Process Techniques for Engineering High-Performance Materials

Most processed materials retain a memory of their production process at the molecular level. Subtle changes in production-such as variations in temperature or the presence of impurities-can impart performance benefits or drawbacks to individual batches of products. Some product developers have taken advantage of this process dependency to tailor properties to specific customer needs. In other cases, poorly engineered processes have resulted in serious failures. Process Techniques for Engineering High-Performance Materials explores practical strategies to guide you in systematically developing, improving, and producing engineered materials. The book describes an R&D approach that is common to many material types, from polymers, biochemicals, metal alloys, and composites to coatings, ceramics, elastomers, and processed foods. Throughout, hundreds of examples illustrate successes and disasters in the history of materials development. These examples clearly show how product management and development tactics are constrained by the nature of the production process and the strategy of the company. The author offers practical advice on how to: - Foster creativity in an industrial environment and avoid factors that unintentionally suppress technical innovation - Develop products when the properties of the product are highly dependent on processing variables - Avoid the inevitable scale-up problems that occur on process-dependent materials - Get the most out of expensive trial work in a production plant environment - Combine products into a systems solution to customer problems Highlighting important rules for product development, this book helps you better understand the mechanics of engineering processed materials and how to adjust your processes to improve performance.

Tim Oberle holds B.S. and M.S. degrees in chemical engineering from the University of Illinois. His employers have been the American Can Company, W.R. Grace, and Sealed Air Corporation. This experience includes research, manufacturing, and commercial and management roles in the United States, Europe, and Asia. Over the course of 33 years in the industry, he has performed polymer processing, converting, and fitness testing on packaging and cushioning products. These activities routinely involve the engineering of process-dependent materials. Tim has 12 issued patents and additional patents pending.

Introduction to Process Dependency. The Process, the Product, and Its Ultimate Life Span. Fitness-for-Use Testing. Technical Creativity and Idea Generation. Finding Product Opportunity. Prioritizing Project Proposals. Evaluating Critical Parameters in the Process. Organizing Development Projects. Project Execution and Oversight. Small-Scale Trials. Development Trials on Large-Scale Equipment. Managing and Controlling the Process. Controlling Raw Materials. Complex Manufacturing Situations. Human Factors. Managing Customer Expectations. Proprietary Systems. Index.