Aluminum and its alloys are among the more formable materials of commonly fabricated metals. This article discusses the formability, bendability, and springback of aluminum and its alloys. It describes the forming limit diagrams that illustrate the biaxial combinations of strain that can occur without splitting. The article reviews various bending methods, such as draw, compression, ram and press, roll, and stretch or tension bending. It describes the process variations of incremental sheet forming (ISF), such as single-point incremental forming, two-point incremental forming, and kinematic incremental sheet forming. The article concludes with a discussion on spinning, warm forming, and superplastic forming.

In the investment casting process, molten metal is poured into hot molds, allowing for the production of castings with extremely thin sections, knife edges and sharp detail. This article discusses patternmaking and dimensioning, as well as the pattern materials, such as waxes and plastics, for investment casting. It describes the mold refractories, binders, slurry formulation, slurry preparation, cluster preparation, and coating and drying for the manufacture of ceramic shell molds. The article reviews postcasting operations, including knockout, cutoff, core removal, heat treatment, and abrasive cleaning. It discusses the design considerations for investment castings and tabulates common investment casting defects. The article concludes with information on the design examples in investment casting.

Adhesive bonding has been used more and more in automotive joining for a variety of components, including closures and structural modules. This article discusses the functions of adhesive-bonded joints, as well as the limitations and advantages of adhesive bonding. It describes the characteristics of an adhesive joint and reviews the surface preparation for adhesive bonding in terms of surface pretreatment, surface cleaning, chemical conversion coating, and primer coating. The article discusses the thermoplastic resins and thermosetting resins, as well as the factors to be considered in selecting an adhesive. It concludes with information on the testing of adhesive joints.