1 Manufacturing Costs and Global Competition 32
General Trends in Manufacturing 34
Summary
Key Terms
Bibliography
Review Questions
Qualitative Problems
Quantitative Problems
Synthesis, Design, and Projects

2 Metal-Casting Processes and Equipment 37
Fundamentals of Metal Casting 39
Introduction 39
Solidification of Metals 40
Fluid Flow 45
Fluidity of Molten Metal 47
Heat Transfer 49
Defects 51
Summary
Key Terms
Bibliography
Review Questions
Qualitative Problems
Quantitative Problems
Synthesis, Design, and Projects
Metal-Casting Processes and Equipment 60
Introduction 60
Expendable-mold, Permanent-pattern Casting Processes 64
Expendable-mold, Expendable-pattern Casting Processes 72
Permanent-mold Casting Processes 79
Casting Techniques for Single-crystal Components 87
Rapid Solidification 88
Inspection of Castings 89
Melting Practice and Furnaces 89
Foundries and Foundry Automation 91

3 Metal Casting: Design, Materials,and Economics 96
Introduction 96
Design Considerations in Casting 96
Casting Alloys 104
Economics of Casting 109
Summary
Key Terms
Bibliography
Review Questions
Qualitative Problems
Quantitative Problems
Synthesis, Design, and Projects

Forming and Shaping Processes and Equipment 115
4 Metal-Rollinq Processes and Equipment 118
Introduction 118
The Flat-rolling Process 120
Flat~-rolling Practice 124
Rolling Mills 127
Various Rolling Processes and Mills 129
Summary
Key Terms
Bibliography
Review Questions
Qualitative Problems
Quantitative Problems
Synthesis, Design, and Projects

5 Metal-Forging Processes and Equipment 137
Introduction 137
Open-die Forging 139
Impression-die and Closed-die Forging 141
Various Forging Operations 145
Forgeability of Metals; Forging Defects 150
Die Design, Die Materials, and Lubrication 151
Die-manufacturing Methods and Die Failures 133
Forging Machines 155
Economics of Forging 157
Summary 159
Key Terms 160
Bibliography 160
Review Questions 160
Qualitative Problems 160
Quantitative Problems 161
Synthesis, Design, and Projects 161
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