This chapter describes the mechanical properties of fully pearlitic microstructures and their suitability for wire and rail applications. It begins by describing the ever-increasing demands placed on rail steels and the manufacturing methods that have been developed in response. It then explains how wire drawing, patenting, and the Stelmor process affect microstructure, and describes various fracture mechanisms and how they appear on steel wire fracture surfaces. The chapter concludes by discussing the effects of torsional deformation, delamination, galvanizing, and aging on patented and drawn wires.

This article provides a brief description of commercially important thermal spray processes and gives examples of applications and application requirements. The processes covered are flame, wire arc, plasma, high-velocity oxyfuel processes, detonation gun, and cold spray methods. Examples are provided of the applications in aerospace, automotive, and medical device industries as well as the use of thermal spray as an additive manufacturing technique.

Arc welding applies to a large and diversified group of welding processes that use an electric arc as the source of heat to melt and join metals. This chapter provides a detailed overview of specific arc welding methods: shielded metal arc welding, flux cored arc welding, submerged arc welding, gas metal arc welding, gas tungsten arc welding, plasma arc welding, plasma-GMAW welding, electroslag welding, and electrogas welding. The basic characteristics of gases used for shielding during arc welding are briefly discussed.

Passive components can be broadly divided into capacitors, resistors, and inductors. Failure analysis of these components helps determine the root cause and improve the overall quality and reliability of the electronic systems. This article describes different failure analysis approaches used for these components. It discusses different types of capacitors along with their constructions and failure modes. The types include tantalum, aluminum electrolytic, multi-layered ceramics, film, and super capacitors. The article then provides a discussion on the two common types of inductors, namely, common mode choke coil and surface mount powder choke coil.

The chapter presents an overview of the properties and operational limits of superconductive materials, as well as techniques used to fabricate practical superconducting wires. It introduces six properties: critical temperature, critical magnetic field, critical current density, stability, ac loss, and mechanical characteristics; for each property, typical data are provided and the experimental methods used to measure it are briefly described. The properties of the superconducting composites are tied together in the chapter to summarize their effect on superconductor material selection and the geometrical design of superconducting composites. The chapter also contains a reference guide to composite-design factors with links to the relevant chapter sections where each design consideration is addressed.

Temperature is a critical process parameter in the heat treatment and forging of steel and must be accurately measured to properly control it. This appendix discusses the operating principles of thermocouples and infrared pyrometers, describing the various types as well as advantages and applications.

Since the introduction of chip scale packages (CSPs) in the early 90s, they have continuously increased their market share due to their advantages of small form factor, cost effectiveness and PCB optimization. The reduced package size brings challenges in performing failure analysis. This article provides an overview of CSPs and their classification as well as their advantages and applications, and reveals some of the challenges in performing failure analysis on CSPs, particularly for CSPs in special package configurations such as stacked die multi-chip-packages (MCPs) and wafer level CSPs (WLCSPs). The discussion covers special requirements of CSPs such as precision decapsulation for fine ball grid array packages, accessing the failing die for MCP packages, and careful handling for WLCSP. Solutions and best practices are shared on how to overcome these challenges. The article also presents a few case studies to demonstrate how failure analysis work on CSPs can be successfully completed.

This chapter discusses the selection, use, and integration of methods to control process variables in induction heating, including control of workpiece and processing temperature and materials handling systems. The discussion of temperature control includes a review of proportional controllers and heat-regulating devices. Integration of control functions is illustrated with examples related to heating of steel slabs, surface hardening of steel parts, vacuum induction melting for casting operations, and process optimization for electric-demand control. Distributed control within larger manufacturing systems is discussed. The chapter also covers nondestructive techniques for process control and methods for process simulation.

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.

This chapter briefly reviews the experience-based guidelines that were developed for forming and welding advanced high-strength steels (AHSS). It discusses the benefits of using HSS in car body structures and components that are analyzed by the performance indices developed for materials selection.

The orientation of the devices within a package determine the best chosen approach for access to a select component embedded in epoxy both in package or System in Package and multi-chip module (MCM). This article assists the analyst in making decisions on frontside access using flat lapping, chemical decapsulation, laser ablation, plasma reactive ion etching (RIE), CNC based milling and polishing, or a combination of these coupled with optical or electrical endpoint means. This article discusses the general characteristics, advantages, and disadvantages of each of these techniques. It also presents a case study illustrating the application of CNC milling to isolate MCM leakage failure.

This chapter describes the classification of steels and the various compositional categories of commercial steel products. It explains how different alloying elements affect the properties of carbon and low-alloys steels and discusses strength, toughness, and corrosion resistance and how to improve them.

Increasing growth of high-pressure cold spraying applications on the industrial scale have forced global powder producers to face this challenge and develop specific powders for cold spray applications. This chapter provides information on the properties, classification, characteristics, manufacturing, and procedures for packaging of powders specific to cold spray applications.

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.

This appendix includes contact information for titanium manufacturers, suppliers, and service providers.

The refractory metals include niobium, tantalum, molybdenum, tungsten, and rhenium. These metals are considered refractory because of their high melting points, high-temperature mechanical stability, and resistance to softening at elevated temperatures. This article discusses the composition, properties, fabrication procedures, advantages and disadvantages, and applications of these refractory metals and their alloys. A comparison of some of the properties of the refractory metals with those of iron, copper, and aluminum is given in a table. The article concludes with a brief section on refractory metal protective coatings.

Induction heating has found widespread use as a method to raise the temperature of a metal prior to forming or joining, or to change its metallurgical structure. However, induction heating has specialized capabilities that make it suitable for applications outside of metal treatment and fabrication. This chapter summarizes some of the special applications of induction heating, including those in the plastics, packaging, electronics, glass, chemical, and metal-finishing industries. The chapter concludes with a discussion of the application of induction heating for vacuum processes.