This chapter introduces basic extrusion concepts, including types, processes, mechanics, and the principal variables and their effects on extrusion. The chapter defines the two basic types of extrusion commonly used in the aluminum extrusion industry, direct and indirect. The chapter discusses the mechanics of extrusion including plastic deformation and metal flow, plastic strain and strain rate, extrusion pressure, and extrusion force. The principal variables of extrusion, including billet material flow stress, extrusion ratio, dead-metal zone semiangle, speed of deformation, and extrusion temperature are discussed.

Tribology plays a critical role in extrusion. This chapter provides an overview of tribology in extrusions including a discussion about the friction models at various locations of the extrusion tooling/die material interfaces and a discussion about wear and lubrication in extrusion die and tooling. The chapter shows a flow diagram highlighting the significant input variables necessary for computer simulation using the fundamentals of friction and thermodynamics models. The chapter explains the influence of principal variables on temperature rise in extrusion. It describes the most common industrial methods of isothermal extrusion of aluminum alloys.

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 focuses on factors that influence the mechanical properties of a soldered joint, including solder material, base material, solder joint design, soldering surface, soldering temperature, and test methodology.

This chapter presents the nomenclature, generations, thermomechanical processing, microstructure development, and mechanical properties of advanced high-strength steels.

Dual-phase (DP) steels have the widest usage in the automotive industry because of their excellent combination of strength and ductility. This chapter presents the composition, microstructure, mechanical properties, formability, and attributes of DP steels. It also discusses the basic approaches for the commercial production of DP steels.

This chapter presents a discussion on the compositions, microstructures, processing, deformation mechanism, mechanical properties, formability, and attributes of complex-phase steels.

This chapter presents the composition, microstructure, processing, deformation mechanism, mechanical properties, formability, and attributes of transformation-induced plasticity steels.

Martensitic (MS) steel is produced by quenching carbon steel from the austenitic phase into martensite. This chapter presents the compositions, microstructures, processing, deformation mechanism, mechanical properties, hot forming process, and attributes of MS steels.

This chapter presents an overview on the twins and stacking faults. It then provides an overview of the compositions, microstructures, thermodynamics, processing, deformation mechanism, mechanical properties, formability, and special attributes of twinning-induced plasticity steels.

Austenitic stainless steels are iron-base alloys containing more than 50% Fe, 15 to 26% Cr, and less than 45% Ni. This chapter provides a discussion on the types, compositions, microstructures, processing, deformation mechanism, mechanical properties, formability, and special attributes of austenitic stainless steels.

This chapter presents a review of some of the global development and deployment of advanced high-strength steels (AHSS). It discusses collaboration projects between government, industry, and academia and summarizes research that has focused on the influence of alloy composition on the microstructure evolution during plastic deformation and the resulting mechanical properties.

This chapter explains how to measure the shape, size, microstructure, and composition of powders as well as their flowability and crystallization behavior. It presents detailed workflows and calculations based on SEM, TEM, FESEM, and STEM imaging, x-ray diffraction, differential scanning calorimetry, EDS and EELS spectroscopy, and powder sieving. It also discusses the measurement of crystallite size, lattice mismatch, and crystallinity and the relationship between surface area and flowability.

This chapter provides an overview of sintering techniques and the microstructures and properties that can be achieved in different material systems. It covers conventional furnace sintering, microwave and laser sintering, hot and hot-isostatic pressing, and spark plasma sintering. It describes the advantages and disadvantages of each method, the mechanisms involved, and the effect of sintering parameters on the density, grain size, and mechanical properties of titanium and tungsten heavy alloys, stainless steel, cemented carbides, ceramics, composites, and rare earth magnets.

This chapter examines the microstructure of metallic components produced by casting and compares them with microstructures achieved by means of powder metallurgy. It shows how metals and alloys obtained by various processing routes differ in terms of grain size, secondary phases, oxide and carbide dispersions, porosity, dendritic formation, and properties such as hardness, toughness, tensile strength, and yield strength.

The porous structure of powder-metal materials, and thus the sintering method, has a significant impact not only on the properties of PM components, but also on how they respond to surface treatments and fabrication processes such as coating and joining. This chapter explains how the microstructure of PM parts achieved by different sintering methods influences the development of galvanized coatings and the mechanisms involved in sinter bonding and various welding and brazing processes. It presents and interprets the results of several studies in which PM materials, including iron, copper, stainless steel, brass, and bronze alloys, are joined by spot welding, projection welding, and solid-state welding as well as furnace and microwave brazing. It also examines the effects of ZrSiO 4 additions on the friction and wear behaviors of PM bronze brake-lining materials.

This chapter discusses the growing role of powder metallurgy in the production of intermetallic, Heusler, and high-entropy alloys. It reviews the challenges of producing these materials by conventional methods and the advantages of sinter-based PM techniques. It explains why PM processes are better suited for complex materials than casting and compares the properties of intermetallic, Heusler, and high-entropy alloys prepared by casting and powder-metal techniques.