Design-bites - Illustrated product design booklets by Andrew Taylor

Product description

A description of metal forming techniques and associated design rules, including illustrated sections on sheet metal forming, pressing and roll-forming, precision casting, forging, powder sintering and extrusion. Numerous metals and alloys are described, with properties and specific uses, including miscellaneous special alloys. Corrosion prevention is described in detail.

118 pages                file size 1.3 MB

Booklet content

E1: The Metals / Corrosion Prevention Techniques

• Introduction and Generic Properties of metals.
• Ferrous metals, non-ferrous metals
• Classification of metals - International Classification schemes.
• Dry corrosion in metals
• Galvanic corrosion (Electrolytic corrosion, Bi-metallic corrosion, Wet corrosion)
• Corrosion prevention techniques 
• Galvanic corrosion table - compatibility of metals in contact. 

E2: Aluminum Alloys

• Aluminum alloy. Aluminum properties and uses. 
• International classification schemes.
• Summary of aluminum wrought and casting grades
• Table of 76 selected aluminum alloys, with properties, common applications, and US/UK/European equivalent grades
• Sheet bend radius table, Aluminum. 
• Table of familiar (named) aluminum grades, with properties and applications.

E3: Copper Alloys (copper, brass, bronze, copper-nickel)

• Copper alloy properties and uses. (Copper, Brass or Bronze). 
• International classification schemes
• Summary of copper alloy wrought and casting grades
• Copper and high copper alloys
• Brasses. Brass properties and general uses.
• Bronzes. Bronze properties and general uses.
• Cupro-nickel properties, copper nickel alloys, Nickel-silver
• Table of 60 selected coppers, copper alloys, brasses and bronzes, with properties, common applications, and US/UK/European equivalent grades. Copper alloy specifications.
• Table of familiar (named) copper alloy grades, with properties and applications.

E4: Iron and Steel

• Iron and Steel family tree, properties and uses of ferrous metals
• International classification schemes
• Summary of wrought and casting grades
• Cast irons
• Plain carbon steel
• Alloy steels, Stainless steel and Tool steel
• Heat treatment of steel – softening (annealing), hardening and tempering 
• Mild steel sheet, tempers and available finishes
• Table of 52 selected carbon and alloy steels, with properties, common applications, and US/UK/European equivalent grades. Carbon steel grades. Alloy steel grades. 
• Table of 9 selected cast irons, with properties, common applications, and equivalent grades. Cast iron grades. 
• Table of 15 selected tool steels, with properties, common applications, and equivalent grades. Tool steel grades.
• Table of familiar (named) steels, with properties and applications.

E5: Stainless steel

• Properties and uses of stainless steel
• International classification schemes
• Summary of wrought and casting grades
• Austenitic, Ferritic and Martensitic stainless steel grades
• Superalloys, duplex, precipitation and casting grades
• Table of 32 selected stainless steels, with properties, common applications, and US/UK/European equivalent grades. Stainless steel grades.
• Sheet bend radius tables, stainless steel
• Table of available stainless steel finishes

E6: Other metals of interest, special alloys

• Table of 30 special metals and alloys with US/UK/Euopean equivalent grades.
• Nickel alloys and nickel superalloys. Alnico, Ferrite, Dumet, Kovar, Invar, Mu-metal, Monel, Inconel, Hastelloy, Nimonic.
• Tin, mercury and lead alloys. Amalgam, Hoyt, Babbit, Pewter, Britannia, Soft solder.
• Titanium alloys, Nitinol (shape-memory alloy).
• Exotics, Tungsten, Vitallium, Wood's metal, Cerrobend.
• Zinc alloys. Spelter, Zamak, Mazak, ZA alloy.
• Precious metals. Platinum, gold, silver, Sheffield Plate.
• Amorphous metals
• Properties and specific applications
• American, European, British and Global Equivalents

E7: Design in Sheet Metal - Sheet metal forming

• Selecting a suitable sheet thickness, sheet metal gauge 
• Sheet metal forming, sheet fabrication issues
• Sheet bending, bend radius sheet metal, grain direction
• Bend relief and corner cracking
• Domestic hob and oven example
• Design of Flanged holes, louvers, lanced tabs
• Design of Plunge holes, dimples, semi-perfs
• Design for Tongue and slot assembly, dip brazing, spot welding
• Design for Roll forming and crimping
• Design of Folded and rolled seams on metal containers
• Design for Blanking, pressing, deep drawing
• Design for Spinning and bulging.

E8: Design in Solid Metal

• Casting, general design guidelines. Metal casting process. 
• Design for Sand casting, Precision sand casting and shell molding (shell mold casting)
• Design for Investment casting (lost wax casting process)
• Die casting design.
• Molded-in inserts
• Design for Drop forging (forging process) and powder sintering. Sintered metal, sintering process. 
• Design of metal extrusions. Metal extrusion process.
• Getting the parts to fit together, tolerances, tolerancing. 
• Threaded holes in solid metal

Includes www links to further resources, organizations and suppliers.

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