This chapter discusses the factors that affect die steel selection for hot forging, including material properties such as hardenability, heat and wear resistance, toughness, and resistance to plastic deformation and mechanical fatigue. It then describes the relative merits of various materials and the basic requirements for cold forging dies. The chapter also covers die manufacturing processes, such as high-speed and hard machining, electrodischarge machining, and hobbing, and the use of surface treatments.

This chapter familiarizes readers with the design, configuration, and function of tooling and dies used to extrude aluminum alloys. It discuses basic design considerations, including the geometry, location, and orientation of die openings; allowances for thermal shrinkage, stretching, and deflection; and the length and profile of bearing surfaces. It outlines the steps and processes involved in die making, describes the selection and treatment of die materials, and examines the factors that influence friction and wear. It also discusses the general procedures for on-site die correction.

This chapter defines near-net shape forging as the process of forging parts close to their final dimensions such that little machining or only grinding is required as a final step. It then describes the causes of dimensional variations in forging, including die deflection, press deflection, and process inconsistencies, and discusses related innovations.

This chapter begins with a description of the requirements of tooling and tooling material for hot extrusion. It covers the processes of designing tool and die sets for direct and indirect extrusion. Next, the chapter provides information on extrusion tooling and die sets for direct external and internal shape production and tools for copper alloy extrusion. Further, it addresses design, calculation, and dimensioning of single-piece and two-part containers and describes induction heating for containers. Information on static- and elastic-based analysis and dimensioning of containers loaded in three dimensions is provided. Examples of calculations for different containers, along with their stresses and dimensions, are presented and the manufacture, operation, and maintenance of containers are described. The chapter further discusses the properties and applications of hot working materials for the manufacture of extrusion tooling and of different extruded materials for the manufacture of extrusion tooling for direct and indirect forming.

Most of the counterfeit parts detected in the electronics industry are either novel or surplus parts or salvaged scrap parts. This article begins by discussing the type of parts used to create counterfeits. It discusses the three most commonly used methods used by counterfeiters to create counterfeits. These include relabeling, refurbishing, and repackaging. The article presents a systematic inspection methodology that can be applied for detecting signs of possible part modifications. The methodology consists of external visual inspection, marking permanency tests, and X-ray inspection followed by material evaluation and characterization. These processes are typically followed by evaluation of the packages to identify defects, degradations, and failure mechanisms that are caused by the processes (e.g., cleaning, solder dipping of leads, reballing) used in creating counterfeit parts.

This chapter addresses the issue of die failures in hot and cold forging operations. It describes failure classifications, fatigue fracture and wear mechanisms, analytical wear models, and the various factors that limit die life. It also includes several case studies in which finite-element modeling is used to predict die failure and extend die life.

This chapter provides a summary of ongoing efforts to improve quality and productivity in the aluminum extrusion industry. It assesses advancements in several areas including extrusion presses and auxiliary equipment, tool and die technology, billet casting, extrusion thermodynamics and tribology, and process control.

This chapter provides practical information on the forming and forging processes used to manufacture titanium parts, including die forging, precision die forging, hot and cold forming, superplastic forming, and deep drawing. It explains how process variables such as temperature, pressure, and strain rate influence microstructure and properties and provides recommended ranges for commonly formed and forged titanium alloys.

Gear manufacture depends on machinery available, design specifications or requirements, cost of production, and type of material from which the gear is to be made. This chapter discusses the processes involved in methods for manufacturing gears, namely casting, forming, and forging.