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Series Preface xxix Preface xxxi Part I Introduction 1 Outlines for Chapters 1 and 2 1 Introductory Survey 3 1.1 Background 3 1.2 Synergy Between Materials Science and Engineering 4 1.3 Plastics Engineering as a Process (the Plastics Engineering Process) 7 1.4 Types of Plastics 9 1.5 Material Characteristics Determine Part Shapes 11 1.6 Part Fabrication (Part Processing) 27 1.7 Part Performance 28 1.8 Assembly 32 1.9 Concluding Remarks 33 2 Evolving Applications of Plastics 35 2.1 Introduction 35 2.2 Consumer Applications 36 2.3 Medical Applications 67 2.4 Automotive Applications 70 2.5 Infrastructure Applications 77 2.6 Wind Energy 88 2.7 Airline Applications 90 2.8 Oil Extraction 91 2.9 Mining 92 2.10 Concluding Remarks 93 Part II Mechanics 95 Outlines for Chapters 3 through 8 3 Introduction to Stress and Deformation 97 3.1 Introduction 97 3.2 Simple Measures for Load Transfer and Deformation 97 3.3 *Strains as Displacement Gradients 99 3.4 *Coupling Between Normal and Shear Stresses 101 3.5 *Coupling Between Normal and Shear Strains 102 3.6 **Two-Dimensional Stress 103 3.7 Concluding Remarks 105 4 Models for Solid Materials 107 4.1 Introduction 107 4.2 Simple Models for the Mechanical Behavior of Solids 107 4.3 Elastic Materials 108 4.4 *Anisotropic Materials 109 4.5 Thermoelastic Effects 111 4.6 Plasticity 113 4.7 Concluding Remarks 116 5 Simple Structural Elements 119 5.1 Introduction 119 5.2 Bending of Beams 119 5.3 Deflection of Prismatic Beams 123 5.4 Torsion of Thin-Walled Circular Tubes 127 5.5 Torsion of Thin Rectangular Bars and Open Sections 129 5.6 Torsion of Thin-Walled Tubes 130 5.7 *Torsion of Multicellular Sections 131 5.8 Introduction to Elastic Stability 133 5.9 *Elastic Stability of an Axially Loaded Column 138 5.10 Twist-Bend Buckling of a Cantilever 142 5.11 Stress Concentration 142 5.12 The Role of Numerical Methods 145 5.13 Concluding Remarks 145 6 Models for Liquids 147 6.1 Introduction 147 6.2 Simple Models for Heat Conduction 147 6.3 Kinematics of Fluid Flow 149 6.4 Equations Governing One-Dimensional Fluid Flow 151 6.5 Simple Models for the Mechanical Behavior of Liquids 157 6.6 Simple One-Dimensional Flows 159 6.7 Polymer Rheology 171 6.8 Concluding Remarks 173 7 Linear Viscoelasticity 175 7.1 Introduction 175 7.2 Phenomenology of Viscoelasticity 176 7.3 Linear Viscoelasticity 179 7.4 Simple Models for Stress Relaxation and Creep 182 7.5 Response for Constant Strain Rates 189 7.6 *Sinusoidal Shearing 190 7.6.1 Dynamic Mechanical Analysis (DMA) 191 7.6.1.1 DMA Curves for Three-Parameter Model 192 7.6.2 *Energy Storage and Loss 192 7.7 Isothermal Temperature Effects 193 7.7.1 Thermorheologically Simple Materials 194 7.7.2 Physical Interpretation for Time-Temperature Shift 195 7.8 *Variable Temperature Histories 195 7.9 *Cooling of a Constrained Bar 196 7.10 Concluding Remarks 196 8 Stiffening Mechanisms 199 8.1 Introduction 199 8.2 Continuous Fiber Reinforcement 199 8.3 Discontinuous Fiber Reinforcement 203 8.4 The Halpin-Tsai Equations 211 8.5 Reinforcing Materials 211 8.6 Concluding Remarks 213 Further Reading 213 Part III Materials 215 Outlines for Chapters 9 through 15 9 Introduction to Polymers 217 9.1 Introduction 217 9.2 Thermoplastics 217 9.3 Molecular Weight Distributions 226 9.4 Thermosets 227 9.5 Concluding Remarks 227 10 Concepts from Polymer Physics 229 10.1 Introduction 229 10.2 Chain Conformations 229 10.3 Amorphous Polymers 234 10.4 Semicrystalline Polymers 240 10.5 Liquid Crystal Polymers 243 10.6 Concluding Remarks 245 11 Structure, Properties, and Applications of Plastics 247 11.1 Introduction 247 11.2 Resin Grades 248 11.3 Additives and Modifiers 248 11.4 Polyolefins 251 11.5 Vinyl Polymers 254 11.6 High-Performance Polymers 258 11.7 High-Temperature Polymers 265 11.8 Cyclic Polymers 271 11.9 Thermoplastic Elastomers 272 11.10 Historical Notes 273 11.11 Concluding Remarks 274 12 Blends and Alloys 277 12.1 Introduction 277 12.2 Blends 278 12.3 Historical Notes 282 12.4 Concluding Remarks 282 13 Thermoset Materials 285 13.1 Introduction 285 13.2 Thermosetting Resins 285 13.3 High-Temperature Thermosets 296 13.4 Thermoset Elastomers 304 13.5 Historical Notes 309 13.6 Concluding Remarks 311 14 Polymer Viscoelasticity 313 14.1 Introduction 313 14.2 Phenomenology of Polymer Viscoelasticity 313 14.3 Time-Temperature Superposition 319 14.4 Sinusoidal Oscillatory Tests 323 14.5 Concluding Remarks 328 15 Mechanical Behavior of Plastics 331 15.1 Introduction 331 15.2 Deformation Phenomenology of Polycarbonate 332 15.3 