The version of DOS release in 1981 was 1.0. Over the past decade, DOS has undergone several changes. Each time the DOS developers release a new version, they increase the version number.

Windows NT (new technology) is an operating system developed by Microsoft. NT is an enhanced version of the popular Microsoft Windows 3.0, 3.1 programs. NT requires a 386 processor or greater and 8 Mb of RAM. For the best NT performance, you have to use a 486 processor with about 16 Mb or higher. Unlike the Windows, which runs on top of DOS, Windows NT is an operating system itself. However, NT is DOS compatible. The advantage of using NT over Windows is that NT makes better use of the PC's memory management capabilities.

OS/2 is a PC operating system created by IBM. Like NT, OS/2 is DOS compatible and provides a graphical user interface that lets you run programs with a click of a mouse. Also like NT, OS/2 performs best when you are using a powerful system. Many IBM-based PCs are shipped with OS/2 preinstalled.

UNIX is a multi-user operating system that allows multiple users to access the system. Traditionally, UNIX was run on a larger mini computers to which users accessed the systems using terminals and not PC's. UNIX allowed each user to simultaneously run the programs they desired. Unlike NT and OS/2, UNIX is not DOS compatible. Most users would not purchase UNIX for their own use.

Windows 95 & 98 (Windows 2000) are the most popular user-oriented operating systems with a friendly interface and multitasking capabilities. The usage of Windows 95 and its enhanced version Windows 98 is so simple that even little kids learn how to use it very quickly. Windows 95 and 98 are DOS compatible, so all programs written for DOS may work under the new operating system.

Windows 95 requires 486 processor with 16 megabytes of RAM or Pentium 75-90 with 40 megabytes of free hard disk space.

Vocabulary:

complex -- сложный

to consume -- потреблять

consumer -- потребитель

to realize -- понять, осознать

smart -- умный

decade -- декада, десятилетие

version -- версия

to enhance -- увеличивать, расширять

top -- верх, вершина

on top of DOS -- «сверху», на основе ДОС

are shipped -- поставляются

compatible -- совместимый

with a click of a mouse -- одним щелчком кнопки мыши

access -- доступ

to allow -- позволять

multiple users -- многочисленные пользователи

simultaneously -- одновременно

to desire -- желать

to ship -- поставлять, доставлять

General understanding:

1) What problems faced programmers in the 1940's and 1950's?

2) Why were the first programs «complex» and «time-consuming»?

3) What are the basic functions of operating system?

4) What does the abbreviation DOS mean?

5) What company developed the first version of DOS operating system? For what purpose was it done? Was the new operational system successful?

6) What is the difference between the PC-DOS and MS-DOS

7) What does the abbreviation NT stand for? Is NT DOS-compatible? What are the basic requirements for NT?

8) Who is the developer of OS/2?

9) What makes UNIX so different from the other operational systems?

10) What are the special features of Windows 95, Windows 98, Windows 2000?

Exercise 9.1. Match the following:

1) Like NT,... is DOS compatible and provides a graphical user interface that lets you run programmes with a click of a mouse.

2)... is the most commonly used PC operating system

3)... is a multi-user operating system that allows multiple users to access the system

4)... is an operating system developed by Microsoft, an enhanced version of the popular Microsoft Windows programs.

5) The usage of... is so simple that even little kids learn how to use it very quickly.

a) UNIX

b)DOS

c) NT

d) OS/2

e) Windows 95

Exercise 9.2. Which of the listed below statements are true/false. Specify your answer using the text.

1) When computers were first introduced in 40's and 50's programmers had to write programs to instruct CD-ROMs, laser printers and scanners.

2) The operational system controls and manages the use of the hardware and the memory.

3) There are no commands available in operating systems, they are only in word processors.

4) Microsoft developed MS-DOS to compete with IBM's PC-DOS.

5) NT requires computers with 486 CPU and 16 M random access memory.

6) OS/2 is DOS compatible because it was developed by Microsoft.

7) Traditionally, UNIX was run by many users simultaneously.

8) Windows 95 and Windows 98 are DOS compatible and have very «friendly» and convenient interface.

Exercise 9.3. Translate into English:

1) Современная операционные системы контролируют использование системного оборудования, например, принтера и мыши.

2) С точки зрения пользователя, операционные системы PC-DOS и MS-DOS идентичны, с равными возможностями и набором системных команд.

3) OS/2 является DOS -совместимой операционной системой, позволяющей запускать программы при помощи графического интерфейса пользователя.

4) Дополнительные программы для работы с устройствами системного оборудования были очень сложны и поглощали много времени.

5) Операционная система также позволяет запускать программы, такие как простейший текстовый редактор.

6) DOS -- наиболее распространенная операционная система для персонального компьютера.

Questions for group discussion:

1) Why do you think Bill Gates, President of Microsoft Company is one of the richest people on the Earth?

2) Judging from your experience tell if UNIX is used nowadays? What about OS/2?

3) Ask the students in your group who have experience working with Windows 95 and Windows 98 about the advantages and disadvantages of these operational systems.

