This chapter provides an account of the pre-Columbian history of metal discovery in America and then reviews the development of metallurgy in the Middle Ages from early wrought iron practices to the use of coke in iron casting. It discusses the influence of the family of Abraham Darby in England in the development of ironmaking.

This chapter focuses on the evolution of steel production from 1870 to 1900. It begins with a review of the life of the inventor of the air-boiling process, William Kelly. This is followed by a discussion on how Bessemer's air-blowing process entered the steel production industry and the development of the Kelly-Bessemer process by Alexander Holley. The chapter then discusses how Andrew Carnegie lowered the cost to produce steel, how he entered the iron and steelmaking industry, and how Captain Billy Jones joined Carnegie to expand Carnegie steel. The chapter further provides information on the great strike of 1892 at Homestead and the rapid growth in steel markets. It ends with a discussion about the factors that led Carnegie to sell his steel empire.

This chapter explains the distinction between materials and matter through the concept of microstructure. It presents the history of matter science and the establishment of metallography. The chapter provides an overview of the progress of steel technology, progress in synthetic polymers and ceramics, and establishment and development of materials science.

This chapter gives a brief overview of the role of fatigue in component failures. It presents examples of fatigue failures along with statistics on the causes and costs of fatigue damage in various industries. It also includes a chapter-by-chapter summary of the content in the book, noting that the book deals primarily with fatigue at temperatures below the creep range with high-temperature fatigue being treated in a companion publication.

This chapter is a brief account of the applications of stainless steel in processes pertinent to the pulp-and-paper industry.

This chapter is a chronological account of the development of ironmaking in colonial America from 1645 to 1870. The discussion covers the spread of ironmaking in many of the colonies in the northeast, canal building in Pennsylvania, the replacement of charcoal by anthracite coal in ironmaking, the life of ironmaking pioneer John Fritz, and the rapid increase in ironmaking for the railroads.

This chapter discusses the rise of steel minimills in the late 1960s through the leadership of F. Kenneth Iverson and Gerald Heffernan. The discussion covers the development of processes for flat products, flanged beams, and railroad rails. The chapter also covers the growth of the minimill industry along with the consolidation of the industry into large corporations. The chapter ends by providing information on novel processes developed for making iron.

Engineers have many materials to choose from when dealing with weight-related design constraints. The list includes aluminum, beryllium, magnesium, and titanium alloys as well as engineering plastics, structural ceramics, and polymer-, metal-, and ceramic-matrix composites. This chapter provides a brief overview of these lightweight materials, discussing their primary advantages along with their properties, behaviors, and limitations.

This chapter provides information on the major drivers for automakers and the solutions to address these industry drivers and meet their business goals. It discusses the importance of steel in the industry and briefly describes the development and significance of advanced high-strength steels for the industry.

Separation of billets by shearing avoids material loss and is considerably faster than sawing or cutting. This chapter discusses the billet shearing process, the characteristics of sheared surfaces, and the effect of various operating parameters on surface quality. It also includes formulas for calculating shearing force, work, and power and describes various ways to increase production rates.

This chapter provides a detailed account of the development of tool steel technology. It begins with a record of steelmaking in ancient and medieval times. The crucible melting process involved in making steel is then discussed. This is followed by a description of the increasing use of alloys for tool steels. The chapter provides information on the research investigations into the metallurgy of high-speed tool steels at MIT, Union Carbide, and Carbon Laboratories. The major research effort involved in substituting molybdenum for tungsten in high-speed tool steels is discussed. The chapter also describes the role of the Cleveland Twist Drill Company as the first adopter of molybdenum high-speed steel. It ends with a discussion on the advanced work on high-speed steels by Swedish researchers.

This appendix contains bibliographies related to the history of stainless steel.

This chapter reviews the development of filament winding systems and the automated processes used in state-of-the-art filament winding facilities. It first provides a description on the early stages of modern filament winding, followed by brief information on the advances of filament winding in the computer age. Then, the chapter discusses the requirements for filament winding in manufacturing oil and gas industry components and in high-volume production of sporting goods, propane tanks, and curing ovens. The chapter concludes with examples of the versatility of filament winding in producing complex parts.

This chapter provides information on the biennial International Wear of Materials Conference, which is the inspiration for this book. It reviews the fundamentals of tribology, tribosystems, and related terminology. The glossary at the end of this chapter is intended to familiarize readers with some of the fundamental tribology terms that will be repeated throughout this book.

This chapter provides the definitions of fundamental wear mechanisms. The chapter describes the properties and applications of materials used for wear resistance. It discusses the processes involved in screening tests for wear resistance. In addition, the practical application of wear-resistant principles is covered.

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 the use of finite-element methods for modeling cold forging processes. The discussion covers process modeling inputs, such as geometric parameters, material properties, and interface conditions, and includes several application examples.