This chapter briefly reviews the experience-based guidelines that were developed for forming and welding advanced high-strength steels (AHSS). It discusses the benefits of using HSS in car body structures and components that are analyzed by the performance indices developed for materials selection.

A large portion of cast and wrought product production is directed to the ground transportation market. Aluminum castings, extrusions, forgings, and rolled products all find wide application for trucks, trains, subways, and buses and are discussed in this chapter.

This chapter provides information on the major drivers for automakers and the solutions to address these industry drivers and meet their business goals. It discusses the importance of steel in the industry and briefly describes the development and significance of advanced high-strength steels for the industry.

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.

This chapter discusses the work of a famous stainless steel pioneer, Edward G. Budd. The discussion covers his early years, his automobile body business, the arrival of novel kind of stainless steel in America, Earl Ragsdale's shot weld patent, the world's first stainless steel airplane, the world's first stainless steel rubber-tired train, the Flying Yankee, the Mark Twain Zephyr, the development of the Budd Company in the war years and postwar years, and a review of the Budd Era.

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.

The hot-working process extrusion is used to produce semifinished products in the form of bar, strip, and solid sections, as well as tubes and hollow sections. The first part of this chapter describes the composition, properties, and applications of tin and lead extruded products with a deformation temperature range of 0 to 300 deg C and magnesium and aluminum extruded products with a working temperature range of 300 to 600 deg C. The second part focuses on copper alloy extruded products, extruded titanium alloy products, and extruded products in iron alloys with a working temperature range of 600 to 1300 deg C.

Steel castings are produced in thousands of designs for different applications. They fill needs in many industries, including transportation, construction machinery, earthmoving equipment, rolling mills, mining, oil and gas exploration, and power generation. This chapter touches upon the variety of applications for which steel castings can be supplied and the ranges of casting size and complexity. Photographs in this chapter provide an understanding of these applications, their size and complexity, and the types of cast steels produced.

Stainless steels have a wide variety of applications for household products, food-handling equipment, major appliances, medical equipment, and industrial equipment. Stainless is also featured in many architectural designs and monuments. Many of the most important applications of stainless steel can be found in the transportation industry, where both the cutlery martensitic and the chromium-nickel austenitic stainless steels have been used. This chapter provides a detailed discussion on these applications.

This chapter provides information on ultra-light steel family research programs conducted by the global steel industry under the umbrella of WorldAutoSteel. It discusses the collaboration efforts between U.S government, industry, and academia on advanced high-strength steels (AHSS) technology. Some of the projects on AHSS research and development are also reviewed.

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.

Iron and steel have been the most useful materials to meet the needs of several industries for many decades. Each iron and steel alloy offers unique attributes that make them the best choice for an application. This chapter provides an overview of each ferrous alloy—gray iron, malleable iron, compacted graphite iron (CGI), ductile iron, austempered ductile iron (ADI), and carbon steel and low-alloy steel; its versatile attributes; and its individual applications. A large section of the chapter covers the impact of electric vehicles on the future of the iron and steel castings industry, including discussion on electric vehicle categories and weights; impact of center of gravity on stability and steering; lightweighting incentives; and engineering for improved suspension.

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 provides information on the biennial International Wear of Materials Conference, which is the inspiration for this book. It reviews the fundamentals of tribology, tribosystems, and related terminology. The glossary at the end of this chapter is intended to familiarize readers with some of the fundamental tribology terms that will be repeated throughout this book.

Engineers have many materials to choose from when dealing with weight-related design constraints. The list includes aluminum, beryllium, magnesium, and titanium alloys as well as engineering plastics, structural ceramics, and polymer-, metal-, and ceramic-matrix composites. This chapter provides a brief overview of these lightweight materials, discussing their primary advantages along with their properties, behaviors, and limitations.

The technology of fabricating composite hardware and structures by filament winding has evolved empirically through the development and manufacturing of specific components. This chapter reviews areas of technology used in building composite parts and discusses the processes from which the current technology was derived. The discussion covers quality control requirements for composite fabrication technology and cleanliness standards in the workplace. It describes technology developed for specific components, including satellites struts, aircraft hydraulic cylinders, drill pipe, drive shafts, couplings, and cryogenic tubing.

This appendix contains bibliographies related to the history of stainless steel.

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.

Improvement in processing, material substitution, light weighting, and recycling have contributed immensely to the cause of sustainability in the materials cycle. This chapter discusses some of the key indicators of sustainability that have direct relevance to advanced high-strength steels (AHSS) used in a vehicle. The discussion covers the major contributor to greenhouse gas emissions, production routes for manufacturing crude steel, and an optimized index guideline for selecting the best material. Details on the benefits of AHSS on the life cycle of vehicles are provided. The chapter also provides information on recycling and the economics of AHSS.

This chapter describes the making of iconic structures such as the Chrysler Building. It also describes the discoveries of the Nirosta (18-8) stainless steel that was used for the construction of the Chrysler Building. The chapter presents William Van Alen's description of 18-8 stainless steel for the Chrysler Building. It provides information on the opening ceremonies for the Chrysler Building, Van Alen's vision, and the exterior of the building.