This chapter familiarizes readers with the many and varied thermoset composite fabrication processes and the types of applications for which they were developed. It describes wet lay-up, prepreg lay-up, and low-temperature vacuum bag curing prepreg processes, which are best suited for low-volume, medium-sized and larger parts. It also discusses filament winding and preforming processes (including weaving, knitting, stitching, and braiding) in addition to resin-transfer molding, resin film infusion, and pultrusion.

This chapter provides a general description of materials and methods for manufacturing high-performance composites. The materials covered are polymer matrices and prepreg materials and the methods include infusion processes, composite-toughening methods, matrix-toughening methods, and dispersed-phase toughening. In addition, the chapter provides information on interlayer-toughened composites and honeycomb or foam structure composite materials. It also discusses the processes in optical microscopy of composite materials.

Specimen preparation is the first step that determines the quality of the microstructural information that can be obtained using optical microscopy. This chapter describes the sample preparation methods that are applicable to most types of composite materials containing short discontinuous or continuous fibers. The sample preparation methods cover documentation and labeling of samples, sectioning the composite, clamp-mounting composite samples, mounting composite samples in casting resins, and the addition of contrast dyes to casting resins. Information on the molds used for mounting composite materials is provided. The steps recommended to achieve a good mounted specimen without voids or specimen pull-out are also described. The chapter discusses the processes for clamping mounted composite samples in automated polishing heads and mounting composite materials for hand polishing. A summary of the mounting technique is also included.

This chapter covers coatings and treatments that are used to improve the friction and wear behaviors of materials. It describes modifications that work by hardening contacting surfaces, including heat treating, vacuum coating, thermal spray, and plating, and those that separate or lubricate surfaces, including solid film, chemical conversion, and vacuum coatings, surface oiling and texturing, and lubricating platings. It compares and contrasts methods based on thickness and depth and their relative effect on friction, erosion, and wear.

This appendix is a compilation of terms and definitions related to composite filament winding.

This chapter discusses the use of thermoset and thermoplastic resins in polymer matrix composites. It begins by explaining how the two classes of polymer differ and how it impacts their use as matrix materials. It then goes on to describe the characteristics of polyester, vinyl ester, epoxy, bismaleimide, cyanate ester, polyimide, and phenolic resins and various toughening methods. The chapter also covers thermoplastic matrix materials and product forms and provides an introduction to the physiochemical tests used to characterize resins and cured laminates.

This chapter covers the basic aspects of composite materials. It describes the arrangement, form, and function of their constituent materials and explains how they perform better in combination than on their own. It discusses the directional nature of isotropic, anisotropic, and orthotropic materials, the orientation of plies in unidirectional (lamina) and quasi-isotropic (laminate) lay-ups, and the dominant role of fibers in determining strength, stiffness, and other lamina properties. The chapter also compares the engineering attributes of composites with those of metals and includes application examples.

This chapter is a compilation of terms and definitions related to tensile testing.

Plastic gears are continuing to displace metal gears in applications ranging from automotive components to office automation equipment. This chapter discusses the characteristics, classification, advantages, and disadvantages of plastics for gear applications. It provides a comparison between the properties of metals and plastics for designing gears. The chapter reviews some of the commonly used plastic materials for gear applications including thermoplastic and thermoset gear materials. The chapter also describes the processes involved in plastic gear manufacturing.

Stainless steel retains strength and has excellent oxidation resistance from room temperature to nearly 1000 deg C relative to competitive materials. This chapter focuses on the high-temperature oxidation of stainless steel by oxygen or water vapor. It begins by discussing the thermodynamic conditions and electrochemical nature of oxidation and providing information on transient oxidation. This is followed by a description of Wagner's theory for metal oxidation. The volatile nature of Cr 2 O 3 is then reviewed. The chapter further discusses the causes and preventive measures of spalling and cracking of oxide scale. It ends with a section providing information on oxidation behaviors under less-oxidizing atmospheres.

The complexity of semiconductor chips and their packages has continuously challenged the known methods to analyze them. With larger laminates and the inclusion of multiple stacked die, methods to analyze modern semiconductor products are being pushed toward their limits to support these 2.5D and 3D packages. This article focuses on these methods of fault isolation, non-destructive imaging, and destructive techniques through an iterative process for failure analysis of complex packages.

This appendix is a compilation of terms and definitions associated with the processing, microstructure, and properties of powder metal stainless steels.

This chapter discusses the advantages and disadvantages of sandwich and integral cocured structures, and the methods by which they are made. It begins by explaining where and how sandwich construction is used and why it is so efficient. It then describes the design and fabrication of honeycomb panels and foam cores along with their respective applications and unique attributes. The chapter also discusses the cocuring process and its use in fabricating unitized structures.