Tensile Characteristics of PEI 360 15.4 Deformation Phenomenology of PBT 363 15.5 Stress-Deformation Behavior of Several Plastics 376 15.6 Phenomenon of Crazing 387 15.7 *Multiaxial Yield 393 15.8 *Fracture 401 15.9 Fatigue 403 15.10 Impact Loading 412 15.11 Creep 419 15.12 Stress-Deformation Behavior of Thermoset Elastomers 419 15.13 Concluding Remarks 420 Further Reading 420 Part IV Part Processing and Assembly 421 Outlines for Chapters 16 through 21 16 Classification of Part Shaping Methods 423 16.1 Introduction 423 16.2 Part Fabrication (Processing) Methods for Thermoplastics 424 16.3 Evolution of Part Shaping Methods 429 16.4 Effects of Processing on Part Performance 431 16.5 Bulk Processing Methods for Thermoplastics 439 16.6 Part Processing Methods for Thermosets 440 16.7 Part Processing Methods Advanced Composites 442 16.8 Processing Methods for Rubber Parts 443 16.9 Concluding Remarks 445 17 Injection Molding and Its Variants 447 17.1 Introduction 447 17.2 Process Elements 447 17.3 Fountain Flow 462 17.4 Part Morphology 473 17.5 Part Design 475 17.6 Large- Versus Small-Part Molding 493 17.7 Molding Practice 504 17.8 Variants of Injection Molding 526 17.8.7 In-Mold Decoration and Lamination 552 17.9 Concluding Remarks 553 References 553 18 Dimensional Stability and Residual Stresses 555 18.1 Introduction 555 18.2 Problem Complexity 556 18.3 Shrinkage Phenomenology 556 18.4 Pressure-Temperature Volumetric Data 563 18.5 Simple Model for How Processing Affects Shrinkage 567 18.6 *Solidification of a Molten Layer 578 18.7 **Viscoelastic Solidification Model 585 18.8 **Warpage Induced by Differential Mold-Surface Temperatures 602 18.9 Concluding Remarks 609 19 Alternatives to Injection Molding 615 19.1 Introduction 615 19.2 Extrusion 615 19.3 Blow Molding 627 19.4 Rotational Molding 643 19.5 Thermoforming 659 19.6 Expanded Bead and Extruded Foam 669 19.7 3D Printing 670 19.8 Concluding Remarks 672 20 Fabrication Methods for Thermosets 675 20.1 Introduction 675 20.2 Gel Point and Curing 675 20.3 Compression Molding 678 20.4 Transfer Molding 681 20.5 Injection Molding 681 20.6 Reaction Injection Molding (RIM) 683 20.7 Open Mold Forming 685 20.8 Fabrication of Advanced Composites 686 20.9 Fabrication of Rubber Parts 698 20.10 Concluding Remarks 708 21 Joining of Plastics 711 21.1 Introduction 711 21.2 Classification of Joining Methods 712 21.3 Mechanical Fastening 713 21.4 Adhesive Bonding 721 21.5 Welding 722 21.6 Thermal Bonding 723 21.7 Friction Welding 741 21.8 Electromagnetic Bonding 762 21.9 Concluding Remarks 770 Part V Material Systems 771 Outlines for Chapters 22 through 25 22 Fiber-Filled Material Materials - Materials with Microstructure 773 22.1 Introduction 773 22.2 Fiber Types 773 22.3 Processing Issues 774 22.4 Material Complexity 774 22.5 Tensile and Flexural Moduli 780 22.6 Short-Fiber-Filled Systems 784 22.7 Long-Fiber Filled Systems 817 22.8 *Fiber Orientation 833 22.9 Concluding Remarks 851 23 Structural Foams -Materials with Millistructure 853 23.1 Introduction 853 23.2 Material Complexity 855 23.3 Foams as Nonhomogeneous Continua 856 23.4 Effective Bending Modulus for Thin-Walled Prismatic Beams 860 23.5 Skin-Core Models for Structural Foams 863 23.6 Stiffness and Strength of Structural Foams 866 23.7 The Average Density and the Effective Tensile and Flexural Moduli of Foams 879 23.8 Density and Modulus Variation Correlations 884 23.9 Flexural Modulus 887 23.10 **Torsion of Nonhomogeneous Bars 890 23.11 Implications for Mechanical Design 898 23.12 Concluding Remarks 899 24 Random Glass Mat Composites -Materials with Macrostructure 901 24.1 Introduction 901 24.2 GMT Processing 901 24.3 Problem Complexity 904 24.4 Effective Tensile and Flexural Moduli of Nonhomogeneous Materials 906 24.5 Insights from Model Materials 909 24.6 Characterization of the Tensile Modulus 921 24.7 Characterization of the Tensile Strength 924 24.8 Statistical Characterization of the Tensile Modulus Experimental Data 934 24.9 Statistical Properties of Tensile Modulus Data Sets 943 24.10 Gauge-Length Effects and Large-Scale Material Stiffness 946 24.11 Methodology for Predicting the Stiffness of Parts 951 24.12 *Statistical Approach to Strength 962 24.13 Implications for Mechanical Design 969 24.14 Concluding Remarks 969 25 Advanced Composites -Materials with Well-Defined Reinforcement Architectures 973 25.1 Introduction 973 25.2 Resins, Fibers, and Fabrics 974 25.3 Advanced Composites 977 25.4 Rubber-Based Composites 990 25.5 Concluding Remarks 1008 Index 1011

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