Text B: «WINDOWS 95»

Windows 95 is a new operational system with an easy interface based on the expanding windows principle which uses icons to graphically represent files and their types.

Windows 95 makes the way you and your computer interact easy. Most everyday tasks are now easier to accomplish than ever before. For example, the second mouse button has become a powerful weapon. The old Windows 3.0 Program Manager and File Manager have been replaced. The desktop tools that replace them are very like those found on a Macintosh. For example, there is a Recycle Bin that makes it easier to recover accidentally deleted files.

Your computer probably will crash less running Windows 95 than it did with Windows 3.1 and 3.0 or even DOS. Most memory related problems have been removed. Built-in networking features make it easy to reliably share files with co-workers across the room or across the world. And MS-DOS as we know it is so well hidden that you'll rarely give it a thought. Yes, you can still run DOS programs and older Windows applications but most users will probably want to spend most of their time using Windows 95 applications instead.

Microsoft says that it is moving forward to the time when we'll all think more about our data and less about the specific name-brand programs used to create them.

Window 95 plug-and-play capability makes it easy to upgrade your computer hardware. And portable computer users will like what Microsoft has done to make their lives calmer.

A new Windows shortcuts capability makes it easy to reach frequently used files and other necessities. A new Find feature helps you to locate and examine the contents of files in a flash.

Most of this is accomplished without sacrificing performance. In fact, many things (like printing) usually happen faster now, due to 32-bit support and other Windows 95 advancements.

Vocabulary:

to interact -- взаимодействовать

to accomplish -- выполнять, достигать

weapon -- оружие

to replace -- замещать

Recycle Bin -- корзина

to crash -- ломаться, давать сбои

to remove -- удалять

co-workers -- коллеги, сослуживцы

rarely -- редко

to plug -- подключать

frequently -- часто

support -- поддержка

necessity -- необходимость

flash -- вспышка, зд. in a flash -- моментально

to give smth. a thought -- подумать о чем- либо

brand-name -- торговая марка

calm -- спокойный

shortcut -- кратчайший путь

to sacrifice -- жертвовать

advancement-- прогресс, продвижение

General understanding:

1) What is Windows 95?

2) What new principles are used in Windows 95?

3) What is a Recycle Bin feature?

4) What problems has Windows 95 solved?

5) Is it possible to run old DOS programs under Windows 95?

6) What is a «plug-n-play» capability?

7) What is a «shortcut» capability?

8) What is a «Find» feature?

9) Why many things work faster now with Windows 95?

Exercise 9.4. Which of the listed above statements are true/false. Specify your answer using the text.

An «icon» is graphical image that represents file and its type.

Second button is not used in Windows 95 because most people use 1-button mouse.

3) There are no similarities between Macintosh and Windows 95 desktop tools.

4) Windows 95 has some tools which help to communicate with other people through computer network.

5) It's no longer possible to use MS-DOS commands and run MS-DOS files.

6) Microsoft corporation is oriented to produce as many programs as needed to meet people needs and make them buy specific brand- name products.

7) New plug-n-play capability is for those who like to play computer games 24 hours a day and seven days a week.

8) A new shortcut feature is used to cut long programs very short to save disk space.

9) New Find feature helps you to locate the contents of files.

10) It must be mentioned that all new Windows features are possible only because of the low level of performance and quality.

Exercise 9.5. Find the equivalents in the text:

1) Ваш компьютер вероятно будет давать меньше сбоев с Виндоуз 95, чем с более ранними версиями и даже ДОС.

2) Корпорация Майкрософт заявляет, что она делает все для того, чтобы приблизить время, когда мы все будем думать больше о наших данных, чем о конкретных «фирменных» программах, которые используются для создания этих данных.

3) Новая функция поиска позволяет обнаружить местоположение и исследовать содержимое файла в мгновение ока.

4) Большинство этих функций достигнута в ущерб производительности.

5) ДОС, каким мы его знаем, так хорошо запрятан, что вы редко думаете о его использовании.

6) В Виндоуз 95 существует инструмент Корзина, который позволяет легко восстанавливать случайно удаленные файлы.

7) Инструменты Рабочего Стола очень схож с инструментами Макинтоша.

8) Вторая кнопка мыши стала мощным оружием.

Exercise 9.6. What is:

1) window

2) icon

3) recycle bin

4) plug-and-play capability

5) shortcut feature

Exercise 9.7. Practice:

1) Start Windows 95. Empty the Recycle Bin. See the free diskspace on drives A and C. See the catalgue of disk C.

2) Resize, maximize and minimize the window. Close the window. Move it, holding the left button.

3) Create a folder COMPUTER. Copy any 2 filesinto it. Rename the folder. Delete two files into the Recycle Bin then recover them. Delete the whole folder.

4) Create a textual file in WordPad program. Save it as TEXT. Rename it as MYFILE. Create a shortcut for it. Put the shortcut on the DeskTOP.

5) Create a picture in Paintbrush program. Save it as MYPICTURE. Create folder PICTURES. Copy file MYPICTURE to the PICTURES folder.

6) QUIT Windows 95.

Questions for group discussion:

1) What are the poor features of Windows 95?

