This chapter describes sheet metal forming operations, including cutting, blanking, piercing, and bending as well as deep drawing, spinning, press-brake and stretch forming, fluid forming, and drop hammer and electromagnetic forming. It also discusses the selection and use of die materials and lubricants along with superplastic forming techniques.

Any forming process that converts stored energy to plastic deformation in less than a few milliseconds is considered a high-velocity or impulse forming process. This chapter discusses the operating principles, equipment, and applications of the most common high-rate forming processes, including high-velocity hydroforming, high-velocity mechanical forming, and electromagnetic or energy-based forming.

This chapter provides a concise, design-oriented summary of more than 30 sheet forming processes within the categories of bending and flanging, stretch forming, deep drawing, blank preparation, and incremental and hybrid forming. Each summary includes a description and diagram of the process and a bullet-point list identifying relevant equipment, materials, variations, and applications. The chapter also discusses critical process variables, interactions, and components and the classification of sheet metal parts based on geometry.

This chapter discusses radiography methods using x-rays, gamma rays, and neutrons. It begins with a discussion on the applications and principles of radiography followed by sections providing information on the sources of radiation, classifications, and characteristics of x-ray tubes. Three primary attenuation processes of electromagnetic radiation, namely photoelectric effect, Compton scattering, and pair production, are covered. The chapter then discusses the principles of shadow formation, the process involved in the conversion of radiation into a form suitable for observation, and the characteristics of x-ray film. It provides information on various exposure factors in film radiography. The chapter provides a description of the characteristics that differentiate neutron radiography from x-ray or gamma ray radiography. The application of neutron radiography is described in terms of its advantages for improved contrast on low atomic number materials, discrimination between isotopes, or inspection of radioactive specimens.

This chapter discusses the types of sensors used in sheet forming operations and the information they provide. It explains how force sensors protect equipment from overloads due to tool wear, friction, and misfeeds, how displacement and proximity sensors help to prevent die crashes, how acoustic emission, ultrasonic, and eddy current sensors detect tool breakage and part defects such as cracks, and how roller ball and optical sensors measure material flow. It also discusses the role of draw-in, wrinkle, oil-monitoring, and vision sensors and explains how material properties can be derived in real time from various sensor outputs.

Liquid penetrant, magnetic particle, and eddy current inspection are used to detect surface flaws. This chapter is a detailed account of the physical principles, process description, equipment requirements, selection criteria, advantages, limitations, and applications of these surface flaw detection techniques.

Electromagnetic induction, or simply "induction," is a method of heating electrically conductive materials such as metals. It is commonly used for heating workpieces prior to metalworking and in heat treating, welding, and melting. This technique also lends itself to various other applications involving packaging and curing of resins and coatings. This chapter provides a brief review of the history of induction heating and discusses its applications and advantages.

This appendix provides practical information on induction coils and how they are made. It discusses soldering methods, preferred materials, design challenges, and best practices and procedures. It also discusses the design, construction, and application of magnetic flux concentrators and the growing use of computer simulation.

This chapter discusses the basic principles of induction heating and related engineering considerations. It describes the design and operation of induction coils, the magnitude and distribution of magnetic fields, and the forces that generate eddy currents in metals. It explains how induced electrical current causes metal to heat in proportion to their electrical resistance and how it affects temperature dependent properties such as resistivity and specific heat and, in turn, heating rates and efficiencies. It also discusses the effect of hysteresis and explains why eddy currents tend to be confined to the outer surface of the workpiece, a phenomenon known as the skin effect. The chapter includes several data plots showing how the depth of heating varies with frequency and how heating time, power density, and thermal conduction rate correspond with hardening depth.

This chapter provides an overview of the various inspection methods used with metals and alloys, namely visual inspection, coordinate measuring machines, machine vision, hardness testing, tensile testing, chemical analysis, metallography, and nondestructive testing. The nondestructive testing methods discussed are liquid penetrant inspection, magnetic particle inspection, eddy current inspection, radiographic inspection, and ultrasonic testing.

This chapter focuses on the inspection of steel bars for the detection and evaluation of flaws. The principles involved also apply, for the most part, to the inspection of steel wire. The nondestructive inspection methods discussed include magnetic particle inspection, liquid penetrant inspection, ultrasonic inspection, and electromagnetic inspection. Eddy current and magnetic permeability are also covered.

This appendix is a glossary of terms related to induction heat treating.