This chapter discusses many aspects of extrusion die and tooling, including the terminology and function of extrusion die and tooling, the types of dies, the fundamentals of die design, manufacturing, correction, material, and the surface treatments of die bearings and tribology in extrusion dies. It then presents the fundamentals and function of finite-element modeling simulation. The chapter describes the role of tribology and thermodynamics in the die bearing to control the flow and dimensional stability of extrusion exiting the die.

This chapter explains how powder metallurgy technologies are being leveraged for the production of automotive components, electric motors, rare-earth permanent magnets, and the infrastructure for high-speed rail transport.

In the case of gearboxes, vibration is the primary mode of failure even at the mid-range of operating speeds. Avoiding such failures requires an understanding of gearbox design, vibration theory, and material properties. This chapter details sources and types of gearbox vibrations; characteristics of gearbox vibrations; fundamentals of periodic vibrations; and vibration theory. It provides housing design for single-stage offset parallel gearboxes, high-speed gearboxes, and epicyclic gearboxes. The chapter then provides an analysis and selection of design factors for vibration reduction. It presents five types of gear tooth geometry errors. The chapter also focuses on gear quality inspection and on bearing-induced vibrations.

This appendix provides a list of books and technical papers utilized as reference material during the development of this book.

Aluminum alloy products offer architectural and building solutions that exploit the benefits inherent in this metal: light weight, excellent durability, low maintenance, and thermal management opportunities. This chapter discusses the major applications for aluminum building products and related competitive materials. The commonly used alloys and tempers and their performance benefits are outlined for extruded profiles, rolled sheet and foil, and die cast products.

Boiler tubes operating at high temperatures under significant pressure are vulnerable to stress rupture failures. This chapter examines the cause, effect, and appearance of such failures. It discusses the conditions and mechanisms that either lead to or are associated with stress rupture, including overheating, high-temperature creep, graphitization, and dissimilar metal welds. It explains how to determine which mechanisms are in play by interpreting fracture patterns and microstructural details. It also describes the investigation of several carbon and low-alloy steel tubes that failed due to stress rupture.

With cold work, mechanical strength (measured either by yield strength or ultimate tensile strength) increases and ductility (measured by elongation, reduction of area, or fracture toughness) normally decreases. This chapter discusses the mechanisms that produce these changes and the factors that influence them. It explains how cold working increases dislocation density and how that affects the stress-strain characteristics of steel, particularly the onset of deformation. It describes the effects of deformation on ferrite, austenite, cementite, and pearlite, and how to optimize their microstructure for various applications through controlled deformation. It also provides information on subcritical annealing, the examination and control of texture, the use of optical microscopy to monitor the effects of recrystallization, and the effect of cold working on threaded fasteners, nails, and filaments used to manufacture cords.

Induction heat treating is used in a wide range of applications. Typical uses, as described in this chapter, include the surface hardening of many types of shafts as well as gears and sprockets and the through-hardening of gripping teeth, cutting edges, and impact zones incorporated into various types of tools and track pins manufactured for off-highway equipment.

This chapter discusses the fatigue behavior of bolted, riveted, and welded joints. It describes the relative strength of machined and rolled threads and the effect of thread design, preload, and clamping force on the fatigue strength of bolts made from different steels. It explains where fatigue failures are likely to occur in cold-driven rivet and friction joints, and why the fatigue strength of welded joints can be much lower than that of the parent metal, depending on weld shape, joint geometry, discontinuities, and residual stresses. The chapter also explains how to improve the fatigue life of welded joints and discusses the factors that can reduce the fracture toughness of weld metals.

This chapter provides a brief overview of monotectic alloy systems and reactions. It begins by presenting a monotectic phase diagram and identifying important points, lines, and regions. It then describes the monotectic reactions that occur in copper-lead systems and the associated solidification structures. It also discusses the morphology of the microstructure produced during directional solidification and the classification criteria of low- and high-dome alloys.