2) Computer society thinks, that Intel company, the most powerful CPU producer, has an agreement with Microsoft corporation that the latter will develop more and more sophisticated, large and demanding software to force users to buy new processors and upgrade their computers. Do you think this might be true? How does this suggestion correlate with the new Windows 2000 and Microsoft Office 2000? Do you think that Bill Gates' monopoly on Windows operating systems is very dangerous for the competition and price-making process?

3) Ask anyone in the group who has a computer if Windows 98 is better than Windows 2000? Why and why not?

Text C: «INTRODUCTION TO THE WWW AND THE INTERNET»

Millions of people around the world use the Internet to search for and retrieve information on all sorts of topics in a wide variety of areas including the arts, business, government, humanities, news, politics and recreation. People communicate through electronic mail (e-mail), discussion groups, chat channels and other means of informational exchange. They share information and make commercial and business transactions. All this activity is possible because tens of thousands of networks are connected to the Internet and exchange information in the same basic ways.

The World Wide Web (WWW) is a part of the Internet. But it's not a collection of networks. Rather, it is information that is connected or linked together like a web. You access this information through one interface or tool called a Web browser. The number of resources and services that are part of the World Wide Web is growing extremely fast. In 1996 there were more than 20 million users of the WWW, and more than half the information that is transferred across the Internet is accessed through the WWW. By using a computer terminal (hardware) connected to a network that is a part of the Internet, and by using a program (software) to browse or retrieve information that is a part of the World Wide Web, the people connected to the Internet and World Wide Web through the local providers have access to a variety of information. Each browser provides a graphical interface. You move from place to place, from site to site on the Web by using a mouse to click on a portion of text, icon or region of a map. These items are called hyperlinks or links. Each link you select represents a document, an image, a video clip or an audio file somewhere on the Internet. The user doesn't need to know where it is, the browser follows the link.

All sorts of things are available on the WWW. One can use Internet for recreational purposes. Many TV and radio stations broadcast live on the WWW. Essentially, if something can be put into digital format and stored in a computer, then it's available on the WWW. You can even visit museums, gardens, cities throughout the world, learn foreign languages and meet new friends. And, of course, you can play computer games through WWW, competing with partners from other countries and continents.

Just a little bit of exploring the World Wide Web will show you what a lot of use and fun it is.

Vocabulary:

World Wide Web -- «Всемирная Паутина»

to retrieve -- извлекать

variety -- разнообразие, спектр

recreation -- развлечение

network -- сеть

to share -- делить

humanities -- гуманитарные науки

business transactions -- коммерческие операции

access -- доступ

to browse -- рассматривать, разглядывать

browser -- браузер (программа поиска информации)

to provide -- обеспечивать (чем-либо)

provider -- провайдер (компания, предоставляющая доступ к WWW через местные телефонные сети)

broadcast live -- передавать в прямом эфире site -- страница, сайт

to link -- соединять

hyperlink -- гиперссылка

to compete -- соревноваться

General understanding:

1) What is Internet used for?

2) Why so many activities such as e-mail and business transactions are possible through the Internet?

3) What is World Wide Web?

4) What is Web browser?

5) What does a user need to have an access to the WWW?

6) What are hyperlinks?

7) What resources are available on the WWW?

8) What are the basic recreational applications of WWW?

Exercise 9.8. Which of the listed below statements are true/false. Specify your answer using the text.

1) There are still not so many users of the Internet.

2) There is information on all sorts of topics on the Internet, including education and weather forecasts.

3) People can communicate through e-mail and chat programs only.

4) Internet is tens of thousands of networks which exchange the information in the same basic way.

5) You can access information available on the World Wide Web through the Web browser.

6) You need a computer (hardware) and a special program (software) to be a WWW user.

7) You move from site to site by clicking on a portion of text only.

8) Every time the user wants to move somewhere on the 'eh he/she needs to step by step enter links and addresses.

9) Films and pictures are not available on the Internet.

10) Radio and TV-broadcasting is a future of Internet. They're not available yet.

Exercise 9.9. Define the following using the vocabulary:

1) Internet

2) World Wide Web

3) Web browser

4) Internet provider

5) Hyperlinks

Exercise 9.10. Find the equivalents:

1) Объем ресурсов и услуг, которые являются частью WWW, растет чрезвычайно быстро.

2) Каждая ссылка, выбранная вами представляет документ, графическое изображение, видеоклип или аудио файл где-то в Интернет.

3) Интернет может быть также использован для целей развлечения.

4) Вы получаете доступ к ресурсам Интернет через интерфейс или инструмент, который называется веб-браузер.

5) Вся эта деятельность возможна благодаря десяткам тысяч компьютерных сетей, подключенных к Интернет и обменивающихся информацией в одном режиме.

6) Пользователи общаются через электронную почту, дискуссионные группы, чэт-каналы (многоканальный разговор в реальном времени) и другие средства информационного обмена.

Exercise 9.11. Match the following:

1) You access the information through one interface or tool called a...

2) People connected to the WWW through the local... have access to a variety of information.

3) The user doesn't need to know where the site is, the... follows the...

