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.

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 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 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.

This chapter provides an introduction to metal forming processes and where they fit among the five general areas of manufacturing. It also discusses the basic differences between bulk deformation and sheet-metal forming processes and how they relate to hybrid forming processes such as drawing, bending, and coining.

This chapter presents guidelines for product designers to choose the best process and alloys while designing a casting. The discussion covers some of the factors pertinent to the selection of the best process for the product function and performance, namely geometric factors, mechanical properties, tooling cost per piece, and overall cost factors. The chapter contains tables listing several markets, products, popular processes, and common alloys and the common processes used for a variety of markets and products.

This appendix is a glossary of terms and definitions associated with sheet metal forming.