This article provides the basics of overall quench process distortion. It describes the influence of quenching processes on the generation of distortion. Examples for the distortion behavior of different types of components are presented. Then, comparisons between different quenching processes are provided. The article presents some possibilities for minimization of shape changes by the quenching process itself. Several suggestions are given for quenching processes in evaporating fluids. An example is provided for out-of-roundness reduction for rings by well-defined inhomogeneous quenching in a gas nozzle field. Another example shows how intensive and high-speed quenching can help to reduce the bending of shafts with an asymmetrical cross-section. The last example shows the result when external loads and nonsymmetric quenching act together. The article also presents test samples for the judgment about distortion potential arising from heat treatment equipment.

High-volume additive manufacturing (AM) for structural automotive applications, along the lines of economically viable technologies such as powder metallurgy, castings, and stampings, remains a lofty goal that must be realized to obtain the well-known advantages of AM. This article presents two key opportunities for AM related to automotive applications, specifically within the realm of metal laser powder-bed fusion: alloys and product designs capable of high throughput. The article also presents the general methodology of alloy development for automotive AM. It provides examples of unique designs for reciprocating components in elevated-temperature applications that are also exposed to demanding tribological conditions. The article also discusses the future of AM for automotive applications.

The aviation industry has been driving the use of additive manufacturing (AM), moving from one-off demonstrator or pathfinder components toward higher-volume serial production applications. This article presents an introduction to AM in aviation, explaining how aviation requirements apply to AM. It also presents advancements, standards, and future expectations of aviation.

This article presents the use of additive manufacturing (AM) in the space industry. It discusses metal AM processes and summarizes metal AM materials, including their relevant process categories and references. It also presents the design for AM for spacecraft. The article also provides an overview of in-space manufacturing and on-orbit servicing, assembly, and manufacturing. It presents some of the specific areas that must be understood for the qualification of AM. The article also discusses future trends, challenges, and opportunities for aerospace.

In addition to failures in shafts, this article discusses failures in connecting rods, which translate rotary motion to linear motion (and conversely), and in piston rods, which translate the action of fluid power to linear motion. It begins by discussing the origins of fracture. Next, the article describes the background information about the shaft used for examination. Then, it focuses on various failures in shafts, namely bending fatigue, torsional fatigue, axial fatigue, contact fatigue, wear, brittle fracture, and ductile fracture. Further, the article discusses the effects of distortion and corrosion on shafts. Finally, it discusses the types of stress raisers and the influence of changes in shaft diameter.

The types of metal components used in lifting equipment include gears, shafts, drums and sheaves, brakes, brake wheels, couplings, bearings, wheels, electrical switchgear, chains, wire rope, and hooks. This article primarily deals with many of these metal components of lifting equipment in three categories: cranes and bridges, attachments used for direct lifting, and built-in members of lifting equipment. It first reviews the mechanisms, origins, and investigation of failures. Then the article describes the materials used for lifting equipment, followed by a section explaining the failure analysis of wire ropes and the failure of wire ropes due to corrosion, a common cause of wire-rope failure. Further, it reviews the characteristics of shock loading, abrasive wear, and stress-corrosion cracking of a wire rope. Then, the article provides information on the failure analysis of chains, hooks, shafts, and cranes and related members.

This article focuses on common failures of the components associated with the flow path of industrial gas turbines. Examples of steam turbine blade failures are also discussed, because these components share some similarities with gas turbine blading. Some of the analytical methods used in the laboratory portion of the failure investigation are mentioned in the failure examples. The topics covered are creep, localized overheating, thermal-mechanical fatigue, high-cycle fatigue, fretting wear, erosive wear, high-temperature oxidation, hot corrosion, liquid metal embrittlement, and manufacturing and repair deficiencies.