4) In 1996 there were more than 20 million users of the...

5) Each... provides a graphical interface.

6) Local... charge money for their services to access... resources.

Words to match with:

1) web browser, providers, link, WWW,

Questions for group discussion:

1) Some people think that Internet is very harmful, especially for young people, because it carries a lot of information about sex, drugs, violence and terrorism. Do you think that some kind of censorship is necessary on the WWW?

2) World famous authors and publishers say that the Internet violates their copyright because Web-programmers put all kinds of books, pictures, music, films and programs free on the Internet and this reduces their sales and profits.

3) Has anyone in your group experience working on the Internet? Ask them 1) about the difficulties they had; 2) useful information retrieved; 3) fun they got? Why so few people have experience working on the Internet?

FAMOUS PEOPLE OF SCIENCE AND ENGINEERING

Bill Gates

William Henry Gates was born in Seattle, Washington, in 1955.

He is an American business executive, chairman and chief executive officer of the Microsoft Corporation. Gates was the founder of Microsoft in 1975 together with Paul Alien, his partner in computer language development. While attending Harvard in 1975, Gates together with Alien developed a version of the BASIC computer programming language for the first personal computer.

In the early 1980s. Gates led Microsoft's evolution from the developer of computer programming languages to a large computer software company. This transition began with the introduction of MS-DOS, the operating system for the new IBM Personal Computer in 1981. Gates also led Microsoft towards the introduction of application software such as the Microsoft Word processor.

Much of Gates' success is based on his ability to translate technical visions into market strategy. Although Gates has accumulated great wealth from his holdings of Microsoft stock, he has been known as a tough competitor who seems to value winning in a competitive environment over money. Gates still continues to work personally in product development at Microsoft.

1. ALLOYS

Bronze and brass, the first alloys in the history of metallurgy, were probably obtained by man accidentally when melting mixed metal ores. Much later alloys of iron were obtained.

Steel was made in small quantities in early times until the mid-19th century when it was manufactured on a large scale in the iron and steel industry.

The commercial production of pure aluminium in about 1890 began a new range of alloys and among them duralumin, an alloy of about 94 per cent aluminium, with small quantities of copper, manganese, magnesium, and silicon. Most of aluminium alloys are both light and strong.

Nickel is often mixed with other metals for special purposes: permalloy is a nickel-iron alloy that is magnetically soft. The polarity of its magnetic field can be easily changed and it is used for transformer cores. Monel metals contain about two parts nickel to one part copper, plus other elements. They are stronger than nickel and extremely corrosion-resistant. These properties make them useful in chemical production.

Electrum is a natural or artificial alloy of gold and silver containing 15-45 per cent of silver. It was used in the ancient world for coinage.

Bismuth is frequently used as a part of alloys with low melting-points. Today alloys can be designed for particular applications with certain properties.

2. MANUFACTURING OF PLASTICS

The manufacture of plastic and plastic products involves procuring the raw materials, synthesizing the basic polymer, compounding the polymer into a material useful for fabrication, and moulding or shaping the plastic into its final form.

Raw Materials

Originally, most plastics were made from resins derived from vegetable matter, such as cellulose (from cotton), oils (from seeds), starch derivatives, or coal. Casein (from milk) was among the nonvegetable materials used. Although the production of nylon was originally based on coal, air, and water, and nylon 11 is still based on oil from castor beans, most plastics today are derived from petrochemicals. These oil-based raw materials are relatively widely available and inexpensive. However, because the world supply of oil is limited, other sources of raw materials, such as coal gasification, are being explored.

Synthesizing the Polymer

The first stage in manufacturing plastic is polymerization. As noted, the two basic polymerization methods are condensation and addition reactions. These methods may be carried out in various ways. In bulk polymerization, the pure monomer alone is polymerized, generally either in the gaseous or liquid phase, although a few solid-state polymerizations are also used. In solution polymerization, an emulsion is formed and then coagulated. In interfacial polymerization, the monomers are dissolved in two immiscible liquids, and the polymerization occurs at the interface of the two liquids.

Additives

Chemical additives are often used in plastics to produce some desired characteristic. For instance, antioxidants protect a polymer from chemical degradation by oxygen or ozone; similarly, ultraviolet stabilizers protect against weathering. Plasticizers make a polymer more flexible, lubricants reduce problems with friction, and pigments add colour. Among other additives are flame retardants and antistatics.

Many plastics are manufactured as composites. This involves a system where reinforcing material (usually fibres made of glass or carbon) is added to a plastic resin matrix. Composites have strength and stability comparable to that of metals but generally with less weight. Plastic foams, which are composites of plastic and gas, offer bulk with low weight.

Shaping and Finishing

The techniques used for shaping and finishing plastics depend on three factors: time, temperature, and flow (also known as deformation). Many of the processes are cyclic in nature, although some fall into the categories of continuous or semicontinuous operation.

