Root cause of failure in automotive electronics cannot be explained by the failure signatures of failed devices. Deeper investigations in these cases reveals that a superimposition of impact factors, which can never be represented by usual qualification testing, caused the failure. This article highlights some of the most frequent early life failure types in automotive applications. It describes some of the critical things to be considered while handling packages and printed circuit board layout. The article also provides information on failure anamnesis that shows how to use history, failure signatures, environmental conditions, regional failure occurrences, user profile issues, and more in the failure analysis process to improve root cause findings.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.

This chapter is a detailed account of the applications of stainless steel in automotive and transport systems. The discussion covers exhaust systems, structural components, automotive components, trucks, and rail transport.

This chapter discusses the growing use of sintered stainless steels in automotive applications and various types of filters and filtering media. It also describes how these materials are produced in the form of metal foams and cellular structures and how they serve as flake pigments in corrosion-resistant coatings.

Transformation-induced plasticity (TRIP) steels are characterized by their excellent strength and high ductility, which allow the production of more complicated parts for lightweight automotive applications. This chapter provides an overview of the compositions, microstructures, processing, deformation mechanism, mechanical properties, hot forming, tempering, and special attributes of TRIP the steels.

This chapter consists of three parts. The first part provides data and guidelines for selecting materials and processing routes. It compares the basic properties of metals, ceramics, and polymers, identifies important measures of performance, and discusses manufacturing processes and their compatibility with specific materials. The chapter then presents general guidelines for selecting lightweight materials, and concludes with a review of lightweight metals, plastics, and composites used in automotive applications.

Titanium castings are used in a wide range of aerospace, chemical process, marine, biomedical, and automotive applications. This chapter provides an overview of titanium casting and associated processes and how they compare with other manufacturing methods. It also discusses the role heat treating and its effect on the tensile properties of different titanium alloys.

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.

Unlike conventional quench and temper heat treatment, austempering is an iron and steel heat-treatment process that enhances mechanical properties through the isothermal transformation of austenite with a minimum amount of quenching stresses. This chapter begins with a discussion of austemperability requirements. Then outlines of austenitizing and austempering cycles and resultant microstructures are presented. This is followed by sections discussing the mechanical properties, advantages, limitations, machinability, process variants, and applications of austempered ductile iron (ADI). Information on the growth of premachined ADI components is also provided. Further, the chapter describes two slightly different systems for austempering: atmospheric-salt and salt-salt systems. Finally, it presents general guidelines for component designers, casting manufacturers, and heat treaters to apply ADI more widely and with improved success.

This chapter summarizes the performance attributes of advanced high-strength steels, namely stiffness, strength, strain hardening, fatigue, crashworthiness, formability, toughness, and bake hardening.

This chapter provides a brief introduction to manufacturing processes used to produce metal parts and how they differ in terms of achievable geometries, tolerances, surface finishes, and production rate.

This chapter provides an overview of the nomenclature, generations, and thermomechanical processing of advanced high-strength steels (AHSS) and provides information on the development of microstructure. It also presents a review of the mechanical property trends of AHSS.

This chapter describes the different aluminum products used to manufacture modern automobile components. It discusses how automakers use these products to reduce weight, improve performance, and manage production costs. It also reflects on the changes in the aluminum industry, automakers, and their relationships. Organized by product type—castings, sheet, and extrusions—each section of the chapter describes the relevant alloys, tempers, and properties required to meet specific needs for component parts and final assembly.

Aluminum is the second most widely used metal in the world. It is readily available, offers a wide range of properties, and can be shaped, coated, and joined using a variety of methods. This chapter discusses some of the key attributes of wrought and cast aluminum alloys and the classifications, designations, and grades of available product forms. It also explains how aluminum alloys are used in aerospace, automotive, rail, and marine applications as well as in building and construction, electrical products, manufacturing equipment, packaging, and consumer durables such as appliances and furniture.

This article provides a brief description of commercially important thermal spray processes and gives examples of applications and application requirements. The processes covered are flame, wire arc, plasma, high-velocity oxyfuel processes, detonation gun, and cold spray methods. Examples are provided of the applications in aerospace, automotive, and medical device industries as well as the use of thermal spray as an additive manufacturing technique.