The modeling and simulation activities in the field of high-pressure cold spray can be divided into two main parts: solid mechanics and fluid dynamics. This chapter focuses on these parts of modeling work in cold spray research. The discussion covers the objective, principal concepts, methods, and outcome of modeling and simulation of particle impact and of in-flight history of particles in cold spraying. The concept of integration of particle impact and fluid flow modeling to optimize cold spray deposition for a given material is also explained.

Brazing and soldering jointly represent one of several methods for joining solid materials. This chapter summarizes the principal characteristics of the various joining methods. It then discusses key parameters of brazing including surface energy and tension, wetting and contact angle, fluid flow, filler spreading characteristics, surface roughness of components, dissolution of parent materials, new phase formations, significance of the joint gap, and the strength of metals. The chapter also describes issues in processing aspects that must be considered when designing a joint, and the health, safety, and environmental aspects of brazing.

Aluminum generally has excellent resistance to corrosion and gives years of maintenance-free service in natural atmospheres, fresh waters, seawater, many soils and chemicals, and most foods. This chapter explains why aluminum and aluminum alloys are naturally resistant to corrosion and describes the conditions and circumstances under which their natural defenses break down. It discusses the causes and forms of corrosion observed in aluminum alloys and the effect of composition, microstructure, processing history, and environmental variables such as impurities, fluid flow, surface area, pressure, and temperature.

This article describes the weldability tests that are used to evaluate the effects of welding on such properties and characteristics as base-metal and weld-metal cracking; base-metal and weld-metal ductility; weld penetration; and weld pool shape and fluid flow. It also describes several weldability tests for evaluating cracking susceptibility, classified as self-restraint or externally loaded tests. The article discusses the processes, advantages, and disadvantages of the weld pool shape tests, the weld penetration tests, and the Gleeble test.

Soldering and brazing represent one of several types of methods for joining solid materials. These methods may be classified as mechanical fastening, adhesive bonding, soldering and brazing, welding, and solid-state joining. This chapter summarizes the principal characteristics of these joining methods. It presents a comparison between solders and brazes. Further details on pressure welding and diffusion bonding are also provided. Key parameters of soldering are discussed, including surface energy and surface tension, wetting and contact angle, fluid flow, filler spreading characteristics, surface roughness of components, dissolution of parent materials and intermetallic growth, significance of the joint gap, and the strength of metals. The chapter also examines the principal aspects related to the design and application of soldering processes.

This chapter discusses the design and operation of hydraulic presses. It begins by describing the role of each major component in a hydraulic system. It then explains the difference between pump-driven and accumulator-driven presses and the types of applications for which are suited. The chapter goes on to describe the load, energy, and time-dependent characteristics of hydraulic presses and the factors that determine accuracy. It also explains how hydraulic presses are used for deep drawing, fine blanking, and hydroforming as well as warm forming and hot stamping operations.

This chapter describes the various types of cushion systems used in forming presses and their effect on part quality. It begins with a review of the deep drawing process, explaining that wrinkling, tearing, and fracture are the result of excess or insufficient material flow, which can be prevented by maintaining the correct amount of holding force on the periphery of the blank. It then describes how blank holding force is generated in double-action presses and the extent to which displacement profiles can be adjusted on both the inner and outer slides. The discussion then turns to single-action presses that incorporate some type of cushion system. The chapters describes the many ways that cushion systems are implemented in forming presses and the force and displacement characteristics achievable with each method. It also explains how multipoint cushion systems are designed and how they facilitate uniform metal flow into the die cavity of large deep-drawn parts.

This appendix discusses the sizing, scaling, and configuration requirements of the basic components in a quench cooling system, including tanks, pumps, hoses, and inlet and outlet fixtures and the materials from which they are made.

Elevated-temperature failures are the most complex type of failure because all of the modes of failures can occur at elevated temperatures (with the obvious exception of low-temperature brittle fracture). Elevated-temperature problems are real concerns in industrial applications. The principal types of elevated-temperature failure mechanisms discussed in this chapter are creep, stress rupture, overheating failure, elevated-temperature fatigue, thermal fatigue, metallurgical instabilities, and environmentally induced failure. The causes, features, and effects of these failures are discussed. The cooling techniques for preventing elevated-temperature failures are also covered.

This chapter focuses on various factors to be considered at design stage to minimize corrosion. It begins by providing information on design considerations and general corrosion awareness. This is followed by a description of several factors influencing materials-component failure. Details on design and materials selection, which assist in controlling corrosion, are then provided. The chapter ends with a discussion on the design factors that influence corrosion.

This chapter gives an overview of how steel castings may be effectively adapted to modern concurrent engineering processes. The chapter discusses computer aided design programs, solid modeling, solidification simulation programs, and rapid prototyping.

This chapter discusses the particular corrosion problems encountered and the methods of control used in petroleum production and the storage and transportation of oil and gas up to the refinery. It begins by describing those aspects of corrosion that tend to be unique to corrosion as encountered in applications involving oil and gas exploration and production. This is followed by a section reviewing the methods of corrosion control, namely the proper selection of materials, protective coatings, cathodic protection systems, use of inhibitors, use of nonmetallic materials, and control of the environment. The chapter ends with a discussion on the problems encountered and protective measures that are based on the state-of-the-art as practiced daily by corrosion and petroleum engineers and production personnel.