One of the most widely used operations is that of extrusion. An extruder is a device that pumps a plastic through a desired die or shape. Extrusion products, such as pipes, have a regularly shaped cross section. The extruder itself also serves as the means to carry out other operations, such as blow moulding and injection moulding. In extrusion blow moulding, the extruder fills the mould with a tube, which is then cut off and clamped to form a hollow shape called a parison. The hot, molten parison is then blown like a balloon and forced against the walls of the mould to form the desired shape. In injection moulding, one or more extruders are used with reciprocating screws that move forwards to inject the melt and then retract to take on new molten material to continue the process. In injection blow moulding, which is used in making bottles for carbonated drinks, the parison is first injection moulded and then reheated and blown.

In compression moulding, pressure forces the plastic into a given shape. Another process, transfer moulding, is a hybrid of injection and compression moulding: the molten plastic is forced by a ram into a mould. Other finishing processes include calendering, in which plastic sheets are formed, and sheet forming, in which the plastic sheets are formed into a desired shape. Some plastics, particularly those with very high temperature resistance, require special fabrication procedures. For example, polytetrafluoroethene (Teflon) has such a high melt viscosity that it is first pressed into shape and then sintered--exposed to extremely high temperatures that bond it into a cohesive mass without melting it. Some polyamides are produced by a similar process.

Uses

Plastics have an ever-widening range of uses in both the industrial and consumer sectors.

Packaging

The packaging industry is a leading user of plastics. Much LDPE (low-density polyethene) is marketed in rolls of clear-plastic wrap. High-density polyethene (HPDE) is used for some thicker plastic films, such as those used for plastic waste bags and containers. Other packaging plastics include polypropene, polystyrene, polyvinyl chloride (PVC), and polyvinylidene chloride. Polyvinylidene chloride is used primarily for its barrier properties, which can keep gases such as oxygen from passing into or out of a package. Similarly, polypropene is an effective barrier against water vapour. Polypropene is also often used in housewares and as a fibre for carpeting and rope.

Construction

The building industry is a major consumer of plastics, including many of the packaging plastics mentioned above. HDPE is used for pipes, as is PVC. PVC is also used in sheets for building materials and similar items. Many plastics are used to insulate cables and wires, and polystyrene in the form of foam serves as insulation for walls, roofs, and other areas. Other plastic products are roofing, door and window frames, mouldings, and hardware.

Other Uses

Many other industries, especially motor manufacturing, also depend on plastics. Tough engineering plastics are found in vehicle components like fuel lines, fuel pumps, and electronic devices. Plastics are also used for interior panelling, seats, and trim. Many car bodies are made of fibreglass-reinforced plastic.

Among the other uses of plastic are housings for business machines, electronic devices, small appliances, and tools. Consumer goods range from sports equipment to luggage and toys

3. PRINCIPLES AND PROCESS OF POLYMERISATION IN PLASTICS PRODUCTION

Condensation polymerisation and addition polymerisation are the two main processes in plastics production. The manufacture of plastics depends upon the building of chains and networks during polymerisation.

A condensation polymer is formed by a synthesis that involves the gradual reaction of reactive molecules with one another, with the elimination of small molecules such as water. The reaction gradually slows down as polymers are built up.

An addition polymer forms chains by the linking of small identical units without elimination of small molecules.

The most important concept in condensation polymers is that of «functionality», i.e., the number of reactive groups in each molecule participating in the chain buildup. Each molecule must have at least two reactive groups, of which hydroxyl (-OH), acidic endings (-COOH), and amine endings (-NH) are the simplest.

Hydroxyl is characteristic of alcohol endings, combining with an acid ending to give an ester, the polymer being known as a polyester. Examples are polyethylene terephthalate obtained by reaction of ethylene glycol containing hydroxyl groups at each end and terephthalic acid containing two acidic groups and polycarbonate resins.

Alcohols are a particular class of oxygen-containing chemical compounds with a structure analogous to ethyl alcohol (C-HOH). Amines are various compounds derived from ammonia by replacement of hydrogen by one or more hydrocarbon radicals (molecular groups that act as a unit). Esters are compounds formed by the reaction between an acid and an alcohol or phenol with the elimination of water.

Bulk addition polymerization of pure monomers is mainly confined to styrene and methyl methacrylate The process is highly exothermic, or heat producing. The dissipation of heat (necessary to maintain chain length) is achieved in the case of styrene by intensive stirring of the viscous, partially polymerized mixture, which is then passed down a tower through zones of increasing temperature. Alternatively, polymerization may be completed in containers that are small enough to avoid an excessive temperature rise as a result of the heat released during polymerization.

Methyl methacrylate is also partially polymerized before being poured into molds consisting of between sheets of plate glass, to produce clear acrylic sheet.

Ethylene is polymerized in tubular reactors about 30 metres long and less than 25 millimetres in diameter at pressures of 600-3,000 to give 10-20 percent conversion to low-density polyethylene. Residual gas is recycled.

Polymerization of monomers in solution allows easy temperature control, but the molecular weight of polymers formed is reduced because of chain transfer reactions

Solvent removal from such a solution may also be very difficult. The process can be applied advantageously to vinyl acetate and acrylic esters.

