Aluminum products such as fasteners and automotive components are often produced by cold extrusion because it facilitates high volume production of near-net-shape parts. This article describes the cold extrusion process for aluminum alloys and the associated requirements for tooling, dies, punches, and other equipment. It covers typical tool materials and their working properties, and provides best practices for sizing aluminum slugs and preparing them for use. The article also discusses the wide range of achievable shapes from shallow cup-like extrusions to deep cups and complex parts with longitudinal flutes, stems, and grooves.

This article compares and contrasts mechanical joining techniques used in the manufacture of aluminum assemblies, including seaming, swaging, flanging, crimping, clinching, dimpling, interference and snap fits, and interlocking joints. It provides basic illustrations of the various methods and summarizes the advantages and disadvantages of each. The article also discusses the use of staples, nails, rivets, and threaded fasteners and provides relevant property and performance data.

Low-temperature surface hardening is mostly applied to austenitic stainless steels when a combination of excellent corrosion performance and wear performance is required. This article provides a brief history of low-temperature surface hardening of stainless steel, followed by a discussion on physical metallurgy, including crystallographic identity, thermal stability and decomposition, nitrogen and carbon solubility in expanded austenite, and diffusion kinetics of interstitials. It provides a description of low-temperature nitriding and nitrocarburizing processes for primarily austenitic and, to a lesser extent, other types of stainless steels along with practical examples and industrial applications of these steels.

This article describes the control of water chemistry in the steam cycle of a power plant for achieving corrosion control, deposition prevention, and higher cycle efficiency. It discusses the materials requirements of the components exposed to supercritical water in supercritical (SC) and ultrasupercritical (USC) power plants. These components include high-pressure steam piping and headers, superheater and reheater tubing, water wall tubing in the boiler, high-and intermediate-pressure rotors, rotating blades, and bolts in the turbine section. The article reviews the boiler alloys, used in SC and USC boilers, such as ferritic steels, austenitic steels, and nickel-base alloys. It provides information on the materials used in turbine applications such as ferritic rotor steels, turbine blade alloys, and bolting materials. The article explains various factors influencing steamside corrosion in SC power plants. It also deals with the role of overall efficiency in the USC power generation.

This article focuses on the corrosion and deterioration of components on recreational and small workboats. It discusses the materials selection and corrosion control for the components. These components include hulls, fittings, fasteners, metal deck gear, winches, backing plates, lifeline supports, inboard engines, cooling systems, propulsion systems, electrical and electronic systems, plumbing systems, masts, spars, and rigging.

This article describes the corrosion of principal parts of mining equipment such as mine shafts, wire rope, rock bolts, and pump and piping systems. It discusses the diagnosis and prevention of various types of corrosion including uniform corrosion, pitting corrosion, crevice corrosion, erosion-corrosion, and intergranular corrosion. The article explains the corrosion in tanks, reactor vessels, cyclic loading machinery, and pressure leaching equipment.

Mounting of the specimen is often desirable or necessary for handling and metallographic polishing after the specimen is cut into an appropriate size. This article illustrates the different mechanical clamps used in mounting small specimens. It provides useful information on compression molded mounts, which are molded with thermoplastic and thermosetting resins. The article reviews several resins and their key factors, which help in the selection of the most appropriate mounting method and resin. It also discusses the characteristics of plastic mounting materials. The article provides information on the molds and resins used for castable mounts, vacuum treatment of mounts, special mount arrangements, and mount marking and storage.

This article discusses different types of mechanical fasteners, including threaded fasteners, rivets, blind fasteners, pin fasteners, special-purpose fasteners, and fasteners used with composite materials. It describes the origins and causes of fastener failures and with illustrative examples. Fatigue fracture in threaded fasteners and fretting in bolted machine parts are also discussed. The article provides a description of the different types of corrosion, such as atmospheric corrosion and liquid-immersion corrosion, in threaded fasteners. It also provides information on stress-corrosion cracking, hydrogen embrittlement, and liquid-metal embrittlement of bolts and nuts. The article explains the most commonly used protective metal coatings for ferrous metal fasteners. Zinc, cadmium, and aluminum are commonly used for such coatings. The article also illustrates the performance of the fasteners at elevated temperatures and concludes with a discussion on fastener failures in composites.