This article focuses on failure analyses of aircraft components from a metallurgical and materials engineering standpoint, which considers the interdependence of processing, structure, properties, and performance of materials. It discusses methodologies for conducting aircraft investigations and inspections and emphasizes cases where metallurgical or materials contributions were causal to an accident event. The article highlights how the failure of a component or system can affect the associated systems and the overall aircraft. The case studies in this article provide examples of aircraft component and system-level failures that resulted from various factors, including operational stresses, environmental effects, improper maintenance/inspection/repair, construction and installation issues, manufacturing issues, and inadequate design.

This article illustrates the relationships among commonly used 2xxx series alloys. It contains tables that list values for composition limits of aluminum-lithium alloys, and aerospace alloys and their temper conditions according to primary design requirements.

Alloy 2124, aerospace plate alloy, is a high-purity version of 2024. This datasheet provides information on key alloy metallurgy, fabrication characteristics, processing effects on physical and mechanical properties, and applications of this series alloy.

Alloy 2196 is a higher Li-containing alloy registered in 2000 for various aircraft extrusion parts. This datasheet provides information on composition limits and applications of alloy 2196 and 2296 as well as processing effects on mechanical properties of 2196-T8511 extrusions. A performance comparison of 2196-T8511 extrusion with alloy 2024 is also presented.

Alloy 2198 is an Al-Cu-Li alloy that is used in combination with 2196-T8 stringers for the fuselage skins of the Bombardier C-Series. This datasheet provides information on composition limits of the alloy 2198 and provides a performance comparison of 2198-T8 and 2024-T351 alloys.

The aluminum alloy 7099 is a Kaiser aluminum high-strength Al-Mg-Zn-Cu alloy with zirconium that offers a less quench-sensitive alloy for properties in thicker sections for airframe structures such as wing ribs, spars, and skins, as well as fuselage frames and floor beams. This datasheet provides information on key alloy metallurgy and processing effects on mechanical properties of this 7xxx series alloy.

The 206.0, A206.0, and B206.0 alloys (aluminum alloys 2xxx) are structural castings in the heat-treated temper for automotive and aerospace applications where high tensile and yield strengths with moderate elongations are needed. This datasheet provides information on key alloy metallurgy and fabrication characteristics of these 2xxx series alloys, as well as the effects of processing on their typical physical and mechanical properties.

This datasheet provides information on key alloy metallurgy, mill product specifications, processing effects on physical and mechanical properties, and applications of high-strength aerospace alloys 2024 and Alclad 2024. It contains tables that list values of tensile property limits for 2024 sheet, plate, and round product forms. Figures illustrate the effect of stretching and aging on toughness of the 2024 sheet and the effect of temperature on tensile properties of 1.0 mm thick Alclad 2024-T3 sheet.

This datasheet provides information on composition limits, fabrication characteristics, processing effects on physical and mechanical properties, and applications of the high-strength extrusion aluminum alloy 6069.

Alloy 2027 is an Al-Cu-Mg-Mn-Zr alloy providing improved mechanical properties compared with those of alloy 2024. Alloy 2027-T3511 extrusions are typically used for stringers to stiffen wing skin panels machined from damage tolerant 2xxx alloy plates. This datasheet provides information on key alloy metallurgy and processing effects on mechanical properties of plate and extrusions of this 2xxx series alloy.

Alloy 7055 is widely used in the aerospace industry in applications as plate and extrusions. This datasheet provides information on key alloy metallurgy and processing effects on fracture, mechanical, tensile, and compressive properties of this 7xxx series alloy.

Alloy 6156 is an Al-Si-Mg-Cu-Mn weldable alloy, developed for the lower portion of the fuselage, which required a T6 temper strength level and high damage tolerance properties. This datasheet provides information on key alloy metallurgy of this 6xxx series alloy. Fatigue crack growth and material toughness for various thicknesses of alloy 6156 clad T62 are illustrated.

Alloy 2055 is an Al-Cu-Li alloy developed as a replacement for high-strength 7xxx and 2xxx alloys in applications such as fuselage stringers and floor beams. This datasheet provides information on its key alloy metallurgy and illustrates the damage tolerance of 2055-T84 extrusions and 7xxx extrusions.