This chapter describes the mechanical properties of fully pearlitic microstructures and their suitability for wire and rail applications. It begins by describing the ever-increasing demands placed on rail steels and the manufacturing methods that have been developed in response. It then explains how wire drawing, patenting, and the Stelmor process affect microstructure, and describes various fracture mechanisms and how they appear on steel wire fracture surfaces. The chapter concludes by discussing the effects of torsional deformation, delamination, galvanizing, and aging on patented and drawn wires.

This chapter focuses on the inspection of steel bars for the detection and evaluation of flaws. The principles involved also apply, for the most part, to the inspection of steel wire. The nondestructive inspection methods discussed include magnetic particle inspection, liquid penetrant inspection, ultrasonic inspection, and electromagnetic inspection. Eddy current and magnetic permeability are also covered.

This chapter opens with a discussion of the classification of rod and tube extrusion processes. The standard processes involve hot working (extrusion at temperatures above room temperature), but some specialized cold working processes are also used for rod and tube extrusion. The next section reviews principles, variations, thermal conditions, axial load calculation, material flow, and applications of direct extrusion and indirect extrusion, with examples provided for extrusion of aluminum and copper alloys. Next, the chapter focuses on the process principles, advantages, and applications of conventional hydrostatic extrusion and thick film processes. This is followed by sections providing information on the special extrusion processes, namely conform process and cable sheathing. The chapter ends with a discussion on direct and indirect tube extrusion.