Advanced thermoplastic composites possess impact resistance, fracture toughness, and elevated temperature endurance properties due to their melt-fusible nature. This article presents the material options available for thermoplastic composites such as pseudothermoplastics, post-impregnated thermoplastics, and true thermoplastics. It describes the processing methods of thermoplastic composites, including weaving, seaming, autoclaving, preconsolidation, roll consolidation, roll forming/pultruding, thermoforming, press forming, hydroforming, and diaphragm forming. The article provides information on different types of joints, namely, fastened, adhesive bonded, dual polymer bonded, co-consolidated, and welded joints. It explains the joining methods of thermoplastic composites, such as press forming, diaphragm forming, autoclaving, ultrasonic welding, resistance welding, and induction welding.

This article focuses on the factors to be considered for selecting fasteners for joining carbon fiber composites. These considerations include corrosion compatibility, fastener materials, strength, stiffness, head configurations, importance of clamp-up, hole fit, and lightning protection.

This article reviews the common methods of shear and multiaxial testing for the evaluation of engineering components such as fasteners and mill products. It discusses shear test methods, including through-thickness tests, in-plane shear tests, and double-notched shear test. The article provides information on torsional (rotational shear) tests as well as the basic equipment and setup of torsion testing. Motors, twist and torque transducers, torque sensors, and heating systems as well as the specimen preparation procedure are also discussed.

This article provides an overview of the relationships between torque, angle-of-turn, tension, and friction and explains how they are measured and evaluated. It focuses on the principle, test equipment, procedure, evaluation, and test report of various testing methods, namely, friction coefficient testing, torque tension testing, locknut testing, and angular ductility and rotational capacity tests. The article reviews the basic methods and fundamental principles for mechanical testing of externally and internally threaded fasteners and bolted joints. The test methods for externally threaded fasteners include product hardness, proof load, axial and wedge tension testing of full-sized products, tension testing of machined test specimens, and total extension at fracture testing. Product hardness, proof load, and cone proof-load test are the test methods for internally threaded fasteners. The article concludes with a description of torque-angle signature analysis and the specification of measurement accuracy for torque and clamp force.

The structural efficiency of a composite structure is established by its joints and assembly. Adhesive bonding, mechanical fastening, and fusion bonding are three types of joining methods for polymer-matrix composites. This article provides information on surface treatment and the applications of adhesive bonding. It discusses the types of adhesives, namely, epoxy adhesives, epoxy-phenolic adhesives, condensation-reaction PI adhesives, addition-reaction PI adhesives, bismaleimide adhesives, and structural adhesives. The article provides information on fastener selection considerations, including corrosion compatibility, fastener materials and strength, head configurations, importance of clamp-up, interference fit fasteners, lightning strike protection, blind fastening, and sensitivity to hole quality. Types of fusion bonding are presented, namely, thermal welding, friction welding, electromagnetic welding, and polymer-coated material welding.

Stud arc welding (SW), also known as arc stud welding, is a commonly used method for joining a metal stud, or fastener, to a metal workpiece. This article serves as a basic information source for those interested in accomplishing one-sided, no-hole attachment of metal fasteners. It schematically illustrates the basic equipment used for stud arc welding and describes the operation of the welding process. The article discusses several specific applications that lend themselves to special variations of the stud arc welding technique. It concludes with information on quality control, qualification, and inspection of stud-welding.

This article discusses the properties of threaded fasteners made from carbon and low-alloy steels containing a maximum of 0.55% carbon. It provides guidelines for the selection of steels for bolts, studs, and nuts intended for use at temperatures between -50 and 370 deg C. The article also discusses steels rated for service above 370 deg C and describes internationally recognized grade designations. The specifications provided can be used to outline fastener requirements, control manufacturing processes, and establish functional or performance standards. The most commonly used protective metal coatings for ferrous metal fasteners; zinc, cadmium, and aluminum; are described as well.

This article is an atlas of fractographs that helps in understanding the causes and mechanisms of fracture of titanium alloys and in identifying and interpreting the morphology of fracture surfaces. The fractographs illustrate the fracture surface, fatigue crack growth, intergranular fracture, crack propagation, ductile overload fracture, dimpled rupture, microvoid coalescence, and quasi-cleavage fracture of these alloys.