 471
9.1 IMPORTANCE OF METALLURGY TO WELDING, BRAZING, AND SOLDERING……Page 472
9.2 WELDING THERMAL CYCLES AND HEAT FLOW AROUND WELDS……Page 473
9.3 CONSIDERATIONS IN THE FUSION ZONE……Page 485
9.4 CONSIDERATIONS IN THE PARTIALLY MELTED ZONE……Page 498
9.5 CONSIDERATIONS IN THE HEAT-AFFECTED ZONE……Page 499
9.6 DEFECT FORMATION AND PREVENTION IN WELDED, BRAZED, AND SOLDERED JOINTS……Page 507
9.7 TESTS OF WELDABILITY AND JOINT PROPERTIES……Page 513
SUMMARY……Page 519
QUESTIONS AND PROBLEMS……Page 521
CITED REFERENCES……Page 524
BIBLIOGRAPHY……Page 525
10.1 INTRODUCTION TO VARIANT AND HYBRID JOINING PROCESSES……Page 526
10.2 THERMAL SPRAYING: A VARIANT JOINING PROCESS……Page 527
10.3 BRAZE WELDING: BRAZING OR WELDING?……Page 535
10.4 HYBRID JOINING PROCESSES……Page 538
10.5 OTHER COMBINATIONS: WHAT MAKES SENSE AND WHAT DOES NOT?……Page 551
SUMMARY……Page 553
QUESTIONS AND PROBLEMS……Page 554
BIBLIOGRAPHY……Page 555
PART II: Joining of Specific Materials and Structures……Page 558
11.1 INTRODUCTION……Page 560
11.2 JOINING REFRACTORY METALS AND ALLOYS……Page 565
11.3 JOINING REACTIVE METALS AND ALLOYS……Page 572
11.4 JOINING HEAT-SENSITIVE METALS AND ALLOYS……Page 581
11.5 JOINING DISSIMILAR METALS AND ALLOYS……Page 592
11.6 JOINING INTERMETALLICS……Page 595
11.7 THERMAL SPRAYING OF METALS, ALLOYS, AND INTERMETALLICS……Page 601
SUMMARY……Page 603
QUESTIONS AND PROBLEMS……Page 605
BIBLIOGRAPHY……Page 606
12.1 INTRODUCTION……Page 608
12.2 MECHANICAL JOINING OF CERAMICS……Page 617
12.3 ADHESIVE BONDING, CEMENTING, AND RELATED JOINING OF CERAMICS……Page 620
12.4 BRAZING AND SOLDERING OF CERAMICS……Page 624
12.5 WELDING OF CERAMICS……Page 628
12.6 OTHER METHODS FOR JOINING CERAMICS TO CERAMICS……Page 633
12.7 COMPARISON OF JOINING TECHNIQUES FOR CERAMICS……Page 636
12.8 JOINING GLASSES……Page 637
SUMMARY……Page 641
QUESTIONS AND PROBLEMS……Page 642
CITED REFERENCES……Page 643
BIBLIOGRAPHY……Page 644
13.1 INTRODUCTION……Page 646
13.2 GENERAL METHODS FOR JOINING POLYMERS……Page 651
13.3 JOINING THERMOSETTING POLYMERS……Page 653
13.4 JOINING THERMOPLASTIC POLYMERS……Page 656
13.5 JOINING ELASTOMERIC POLYMERS OR ELASTOMERS……Page 664
13.6 JOINING STRUCTURAL OR RIGID FOAM POLYMERS……Page 665
13.7 JOINING DISSIMILAR POLYMERS……Page 666
SUMMARY……Page 668
QUESTIONS AND PROBLEMS……Page 669
BIBLIOGRAPHY……Page 670
14.1 INTRODUCTION……Page 672
14.2 OPTIONS FOR JOINING COMPOSITES……Page 682
14.3 JOINING OF POLYMER-MATRIX COMPOSITES……Page 685
14.4 JOINING OF METAL-MATRIX COMPOSITES (MMCs)……Page 696
14.5 JOINING OF CERAMIC-MATRIX COMPOSITES (CMCs)……Page 702
14.6 JOINING CARBON, GRAPHITE, OR CARBON–CARBON COMPOSITES (CCCs)……Page 705
14.7 JOINING CEMENT AND CONCRETE……Page 711
14.8 JOINING WOOD: A NATURAL COMPOSITE……Page 712
14.9 ACHIEVING MAXIMUM INTEGRITY IN JOINTS BETWEEN COMPOSITES……Page 716
SUMMARY……Page 717
QUESTIONS AND PROBLEMS……Page 718
BIBLIOGRAPHY……Page 720
15.1 INTRODUCTION……Page 722
15.2 LOGICAL AND ILLOGICAL COMBINATIONS OF MATERIALS……Page 726
15.3 JOINING METALS TO CERAMICS……Page 727
15.4 JOINING METALS TO GLASSES……Page 739
15.5 JOINING METALS TO POLYMERS……Page 747
15.6 JOINING METALS TO COMPOSITES……Page 749
15.7 JOINING OF CERAMICS TO POLYMERS……Page 756
15.8 JOINING CERAMICS TO COMPOSITES……Page 757
15.9 JOINING POLYMERS TO POLYMER-MATRIX COMPOSITES……Page 758
15.10 JOINING WOOD TO OTHER MATERIALS……Page 760
SUMMARY……Page 761
QUESTIONS AND PROBLEMS……Page 764
BIBLIOGRAPHY……Page 766
16.1 INTRODUCTION TO THE JOINING OF STRUCTURES AND LIVING TISSUE……Page 768
16.2 THE CHALLENGES ASSOCIATED WITH JOINING STRUCTURES……Page 769
16.3 THE CHALLENGES OF JOINING IN HOSTILE ENVIRONMENTS……Page 781
16.4 JOINING LIVING TISSUE……Page 786
SUMMARY……Page 797
QUESTIONS AND PROBLEMS……Page 798
BIBLIOGRAPHY……Page 800
Index……Page 802