This chapter identifies the primary causes of service failures and discusses the types of defects from which they stem. It presents more than a dozen examples of failures attributed to such causes as design defects, material defects, and manufacturing or processing defects as well as assembly errors, abnormal operating conditions, and inadequate maintenance. It also describes the precise usage of terms such as defect, flaw, imperfection, and discontinuity.

This chapter describes the various types of cushion systems used in forming presses and their effect on part quality. It begins with a review of the deep drawing process, explaining that wrinkling, tearing, and fracture are the result of excess or insufficient material flow, which can be prevented by maintaining the correct amount of holding force on the periphery of the blank. It then describes how blank holding force is generated in double-action presses and the extent to which displacement profiles can be adjusted on both the inner and outer slides. The discussion then turns to single-action presses that incorporate some type of cushion system. The chapters describes the many ways that cushion systems are implemented in forming presses and the force and displacement characteristics achievable with each method. It also explains how multipoint cushion systems are designed and how they facilitate uniform metal flow into the die cavity of large deep-drawn parts.

This chapter presents various case histories that illustrate a variety of failure mechanisms experienced by the high-strength steel components in aerospace applications. The components covered are catapult holdback bar, AISI 420 stainless steel roll pin, main landing gear (MLG) lever, inboard flap hinge bolt, nose landing gear piston axle, multiple-leg aircraft-handling sling, aircraft hoist sling, internal spur gear, and MLG axle. In addition, the chapter provides information on full-scale fatigue testing, nondestructive testing, and failure analysis of fin attach bolts.

This chapter discusses the role of failure analysis in cases involving product liability, property damage, and personal injury litigation. It also explains how material science and technology shed light on criminal activities such as smuggling, counterfeiting, theft, and the willful destruction of property.

This chapter presents guidelines for product designers to choose the best process and alloys while designing a casting. The discussion covers some of the factors pertinent to the selection of the best process for the product function and performance, namely geometric factors, mechanical properties, tooling cost per piece, and overall cost factors. The chapter contains tables listing several markets, products, popular processes, and common alloys and the common processes used for a variety of markets and products.

The gravity permanent mold (GPM) process produces castings of high strength and integrity with good surface finish and consistent dimensions. This chapter lists castings produced using GPM and semipermanent mold (SPM). It illustrates the basic elements of a conventional tilt pour machine. The chapter also provides an overview of the high-volume rotary table, high-volume production rotary manufacturing cell, cycle time planning, sizes of tilt pour machine and table, and improvement of turntable uptime. It also presents some of the common semipermanent molded castings.

Prior to forging, it is often necessary to preform billet stock to achieve adequate material distribution. This chapter discusses the equipment used for such operations, including transverse rolling machines, electric upsetters, ring-rolling mills, horizontal presses, and rotary (orbital) and radial forging machines. It describes their basic operating principles as well as advantages and disadvantages.

This chapter discusses the design and operation of hydraulic presses. It begins by describing the role of each major component in a hydraulic system. It then explains the difference between pump-driven and accumulator-driven presses and the types of applications for which are suited. The chapter goes on to describe the load, energy, and time-dependent characteristics of hydraulic presses and the factors that determine accuracy. It also explains how hydraulic presses are used for deep drawing, fine blanking, and hydroforming as well as warm forming and hot stamping operations.

Aluminum is the second most widely used metal in the world. It is readily available, offers a wide range of properties, and can be shaped, coated, and joined using a variety of methods. This chapter discusses some of the key attributes of wrought and cast aluminum alloys and the classifications, designations, and grades of available product forms. It also explains how aluminum alloys are used in aerospace, automotive, rail, and marine applications as well as in building and construction, electrical products, manufacturing equipment, packaging, and consumer durables such as appliances and furniture.

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.

Metal-matrix composites can operate at higher temperatures than their base metal counterparts and, unlike polymer-matrix composites, are nonflammable, do not outgas in a vacuum, and resist attack by solvents and fuels. They can also be tailored to provide greater strength and stiffness, among other properties, in preferred directions and locations. This chapter discusses the processes and procedures used in the production of fiber-reinforced aluminum and titanium metal-matrix composites. It explains how the length and orientation of reinforcing fibers affect the properties and processing characteristics of both aluminum and titanium composites. It also provides information on fiber-metal laminates and the use of different matrix metals and reinforcing materials.

This chapter provides an overview of the basic principles and historic development of metal extrusion processes. It starts by illustrating the two major process categories: direct extrusion and indirect extrusion. It then briefly defines hydrostatic extrusion and the conform process. The history coverage addresses early patents for extrusion of lead at the turn of the 17th century up through the major process innovations in the 20th century.

Molding flasks and other supplementary equipment are essential for molding complex shapes at competitive production rates and costs. This chapter addresses the design aspects of molding flasks and accessories, the features and handling accessories of molding machines, core making machines and innovations for productivity and quality, and automated core-setting aids.

This chapter provides an overview of the microstructure-property relationships associated with aluminum-silicon alloys. It includes information on commercial designations and grades, phase compositions, solidification paths, alloying elements, and intermetallic phases. It also provides solubility data and maps out the topics covered in subsequent chapters in the book.