Suspension polymerization producing beads of plastic is extensively applied to styrene, methyl methacrylate, vinyl chloride, and vinyl acetate. The monomer, in which the initiator or catalyst must be soluble, is maintained in droplet form suspended in water by agitation in the presence of a stabilizer such as gelatin, each droplet of monomer undergoing bulk polymerization.

In emulsion polymerization the monomer is dispersed in water by means of a surface-active agent (a substance slightly soluble in water that reduces the surface tension of a liquid), its bulk aggregating into tiny particles held in suspension. The monomer enters the hydrocarbon part of the surface-active micelles and is polymerized there by a water-soluble catalyst.

This process is particularly useful for the preparation of very high molecular weight polymers.

Exposure of certain substances to X-ray or ultraviolet radiation initiates chain reactions that can be used for manufacture of such thermoplastics as polyethylene and polyvinyl chloride.

4. RESINS

Resins that cannot be softened by heating include the phenolics, furan resins, aminoplastics, alkyds, allyls, epoxy resins, polyurethanes, some polyesters, and silicones.

Phenolics or phenol-aldehydes

The important commercial phenolic resin Bakelite is based on phenol and formaldehyde. The two processes in general use are the one-step process producing resol resins (the first stage in the formation of a phenolic resin) that are either liquid or brittle, soluble, fusible solids, from more than one molecule of formaldehyde per phenol molecule; and the two-step process, using an excess of phenol to produce novolacs, resins that have no reactive methylol groups and must be mixed with an aldehyde to undergo further reaction.

Resol resins thermoset on heating and are used for adhesives. Novolacs require a further source of formaldehyde in the form of hexamethylenetetramine to produce molding powders. Both resins are run out from the reaction vessel, after removal of water by distillation, and ground up, then compounded on heated rolls with fillers that vary from wood flour to mica; for strength and heat resistance fibrous asbestos is used as a filler (hexamethylenetetramine is also added at this stage in the case of the two-step resin). Final grinding produces the molding powders, which on further heat treatment will yield the typical thermoset resin.

Phenolic moldings are resistant to heat, chemicals, and moisture and are preferred for wet-dry applications as in washing machines. Their stability to heat and low heat conductivity suit them for use in appliance parts, and their electrical insulation qualities qualify them for electric fittings such as switches, plugs, and distributor caps; resistance to hydraulic fluids has led to their use in automotive parts. All these applications have been made more economical by the development of injection molding and extrusion methods. Complex phenols are used in manufacture of brake linings.

Furan resins

Furfural is a five-membered ring compound (i.e., the basic molecule has a ring shape and contains five atoms) of four carbon atoms and one oxygen atom, carrying the aldehyde group, -- CHO; it reacts like formaldehyde with phenols in the presence of an acid catalyst to give a rigid polymer with high chemical resistance, used for coatings in industry. It can be prepared in semiliquid form with a low viscosity and remarkable penetrating power when applied to porous forms such as foundry sand cores or graphite blocks, being in this respect superior to other liquid resins.

Aminoplastics

Urea resins are made by the condensation in aqueous solution of formaldehyde and urea in the presence of ammonia as an alkaline catalyst, giving a colourless solution to which cellulose filler is added to yield a molding powder upon drying, which when heated in a mold gives a water-white (transparent) molding unless previously coloured by pigment.

The filler confers considerable strength, so that thin sections such as in cups and tumblers can be molded. Very large quantities of urea-formaldehyde resin are used in kitchen and bathroom hardware details, and electric appliance housings and fittings.

Melamine behaves in the same way as urea, but the product is more moisture resistant, harder and stronger, leading to wide use for plates and food containers. Melamine moldings are glossy and harder than any other plastic and retain a dust-free surface. Solutions of the thermoplastic forms of urea-formaldehyde resins are widely used as bonding agents for plywood and wood-fibre products.

Alkyds

Alkyds are polyesters, generally of phthalic acid (with two acid groups) and glycerol, a triol -- i. e., an alcohol with three hydroxyl groups. The solid resins are molded at high speed under low pressure, cured quickly, and are used where insulating properties, strength, and dimensional stability over a wide range of voltage, frequency, temperature, and humidity are required, as in vacuum-tube bases and automotive ignition parts and with glass-fibre reinforcement for switch gear and housings for portable tools.

Polyesters of unsaturated alcohols

The resins known as DAP and DAIP, are crossliked allyl esters of phthalic and isophthalic acid, respectively. They are notable for maintaining rigidity and excellent electrical properties at temperatures up to 230 С, prорerties also manifested by allylic resin-impregnated glass cloth, used in aircraft and missile parts. Other advantages are good storage life and absence of gas evolution during polymerization. The resin allyl diglycol carbonate, optically clear and colourless, is used for making cast objects; fully cured castings are more heat and abrasion resistant than other cast resins.

Epoxy resins

Epoxy resins have outstanding mechanical and electrical properties, dimensional stability, resistance to heat and chemicals, and adhesion to other materials. They are used for casting, encapsulation, protective coatings, and adhesives, and for reinforced moldings and laminates of the highest quality. Popular adhesives (epoxy glues) contain the resin components and the curing agent, usually an amine or an anhydride, in separate packages. The two are mixed just before use.

