Introducing a new engineering product or changing an existing model involves making designs, reaching economic decisions, selecting materials, choosing manufacturing processes, and assessing its environmental impact. These activities are interdependent and should not be performed in isolation from each other. This is because the materials and processes used in making the product can have a large influence on its design, cost, and performance in service. Since the publication of the second edition of this book, changes have occurred in the fields of materials and manufacturing. Industries now place more emphasis on manufacturing products and goods locally, rather than outsourcing. Nanostructured and smart materials appear more frequently in products, composites are used in designing essential parts of civilian airliners, and biodegradable materials are increasingly used instead of traditional plastics. More emphasis is now placed on how products affect the environment, and society is willing to accept more expensive but eco-friendly goods. In addition, there has been a change in the emphasis and the way the subjects of materials and manufacturing are taught within a variety of curricula and courses in higher education. This third edition of the bestselling Materials and Process Selection for Engineering Design has been comprehensively revised and reorganized to reflect these changes. In addition, the presentation has been enhanced and the book includes more real-world case studies.

Table of Contents:
Product Design and Development in the Industrial Enterprise Introduction Feasibility Study, Identification of Needs, and Concept Selection System-Level Design Detail Design and Selection of Materials and Processes Testing and Refinement Launching the Product Selling the Product Planning for Retirement of the Product and Environmental Considerations Product Market Cycle Summary Review Questions Bibliography and Further Readings Performance of Materials in Service Failure under Mechanical Loading Introduction Types of Mechanical Failures Fracture Toughness and Fracture Mechanics Ductile and Brittle Fractures Fatigue Failures Elevated-Temperature Failures Failure Analysis: Experimental Methods Failure Analysis: Analytical Techniques Failure Prevention at the Design Stage Failure Mode Effect Analysis Summary Review Questions Bibliography and Further Readings Corrosion, Wear, and Degradation of Materials Introduction Electrochemical Principles of Metallic Corrosion Types of Metallic Corrosion Combined Action of Stress and Corrosion Corrosion of Plastics and Ceramics Oxidation of Materials Corrosion Control Wear Failures Radiation Damage Summary Review Questions Bibliography and Further Readings Selection of Materials to Resist Failure Introduction Grouping and Identifying Engineering Materials Selection of Materials for Static Strength Selection of Materials for Stiffness Selection of Materials for Fatigue Resistance Selection of Materials for High-Temperature Resistance Selection of Materials for Corrosion Resistance Coatings for Protection against Corrosion Selection of Materials for Wear Resistance Wear-Resistant Coatings Summary Review Questions Bibliography and Further Readings R elationships between Design, Materials, and Manufacturing Processes Nature of Engineering Design Introduction General Considerations in Engineering Design Design for Six Sigma Major Phases of Design Environmentally Responsible Design Design Codes and Standards Effect of Component Geometry Factor of Safety Reliability of Components Product Reliability and Safety Product Liability Summary Review Questions Bibliography and Further Readings Effect of Material Properties on Design Introduction Designing for Static Strength Designing for Stiffness Designing with High-Strength, Low-Toughness Materials Designing against Fatigue Designing under High-Temperature Conditions Designing for Hostile Environments Designing with Specific Materials (Material-Specific Design Features) Summary Review Questions Bibliography and Further Readings Effect of Manufacturing Processes on Design Introduction Product Manufacture in the Industrial Enterprise Classification of Manufacturing Processes Selection of Manufacturing Processes Design for Manufacture and Assembly Design Considerations for Cast Components Design Considerations for Molded Plastic Components Design Considerations for Forged Components Design Considerations for Powder Metallurgy Parts Design of Sheet Metal Parts Designs Involving Joining Processes Designs Involving Heat Treatment Designs Involving Machining Processes Automation of Manufacturing Processes Computer-Integrated Manufacturing Summary Review Questions Bibliography and Further Readings Selection and Substitution of Materials and Processes in Industry Economics and Environmental Impact of Materials and Processes Introduction Elements of the Cost of Materials Factors Affecting Material Prices Comparison of Materials on Cost Basis Value Analysis of Material Properties Economics of Material Utilization Economic Competition in the Materials Field Processing Time Processing Cost Economics of Time-Saving Devices CostBenefit and Cost-Effectiveness Analyses Environmental Impact Assessment of Materials and Processes Recyclability of Engineering Materials and Recycling Economics Life Cycle Cost Summary Review Questions Bibliography and Further Readings Materials Selection Process Introduction Nature of the Selection Process Analysis of the Material Performance Requirements and Creating Alternative Solutions Initial Screening of Solutions Comparing and Ranking Alternative Solutions Selecting the Optimum Solution Computer Assistance in Making Final Selection Using MATLABR in Materials and Process Selection Sources of Information for Materials Selection Summary Review Questions Bibliography and Further Readings Materials Substitution Introduction Materials Audit Considerations in Materials Substitution Screening of Substitution Alternatives Comparing and Ranking of Alternative Substitutes Reaching a Final Decision Using MATLABR in Materials Substitution Summary Review Questions Bibliography and Further Readings Case Studies in Material Selection and Substitution Introduction Design and Selection of Materials for a Turnbuckle Design and Selection of Materials for Surgical Implants Design and Selection of Materials for Lubricated Journal Bearings Analysis of the Requirements and Substitution of Materials for Tennis Rackets Material Substitution in the Automotive Industry Bibliography and Further Readings Appendices Appendix A: Metallic Materials—Classification, General Characteristics, and Properties Appendix B: Polymers—Classification, General Characteristics, and Properties Appendix C: Ceramic Materials—Classification, General Characteristics, and Properties Appendix D: Composite Materials—Classification and Properties Appendix E: Semiconductors and Advanced Materials Appendix F: Conversion of Units and Hardness Values Appendix G: Glossary Index