Cold spray coatings technology has the potential to provide surface enhancement for applications in sectors such as defense and aerospace, oil and gas, power generation, medical, automotive, electronics, and railways. The ability to deposit clean metallic coatings is used in applications requiring corrosion/oxidation protection, erosion/wear protection, additive manufacturing, and fabricating free forms. This chapter discusses the function, advantages, and benefits of some of these applications.

This chapter presents an overview of some of the major causes of tool and die failures. The chapter describes fracture and fracture toughness of tool steels, and the influence of factors such as steel quality and primary processing, mechanical design, heat treatment, grinding and finishing, and distortion and dimensional change.

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 discusses the ways in which the evolution of filament winding software systems has capitalized on the inherent flexibility of computer numerical controlled winding machines and enhanced their productivity. It provides a detailed discussion on different types of geometries that can be wound, from the simple to the highly complex, with insight into the limitations, advantages, and challenges of each. Components covered include classic axisymmetric parts (rings, pipes, driveshafts, pipe reducers, tapered shafts, closed-end pressure vessels, and storage tanks), nonround sections (aeromasts, airfoils, box sections, and fuselage sections), curved-axis parts (elbows, ducts), and special applications (tees). Basic winding concepts, such as band pattern, are discussed and explained, and some simple predictive formulae are introduced. The chapter also provides examples of programming various geometries using advanced software tools and discusses how various materials, such as rovings, tow-preg, prepreg tape, and woven materials, affect winding program generation.

This chapter explains various aspects of the foundry process that the design engineer should consider when designing steel castings. It discusses special feeding aids, such as tapers, padding, ribs, and chills that may be used by foundry personnel to promote directional solidification. The chapter addresses the design of castings to reduce the occurrence of internal shrinkage. It provides a detailed discussion on design considerations for molding, cleaning, machining, and function.

This chapter provides a brief overview of iron and steel manufacturing and the major equipment involved in the process as well as identifying where casting fits into the overall process. In addition, it provides an overview of cast iron manufacturing, including the processes involved in converting pig iron into cast iron and steel.

This chapter provides a brief introduction to manufacturing processes used to produce metal parts and how they differ in terms of achievable geometries, tolerances, surface finishes, and production rate.

This chapter discusses the factors that affect die steel selection for hot forging, including material properties such as hardenability, heat and wear resistance, toughness, and resistance to plastic deformation and mechanical fatigue. It then describes the relative merits of various materials and the basic requirements for cold forging dies. The chapter also covers die manufacturing processes, such as high-speed and hard machining, electrodischarge machining, and hobbing, and the use of surface treatments.