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 describes the formability and forming characteristics of low-carbon sheet steels, coated sheet steels, stainless steels, and aluminum and magnesium alloys. It provides property data as well as flow stress curves for numerous grades of each material and explains how composition, microstructure, and processing methods influence forming behaviors.

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.

This chapter describes the nature of the problems arising from using advanced high-strength steels (AHSS) and discusses potential remedies to minimize the adverse effects that may limit the adoption of AHSS in the automotive industry. The discussion provides information on press energy, springback, residual stress, die wear, hot forming, downgaging limits, welding, binders, draw beads, and tool material wear.

This chapter discusses the properties and behaviors of advanced high-strength steels used in the automotive industry, including dual- and complex-phase steels, transformation-induced plasticity steels, ferritic-bainitic steels, and quenched and partitioned steels. It explains how different manufacturing processes, including coating, affect the grain size, microstructure, and formability of these important steels.

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.

Cold spray coatings technology has the potential to provide surface enhancement for applications in sectors such as defense and aerospace, oil and gas, power generation, medical, automotive, electronics, and railways. The ability to deposit clean metallic coatings is used in applications requiring corrosion/oxidation protection, erosion/wear protection, additive manufacturing, and fabricating free forms. This chapter discusses the function, advantages, and benefits of some of these applications.

This article summarizes the results of work completed by the ASM Thermal Spray Society Advisory Committee to identify key research challenges and opportunities in the thermal spray field. It describes and prioritizes research priorities related to emerging process methods, thermal spray markets and applications, and process robustness, reliability, and economics.

Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides information on the process of conversion of steel and iron parts to aluminum.

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.

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 chapter provides guidelines and insights on the selection of materials, coatings, and treatments for friction and wear applications. It begins with a review of the system nature of tribological effects, the subtleties of friction, and the selection idiosyncrasies of the material systems and lubricants covered in prior chapters. It then presents a systematic approach for selecting tribomaterials, using an automotive fan motor as an example.

This chapter addresses the general effects of composition, mechanical treatment, surface treatment, processing, and fabrication operations on the corrosion resistance of aluminum and its alloys. Different types of surface treatments covered include claddings, anodizing, and conversion coatings. The processing steps that can have relatively significant impact on corrosion resistance are homogenization, rolling, extrusion, quenching, aging, and annealing.

This chapter is intended to identify materials, processes, and designs that will lead to great advances in powder-binder forming technologies. It discusses some of the structures obtained through these advances in powder-binder technologies such as binder jetting and extrusion-based additive manufacturing, including bound-metal deposition and fused-filament fabrication: oxidation-resistant high-temperature alloys, anisotropic structures, submicrometer-scale structures, surface hard materials, and artist metallic clays. Some of the advances discussed include the developments in process involving plastics, emulsions, ceramics, and porous structures and foams. Improvements in the design processes have led to the development of functional structures, controlled porosity, and bioinspired structures.

This chapter discusses the forming characteristics of dual-phase (DP) and transformation-induced plasticity (TRIP) steels. It begins with a review of the mechanical behavior of advanced high-strength steels (AHSS) and how they respond to stress-strain conditions associated with deformation processes such as stretching, bending, flanging, deep drawing, and blanking. It then describes the complex tribology of AHSS forming operations, the role of lubrication, the effect of tool steels and coatings, and the force and energy requirements of various forming presses. It also discusses the cause of springback and explains how to predict and compensating for its effects.

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 article addresses critical aspects in bond testing of thermal spray coatings and provides step-by-step guidance for obtaining representative and reproducible test results based on ASTM C633 and other applicable industry standards. It clarifies details of ASTM C633 requirements and provides examples of the best practice confirmed by hundreds of tests performed worldwide, adopted by numerous industrial standards, and requested to comply with international technical standardization and certification organizations such ISO, AS, SAE, and Nadcap.

This article provides a high-level overview of thermal spray technologies and their applications and benefits. It is intended to educate members of government, industry, and academia to the benefits of thermal spray technology. The article describes the value of thermal spray technology with examples of application success stories. A few applications critical to thermal spray and market growth are briefly discussed. The article also summarizes the key research areas in thermal spray technology.

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.