This chapter discusses the factors that influence the cost and complexity of machining titanium alloys. It explains how titanium compares to other metals in terms of cutting force and power requirements and how these forces, along with cutting speeds and the use of cutting fluids, affect tool life, surface finish, and part tolerances. The chapter also includes a brief review of nontraditional machining methods.

This chapter details low-temperature test procedures and equipment. It discusses the role temperature plays in the properties of typical engineering materials. The effect that lowering the temperature of a solid has on the mechanical properties of a material is summarized for three principal groups of engineering materials: metals, ceramics, and polymers (including fiber-reinforced polymers). The chapter describes the factors that influence the selection of tensile testing procedures for low-temperature evaluation, along with a comparison of tensile and compression tests. It covers the parameters and standards related to low-temperature tensile testing. The chapter discusses the factors involved in controlling test temperature. Finally, the chapter discusses the safety issues concerning the use of cooled methanol, liquid-nitrogen, and liquid helium.

This chapters discusses the considerations involved in the qualification and analysis of induction hardening treatments. The discussion covers material selection and prior heat treatment, hardness and case depth, frequency selection, power density and heating time, part and process tolerances, geometrical effects, quenchant selection, coil design, and work-handling equipment. The chapter also presents several examples, walking readers though each step, and discusses the development of setup instructions and operating procedures.

This appendix provides practical information on induction coils and how they are made. It discusses soldering methods, preferred materials, design challenges, and best practices and procedures. It also discusses the design, construction, and application of magnetic flux concentrators and the growing use of computer simulation.

Forging machines vary based on factors such as the rate at which energy is applied to the workpiece and the means by which it is controlled. Each type has distinct advantages and disadvantages, depending on lot size, workpiece complexity, dimensional tolerances, and the alloy being forged. This chapter covers the most common types of forging machines, explaining how they align with basic forging processes and corresponding force, energy, throughput, and accuracy requirements.

This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.

This chapter discusses the design and operating principles of various types of electromagnetic coils. It explains how induction coils are classified based on the direction of the eddy currents they induce in the workpiece and the corresponding orientation, whether longitudinal or transverse, of the associated magnetic flux. It then discusses the factors that influence coil design and selection, including coupling efficiency, frequency, the number and spacing of turns, and the use of flux intensifiers. It also includes images and illustrations of various types of coils and coil geometries for basic as well as special purpose applications.

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 describes the processes involved in the fabrication of wrought and cast metal products. It discusses deformation processes including bending and forming, material removal processes such as milling, cutting, and grinding, and joining methods including welding, soldering, and brazing. It also discusses powder consolidation, rolling, drawing and extrusion, and common forging methods.

Induction heating, in most applications, is used to selectively heat only a portion of the workpiece that requires treatment. This chapter covers the basic principles, features, and metallurgical aspects of induction heating. The discussion includes the conditions required for induction heating and quenching, the use of magnetic flux concentrators to improve the efficiency of surface heating, and the quenching systems used for induction hardening. The discussion also provides information on time-temperature dependence in induction heating, workpiece distortion in induction surface hardening, residual stresses after induction surface hardening and finish grinding, and input and output control of steel for induction surface hardening of gears.

This chapter discusses the design and operation of forging presses and hammers. It covers the most common types of presses, including hydraulic, mechanical, and screw presses, explaining how they work and comparing and contrasting their load and displacement profiles, stroke lengths, ram velocities, and energy and stiffness requirements. It also includes information on gravity- and power-drop hammers and where and how they are typically used.

This chapter presents a step-by-step approach for analyzing the causes of nonconforming workpieces and determining potential solutions. The discussion covers a wide range of issues, including testing errors, latent and process-related defects, examination and testing techniques, defect characterization, and effective remedial actions.

This chapter examines the stress-corrosion cracking (SCC) failure of stainless steel pipe welds in boiling water reactor (BWR) service. It explains where most of the failures have occurred and provides relevant details about the materials of construction, fabrication techniques, environmental factors, and cracking characteristics. It includes a model that accounts for the primary factors involved in intergranular SCC, namely, tensile stresses above the yield stress of the base material, a sensitized microstructure, and reactor cooling water. The chapter also provides proven remedies and mitigation techniques corresponding to a wide range of issues related to stress, sensitization, and operating conditions.

Induction heat treating is used in a wide range of applications. Typical uses, as described in this chapter, include the surface hardening of many types of shafts as well as gears and sprockets and the through-hardening of gripping teeth, cutting edges, and impact zones incorporated into various types of tools and track pins manufactured for off-highway equipment.

After pouring, castings are allowed to solidify and cool. They are later removed from the molds in the shakeout operation. A series of activities then follow, which are generally referred to as finishing and heat treatment. These activities can be broadly categorized as shakeout, abrasive blast cleaning, removal of risers, ingates, and discontinuities, rough inspection, removal of discontinuities, finishing welding, heat treatment, and final visual, dimensional, and NDT inspection. This chapter provides a detailed discussion on these activities.

Plastic gears are continuing to displace metal gears in applications ranging from automotive components to office automation equipment. This chapter discusses the characteristics, classification, advantages, and disadvantages of plastics for gear applications. It provides a comparison between the properties of metals and plastics for designing gears. The chapter reviews some of the commonly used plastic materials for gear applications including thermoplastic and thermoset gear materials. The chapter also describes the processes involved in plastic gear manufacturing.

The testing of plastics includes a wide variety of chemical, thermal, and mechanical tests. This chapter reviews the tensile testing of plastics, which has been standardized in ASTM D 638, "Standard Test Method for Tensile Properties of Plastics," and other comparable standards. It describes the fundamental factors that affect data from tensile tests, examines the stipulations in standardized tensile testing, and discusses the utilization of data from tensile tests.

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 design and application of sheet forming presses. The discussion covers critical variables and design parameters, key components, basic machine configurations, and energy and load requirements. The chapter also discusses time-dependent characteristics, dimensional accuracy, and stiffness as well as die change procedures.

To a large extent, the induction coil and its coupling to the workpiece determine the precise heating pattern that is developed. However, it is often desirable to modify this pattern in order to produce a special heating distribution or to increase energy efficiency. At other times, the high heating rates of induction are needed for processing nonconductors. This chapter describes broad methods of accomplishing such objectives: modification of the field of magnetic induction, use of devices to prevent auxiliary equipment or certain portions of a workpiece from being heated, and techniques to apply heating to electrically nonconductive materials. These methods make use of devices such as flux concentrators, shields, and susceptors. The chapter provides a description of the materials for these devices and guidelines for their application.