This chapter presents a comprehensive coverage of mechanical fastening methods. It begins with a discussion on the advantages and disadvantages of mechanical fastening followed by sections providing information on mechanically fastened joints and the selection of the correct fastener system. The chapter then describes important structural fasteners, namely bolts, screws, pins, collar fasteners, rivets, blind fasteners, machine pins, and spring clip fasteners. The following sections describe the process involved in presses, shrink fits, hole generation, and fastener installation. The chapter ends with information on miscellaneous mechanical fastening methods.

The technology of fabricating composite hardware and structures by filament winding has evolved empirically through the development and manufacturing of specific components. This chapter reviews areas of technology used in building composite parts and discusses the processes from which the current technology was derived. The discussion covers quality control requirements for composite fabrication technology and cleanliness standards in the workplace. It describes technology developed for specific components, including satellites struts, aircraft hydraulic cylinders, drill pipe, drive shafts, couplings, and cryogenic tubing.

This chapter covers basic machining and assembly operations, with an emphasis on hole preparation for mechanical fasteners. It describes manual, power feed, and automated drilling techniques as well as reaming and countersinking. It discusses various types of fasteners, including rivets, pins, and bolts, along with selection factors and special considerations for composite joints. It also includes information on interference-fit and blind fasteners as well as trimming operations, general assembly considerations, and sealing and painting procedures.

This chapter focuses on common failure characteristics exhibited by mechanical and electrical components. The topic is considered from two perspectives: one possibility is that the system failed because parts were nonconforming to drawing requirements and another possibility is that the system failed even though all parts in the system met their drawing requirements. The common failures discussed in this chapter include those associated with metallic components, composite materials, plastic components, ceramic components, and electrical and electronic components.

This chapter explains how to join beryllium parts using adhesive bonding and mechanical fastening techniques and discusses the advantages and disadvantages of each method. It describes the stresses that need to be considered when designing adhesive bonds, the benefits and limitations of different adhesives, and surface preparation requirements. It explains how adhesives are applied and cured and how curing times and temperatures affect bonding strength. It also discusses the use of bolts and rivets and the different types of joints that can be made with them.

A systematic procedure for minimizing risks involved in heat treated steel components requires a combination of metallurgical failure analysis and fitness for service with respect to safety and reliability based on risk analysis. This chapter begins with an overview of heat treat processing of steels. This is followed by sections on various aspects of heat treatment design and heat treating practices for minimizing distortion. Influence of design, steel grade, and condition is then illustrated in the examples of failures due to heat treatment. A procedure is analyzed to improve the performance of the design process of a component. A heat-transfer model, coupling with a phase transformation model, a thermomechanical model, and a thermochemical model, is also considered. The chapter further provides information on the failure aspects of and heat treatment procedures applied to welded components. It ends with a section on risk-based approach applicable to heat treated steel components.

This chapter provides an overview of the possible mechanisms of failure for heat treated steel components and discusses the techniques for examining fractures, ductile and brittle failures, intergranular failure mechanisms, and fatigue. It begins with a description of the general sources of component failure. This is followed by a section on the stages of a failure analysis, which can proceed one after the other or occur at the same time. These stages of analysis are collection of background data, preliminary visual examination, nondestructive testing, selection and preservation of specimens, mechanical testing, macroexamination, microexamination, metallographic examination, determination of the fracture mechanism, chemical analysis, exemplar testing, and analysis and writing the report. The chapter ends with a discussion on various processes involved in the determination of the fracture mechanism.

This chapter reviews various ways to classify failure categories and summarizes the basic types, causes, and mechanisms of damage, with particular consideration given to whether the likelihood of the types of damage can or cannot be influenced by the heat treating of steel parts. The classical organization for types of damage (failures) is as follows: deformation, fracture, wear, corrosion or other environmental damage, and multiple or complex damage. The chapter also provides some examples of lack of conformance to specification that may at first look like the heat treater did something wrong, but where other contributing factors made it difficult or impossible for the heat treater to meet the specification.