This article provides a discussion on ten rules for the effective production of reliable castings. These rules include good-quality melt, liquid front damage, liquid front stop, bubble damage, core blows, shrinkage damage, convection damage, segregation, residual stress, and location points.

This article discusses the types of patterns used for a specific application such as loose patterns, match plate patterns, cope and drag patterns, and special patterns. It describes the principles of the patternmaking techniques used to make expendable molds and for metal casting processes such as die casting and permanent mold casting. The article reviews the pattern features and mold production considerations used in the pattern design, namely, parting line considerations, addition of gates and risers, core prints, and locating points. It examines the pattern allowances for ensuring a dimensionally correct final pattern. A variety of materials and advanced composite materials used in the manufacture of patterns are discussed. The article evaluates the factors influencing the selection of type of patterns for specific castings.

The stress-intensity concept is based on the parameter that quantifies the stresses at a crack tip. This article summarizes some stress-intensity factors for various crack geometries commonly found in structural components. Through-the-thickness cracks may be located in the middle of a plate; at the edge of a plate; or at the edge of a hole inside a plate. The article discusses uniform farfield loading in terms of point loading of a center crack and point loading of an edge crack. It tabulates the correction factors for stress intensity at shallow surface cracks under tension. Farfield tensile loading and part-through crack in a finite plate are also discussed. The article concludes with a discussion on through-the-thickness crack and part-through crack in a pressurized cylinder.

A characteristic feature of bending is the inhomogeneous (nonuniform) nature of the deformation. Therefore, in a bent specimen, the strain and stress at a given point are dependent on the location of the point with respect to the neutral axis of the cross-sectional area of the specimen. This article discusses the stress-strain relationships, strain curvature, and stress-moment equations for elastic, noncylindrical, elastic-plastic, and pure plastic bending conditions. It also reviews the distribution of residual stress and springback.

A fixture is a special workholding and supporting device designed and built for a particular part or shape that can be made by using standardized components, such as drill bushings, locating buttons, and clamping devices. This article provides a discussion on optimum fixture design and describes the clamping methods, namely, manual clamping, pneumatic clamping, and hydraulic clamping, and their specific principles. It presents an overview on modular fixturing for limited production. The article concludes with information on cost factors in fixturing.

Hardness testing equipment is important as all results from the induction equipment are graded by the hardness testing equipment. This article includes maintenance tips and points to consider regarding hardness test equipment, power supplies, controls, programmable logic controllers, computer systems, water cooling systems, fixtures and machines, air-operated or pneumatic devices, coils, and quench systems. It also presents simple rules that need to be applied while moving the equipment from one location to another.

This article examines material property data and the information needs at various points in the design, manufacture, and use cycle. It contains a table that lists the various sources of materials data. The article describes locating media for sources of data such as suppliers of databases and internet. It discusses the types of sources of data, including computer readable media, data centers, and print media. The article also reviews the methods for evaluation and interpretation of data and examines the processes of obtaining and reporting test data.