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 describes incremental sheet forming processes, including single-point, two-point, and kinematic (two tool) techniques. It provides information on the tooling and equipment used, work flow and forming parameters, process mechanics and forming limits. It also discusses multistage forming strategies, process modeling and simulation, and advanced hybrid forming processes.

This chapter discusses the fusion welding processes, namely oxyfuel gas welding, oxyacetylene braze welding, stud welding (stud arc welding and capacitor discharge stud welding), high-frequency welding, electron beam welding, laser beam welding, hybrid laser arc welding, and thermit welding.

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 design and certification considerations, including materials and process selection, the building block approach to certification, design allowables, and design guidelines. It also includes information on damage tolerance and environmental sensitivity.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.

Polymer-matrix composites are among the lightest structural materials in use today. They are also highly resistant to corrosion and fatigue and their load-carrying capabilities, such as strength and stiffness, can be tailored for specific applications. This chapter discusses the primary advantages and disadvantages of polymer-matrix composites, how they are produced, and how they perform in different applications. It describes the construction of laminates, the fibers and resins used, and the methods by which they are combined. It explains how strength, modulus, toughness, and high-temperature and corrosion behaviors are determined by the orientation, shape, and spacing of fibers, the number of plies, resin properties, and consolidation and forming methods. The chapter also covers secondary fabrication processes, such as thermoforming, machining, and joining, as well as production equipment and product forms, and include guidelines for optimizing tradeoffs when selecting fibers, resins, and production techniques.

This appendix is a compilation of terms and definitions related to composite filament winding.

This chapter is intended to identify materials, processes, and designs that will lead to great advances in powder-binder forming technologies. It discusses some of the structures obtained through these advances in powder-binder technologies such as binder jetting and extrusion-based additive manufacturing, including bound-metal deposition and fused-filament fabrication: oxidation-resistant high-temperature alloys, anisotropic structures, submicrometer-scale structures, surface hard materials, and artist metallic clays. Some of the advances discussed include the developments in process involving plastics, emulsions, ceramics, and porous structures and foams. Improvements in the design processes have led to the development of functional structures, controlled porosity, and bioinspired structures.

This chapter reviews the basic chemistry of beryllium metals and compounds, including beryllium hydroxide, beryllium carbonates, beryllium fluoride, and beryllium chloride. It discusses the uses as well as application challenges of various forms of beryllium and includes information on their chemical properties and reactions.

This article briefly reviews abrasive and adhesive wear failure of reinforced polymers and polymer composites, namely particulate-filled polymers, short-fiber-reinforced polymers, polymers with continuous fibers, and mixed reinforcements and fabrics. It includes scanning electron microscope micrographs of abraded surfaces of composites against 80-grade SiC paper and under 14 N load, and worn surfaces of abraded polyether-imide composites and polyamide 66 unidirectional composites and 66 hybrid composites.

This chapter describes the effect of temperature and strain rate on the mechanical properties and forming characteristics of aluminum and magnesium sheet materials. It discusses the key differences between isothermal and nonisothermal warm forming processes, the factors that affect heat transfer, die heating techniques, and press systems. It also discusses the effect of forming temperature, punch velocity, blank size, and other parameters on deep drawing processes, making use of both experimental and simulated data.

This chapter includes a comprehensive set of definitions used in powder-binder processing.

Stainless steel powders are usually made by water or gas atomization. This chapter describes both processes and the properties and characteristics of the powders they produce. It also discusses secondary processes, including drying, screening, annealing, and lubricating, and the effects of iron contamination on corrosion resistance.

This chapter considers the materials and processing aspects of soldering and the manner in which these interrelate in the development of joining processes. It discusses the processes involved in eliminating or suppressing metallurgical and mechanical constraints as well as constraints imposed by the components.

This chapter discusses the process, principles, and modeling of the diffusion brazing system. The applications of diffusion brazing to wide-gap joining and layer manufacturing are also discussed.

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 first introduces the various factors that may alter the physical and mechanical properties of aluminum castings that are addressed in the other chapters in the book. Then, it presents the historical development of aluminum castings, followed by a discussion on the advantages and limitations of aluminum castings. Next, the chapter describes the major trends that are influencing the increased use of aluminum castings. Finally, it introduces the considerations involved in the selection of an appropriate aluminum alloy and casting process for a given application.