Structural members in a radar antenna system are held together by cadmium-plated high-strength steel bolts, several of which had fractured along the fillet near the head. Investigators determined that the bolts did not seat properly, making contact only at the periphery, which subjected them to high stress concentrations in the fillet region. They also concluded that the intergranular nature of the fracture, as revealed by scanning electron fractography, pointed to hydrogen embrittlement as a contributing factor. This chapter provides a summary of the investigation along with a recommendation to consider adding spring washers to the assembly.

This chapter reviews the fundamentals of stress, strain, and deformation and demonstrates some of the tools and techniques used to analyze how materials and structures respond to tension, compression, bending, and shear. It begins with an overview of the behavior of perfectly elastic and plastic materials and viscous substances. It then describes the stress-strain response of two- and three-dimensional solids, explaining how to determine principle stresses and strains using Mohr’s circle and how to derive equivalent stress and strain using the von Mises relationship. It then goes on to analyze the stress state of load-bearing members, pressurized tubes, and pin-loaded lugs, accounting for the effect of geometric discontinuities, such as cutouts, fillets, and holes, as well as cracks. It also explains how finite element methods are used to solve problems involving complex geometric and loading conditions.

The design process is the first and most important step in corrosion control. Major savings in operating costs are possible by anticipating corrosion problems so as to provide proper design for equipment before assembly or construction begins. This chapter describes the role of the design team in producing a successful final design, general considerations in corrosion-control design, and design details that accelerate corrosion. The details that must be considered when attempting to control corrosion by design include plant/site location, plant environment, component/assembly shape, fluid movement, surface preparation and coating procedures, and compatibility, insulation, and stress considerations. Design solutions for specific forms of corrosion, namely crevice corrosion, galvanic corrosion, erosion-corrosion, and stress-corrosion cracking, are then considered. A brief section is devoted to the discussion on corrosion allowance used for steel parts subject to uniform corrosion. Finally, the chapter describes the design considerations for using weathering steels.

This chapter reviews the nomenclature of different vehicle components helpful in identifying the target applications and discusses the implementation of advanced high-strength steels (AHSS) in automotive and nonautomotive industries. In addition, the chapter provides information on the utilization and trends of AHSS in vehicle bodies and closures.

Helicopter control mechanisms were failing at a higher than normal rate on high-altitude flights in mountainous regions. All of the failures occurred at or near attachment points on pressurized tubes, causing a pressure drop and partial loss of function. Visual and SEM examinations revealed cracks along the inner surface of the tubes, some of which had propagated through the thickness of the wall. Cracks emanating from weld toes were also visible. Based on their observations, investigators concluded that the tubes were subjected to excessive flexural load, causing cracks due to fatigue. They also provide recommendations for avoiding such failures in the future.

This appendix is a compilation of terms, definitions, abbreviations, and symbols associated with the mechanics and mechanisms of fracture.

Joining comprises a large number of processes used to assemble individual parts into a larger, more complex component or assembly. The selection of an appropriate design to join parts is based on several considerations related to both the product and the joining process. Many product design departments now improve the ease with which products are assembled by using design for assembly (DFA) techniques, which seek to ensure ease of assembly by developing designs that are easy to assemble. This chapter discusses the general guidelines for DFA and concurrent engineering rules before examining the various joining processes, namely fusion welding, solid-state welding, brazing, soldering, mechanical fastening, and adhesive bonding. In addition, it provides information on several design considerations related to the joining process and selection of the appropriate process for joining.

This chapter discusses various factors pertinent to the applications of low-pressure permanent mold casting process, namely decorative automotive wheels, critical safety structural components, and chassis components.

This chapter discusses some of the ways that the lessons learned from failures have benefitted society, leading to improved product designs, better materials, safer industrial processes, and more robust codes and standards. It also provides several examples of how the technology and procedures associated with aviation security have been upgraded in the wake of air disasters.

Electromagnetic induction, or simply "induction," is a method of heating electrically conductive materials such as metals. It is commonly used for heating workpieces prior to metalworking and in heat treating, welding, and melting. This technique also lends itself to various other applications involving packaging and curing of resins and coatings. This chapter provides a brief review of the history of induction heating and discusses its applications and advantages.