Polyurethanes

Formed by the reaction between diisocyanates and polyols (multihydroxy compounds), polyurethanes are among the most versatile of plastics, ranging from rigid to elastic forms. Their major use is for foams, with properties varying from good flexibility to high rigidity. Thermoplastic polyurethanes that can be extruded as sheet and film of extreme toughness can also be made.

Polyesters of unsaturated acids

Certain esters can be polymerized to resin and are used on a very large scale in glass-fibre-reinforced plastics.

Unsaturated acid (usually maleic acid in the form of its anhydride) is first polymerized to a relatively short polymer chain by condensation with a dihydric alcohol such as propylene glycol, the chain length being determined by the relative quantities of the two ingredients The resulting condensation polymer is then diluted with a monomer such as styrene and an initiator for addition polymerization added. This mixture is quite stable at room temperature over a long period. Frequently, a silicone compound is added to promote adhesion to glass fibres, and wax to protect the surface from oxygen inhibition of polymerization. Glass-fibre materials are impregnated with the syrup and polymerization is brought about by raising the temperature. Alternatively, the polymerization can be carried out at room temperature by addition of a polymerization accelerator to the syrup immediately before impregnation. After an induction period, which can be controlled, polymerization takes place, with rapid increase in temperature, to give a glass-fibre-reinforced cross-linked polymer, which is effectively a thermoset type of plastic and very resistant to heat. The properties of the resin are frequently varied by replacing part of the unsaturated maleic anhydride by anhydrides of saturated acids.

Silicones

Silicon, unlike carbon, does not form double bonds or long silicon chains. It does, however, form long chains with oxygen such as in siloxanes with hydrocarbon groups attached to the silicon; these result in a wide range of oils, greases, and rubbers.

Produced through a series of reactions involving replacement of certain atoms in the chain, silicon resins, or silicones, can be used for high- and low-pressure lamination, with glass-fibre reinforcement and with mineral or short glass-fibre fillers, or for molding powders. The outstanding characteristic of these products is high dielectric strength (that is, they are good insulators at high voltages) with low dissipation over a wide temperature and humidity range. Silicones are not distorted by heat up to 400 С. They are also physiologically inert and therefore valuable for prostheses (artificial body parts).

5. INDUSTRIAL PLASTICS:

RIGID AND FLEXIBLE FOAMS

Rigid polyurethane foams in sandwich forms have wide applications as building components. They are also the best insulants known today and so have wide application in refrigeration and in buildings, where they are applied in fitted slab form or are foamed into cavities at the building site. They can also be applied by spraying about six millimetres thickness with each pass of the spray gun. The ability to spray a foaming mixture through a single nozzle is a great advantage in application.

A very important use of rigid foam is for furniture parts to reproduce wood structures; these can be injection molded. Polyurethane foam can be screwed and nailed with a retention about equal to white pine lumber.

A major advance in the manufacture of sandwich structures is a new method of injection molding, in which a large machine is used to produce moldings up to 1.2 metres square. Moldings of great strength and any desired surface are obtained.

Flexible foams

Flexible foams, usually polyurethane, are made in slab form up to 2.4 metres in width and as much as 1.5 metres high; these are then cut to required shapes or sizes or are molded. The molded foams may be hot molded.

This involves filling heated aluminum castings and gives a product having high resistance to compression, as for automobile seats; or they may be cold molded, a process used particularly for semi-flexible foams with high load-bearing properties. Used almost exclusively by the automobile industry for crash pads, armrests, and dashboard covers, the process involves machine mixing the ingredients and pouring them into aluminum molds lined with vinyl or acrylo-nitrile-butadiene-styrene skins, which become the cover material for the part.

Polystyrene foams are made in a wide range of densities, from expandable beads, either by extrusion through slot-shaped openings to 40 times the original volume to form boards directly or by foaming in steam chests to form large billets. Using small beads in stainless steel molds, cups can be molded with thin sections.

Thin sheet for packaging can also be made by the tube extrusion technique. Though packaging is a major use for forms made in closed molds, the largest use is for building panels; they can be plastered directly.

Acrylonitrile-butadiene-styrene can be expanded from pellets and is particularly suitable for wood-grain effects and for the production of heavy sections.

Expanded vinyls can be made from plastisols for flooring or textile linings by calendering with a blowing agent and laminating to a fabric base, and by injection molding for insulation and such articles as shoe soles. An improved material is now obtained from cross-linked polyvinyl chloride and competes with polyester in glass reinforced plastic.

6. BASIC PRINCIPLES OF WELDING

A weld can be defined as a coalescence of metals produced by heating to a suitable temperature with or without the application of pressure, and with or without the use of a filler material.

In fusion welding a heat source generates sufficient heat to create and maintain a molten pool of metal of the required size. The heat may be supplied by electricity or by a gas flame. Electric resistance welding can be considered fusion welding because some molten metal is formed.

Solid-phase processes produce welds without melting the base material and without the addition of a filler metal. Pressure is always employed, and generally some heat is provided. Frictional heat is developed in ultrasonic and friction joining, and furnace heating is usually employed in diffusion bonding.

