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 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.

Designs and materials continue to become more complex, with novel technologies developed to create them, and novel instruments invented to analyze them. Engineers at all stages of the design and manufacturing process should appreciate the reasons why formal failure analysis is performed. This chapter describes why failure analysis is conducted and outlines the responsibilities of the failure analyst.

Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides information on the process of conversion of steel and iron parts to aluminum.

This chapter consists of three parts. The first part provides data and guidelines for selecting materials and processing routes. It compares the basic properties of metals, ceramics, and polymers, identifies important measures of performance, and discusses manufacturing processes and their compatibility with specific materials. The chapter then presents general guidelines for selecting lightweight materials, and concludes with a review of lightweight metals, plastics, and composites used in automotive applications.