The electric arc used in welding is a high-current, low-voltage discharge generally in the range 10-2,000 amperes at 10-50 volts. An arc column is complex but, broadly speaking, consists of a cathode that emits electrons, a gas plasma for current conduction, and an anode region that becomes comparatively hotter than the cathode due to electron bombardment. Therefore, the electrode, if consumable, is made positive and, if non-consumable, is made negative. A direct current (dc) arc is usually used, but alternating current (ac) arcs can be employed.

Total energy input in all welding processes exceeds that which is required to produce a joint, because not all the heat generated can be effectively utilized. Efficiencies vary from 60 to 90 percent, depending on the process; some special processes deviate widely from this figure. Heat is lost by conduction through the base metal and by radiation to the surroundings.

Most metals, when heated, react with the atmosphere or other nearby metals. These reactions can be extremely detrimental to the properties of a welded joint. Most metals, for example, rapidly oxidise when molten. A layer of oxide can prevent proper bonding of the metal. Molten-metal droplets coated with oxide become entrapped in the weld and make the joint brittle. Some valuable materials added for specific properties react so quickly on exposure to the air that the metal deposited does not have the same composition as it had initially. These problems have led to the use of fluxes and inert atmospheres.

In fusion welding the flux has a protective role in facilitating a controlled reaction of the metal and then preventing oxidation by forming a blanket over the molten material. Fluxes can be active and help in the process or inactive and simply protect the surfaces during joining.

Inert atmospheres play a protective role similar to that of fluxes. In gas-shielded metal-arc and gas-shielded tungsten-arc welding an inert gas--usually argon--flows from an tube surrounding the torch in a continuous stream, displacing the air from around the arc. The gas does not chemically react with the metal but simply protects it from contact with the oxygen in the air.

The metallurgy of metal joining is important to the functional capabilities of the joint. The arc weld illustrates all the basic features of a joint. Three zones result from the passage of a welding arc: (1) the weld metal, or fusion zone, (2) the heat-affected zone, and (3) the unaffected zone. The weld metal is that portion of the joint that has been melted during welding. The heat-affected zone is a region adjacent to the weld metal that has not been welded but has undergone a change in microstructure or mechanical properties due to the heat of welding. The unaffected material is that which was not heated sufficiently to alter its properties.

Weld-metal composition and the conditions under which it freezes (solidifies) significantly affect the ability of the joint to meet service requirements. In arc welding, the weld metal comprises filler material plus the base metal that has melted. After the arc passes, rapid cooling of the weld metal occurs. A one-pass weld has a cast structure with columnar grains extending from the edge of the molten pool to the centre of the weld. In a multipass weld, this cast structure maybe modified, depending on the particular metal that is being welded.

The base metal adjacent to the weld, or the heat-affected zone, is subjected to a range of temperature cycles, and its change in structure is directly related to the peak temperature at any given point, the time of exposure, and the cooling rates. The types of base metal are too numerous to discuss here, but they can be grouped in three classes: (1) materials unaffected by welding heat, (2) materials hardened by structural change, (3) materials hardened by precipitation processes.

Welding produces stresses in materials. These forces are induced by contraction of the weld metal and by expansion and then contraction of the heat-affected zone. The unheated metal imposes a restraint on the above, and as contraction predominates, the weld metal cannot contract freely, and a stress is built up in the joint. This is generally known as residual stress, and for some critical applications must be removed by heat treatment of the whole fabrication. Residual stress is unavoidable in all welded structures, and if it is not controlled bowing or distortion of the weldment will take place.

Arc welding

Shielded metal-arc welding accounts for the largest total volume of welding today. In this process an electric arc is struck between the metallic electrode and the workpiece. Tiny globules of molten metal are transferred from the metal electrode to the weld joint. Arc welding can be done with either alternating or direct current. A holder or clamping device with an insulated handle is used to conduct the welding current to the electrode. A return circuit to the power source is made by means of a clamp to the workpiece.

Gas-shielded arc welding, in which the arc is shielded from the air by an inert gas such as argon or helium, has become increasingly important because it can deposit more material at a higher efficiency and can be readily automated. The tungsten electrode version finds its major applications in highly alloyed sheet materials. Either direct or alternating current is used, and filler metal is added either hot or cold into the arc. Consumable electrode gas-metal arc welding with a carbon dioxide shielding gas is widely used for steel welding. Metal transfer is rapid, and the gas protection ensures a tough weld.

Submerged arc welding is similar to the above except that the gas shield is replaced with a granulated mineral material as a flux.

Weldability of metals

Carbon and low-alloy steels are the most widely used materials in welded construction. Carbon content largely determines the weldability of carbon steels. Low-alloy steels are generally regarded as those having a total alloying content of less than 6 percent. There are many grades of steel available, and their relative weldability varies.

Aluminum and its alloys are also generally weldable. A very thin oxide film on aluminum tends to prevent good metal flow, however, and suitable fluxes are used for gas welding. Fusion welding is more effective with alternating current when using the gas-tungsten arc process to enable the oxide to be removed by the arc action.