Steel and Iron Based Alloys 5 Ali Ramazani, Banu Berme, and Ulrich Prahl Sheet Steels 7 Development Strategy and Overview 7 Multiphase Microstructure Design 9 HSLA Steel 11 BH Steel 13 DP Steel 14 TR1P Steel 18 CP Steel 20 PM Steel 22 TWIP Steel 24 MnB Steels for Press Hardening 25 LH Steel 27 Q&P Steel 31 1.3Forging Steels 34 AFP Steel 34 HDB Steel 36 Nb Microalloyed Case-Hardening Steels 37 Nb Microalloyed TRIP Steels 38 Casting Steel39 Austempered Ductile Cast Iron (AD1)39 Aluminum and Aluminum Alloys 49 Axel von Hehl and Peter Krug Wrought Alloys and Associated Processes 52 Alloy Classes and Their Basic Constitution 52 Plates and Sheets 54 Alloy Development 54 Process Development 59 Extrusions 63 Alloy Development 63 Process Development 65 Forgings 67 Alloy Development 68 Process Development 70 Casting Alloys and Associated Processes 71 Alloy Classes and Their Basic Constitution 72 Alloy Development 73 Process Development 77 Sand Casting 77 Low-Pressure Die/Sand Casting 78 Investment Casting 78 High-Pressure Die Casting (HPDC) 79 Semisolid Processes 80 Powder Metallurgy of Aluminum Alloys 81 Liąuid Phase Sintering 81 Advanced Powder Metallurgical Alloys and Processes 81 Consolidation and Extrusion 82 Melt Spinning 82 Spray Forming 83 Secondary Processes 84 Joining 84 Heat Treatment 87 Surface Protection 87 Case Studies 88 Advancement on Deep Drawing of 7xxx Sheets for Automotive Applications 88 Advancement on High-Pressure Die Casting with Gas Injection 94 Advancement on Combined Method: Powder Metallurgy, Casting, Forging, and Extrusion 95 Summary and Outlook 98 Further Reading 99 Acknowledgment 100 References 100 Titanium Aluminides 178 Further Reading 179 Part II Polymers 181 James Njuguna Thermoplastics 183 Aravind Dasari Fundaraentals and Recent Advancements in Thermoplastics184 Processing and Evolution of Structure-Basics and Recent Developments 188 Synthesis of Thermoplastics 188 Processing of Thermoplastic Structural Components 189 Evolution of Structure in Thermoplastic Polymers 193 Properties Thermosets 205 Sergio Henńąue Pezzin, Luiz Antonio Ferreira Coelho, Sandro Campos Amico, and Luiz Claudio Pardini Historical Development 206 Current Use and Global Supply Base206 Basic Thermoset Classes:General Aspects 206 Polyester Resins 206 Epoxy Resins 208 Phenolic Resins 209 Polyurethane Resins 210 Typical Processing, Safety, and Handling210 Ecological Aspects 211 6.2Advanced Thermosets and Associated Processes 212 Polyimides 212 Bismaleimide 213 PMR (In situ Polymerization with Monomeric Reactants)214 Polystyryl Pyridine 214 Silicone 215 Cyanate Esters 215 Furane 216 Benzoxazine 217 Urea-Formaldehyde and Melamine-Formaldehyde 218 Phthalonitriles 218 Thermosets for Coatingsand Adhesives 219 Corrosion Protection 220 Adhesive Thermosets 220 Case Studies-ThermosetComposites 221 Composites in Autoniotive Vehicles 223 Composites in the Raił Veliicles 225 Composites in the Aeronautical/AerospaceIndustry 228 Elastomers 237 Krzysztof Pielichowski and James Njuguna Classification of Elastomers 237 Natural Rubber 238 Synthetic Rubbers 240 Thermoplastic Elastomers 243 Fluorine-Containing TPEs 245 Bio-Based TPEs 246 ,Smnarc CamposPart III Composites 253 Polymer Matrix Composites 257 Axel S. Herrmann. Andre Stieglitz, Christian Brauner, Christian Peters, and Patrick Schiebel Materials for Fiber Composites 258 Fibers258 Glass Fibers 258 CarbonFibers259 AramidFibers260 Resin 260 Intermediate Fornis of Reinforcement 262 Fiber Volume Fraction 264 trotsi 214Fiber Orientation Angle 264 Preforming Processes 266 Processes for CompositeManufacturing with Thermoset Matrix Systems 271 Processes for CompositeManufacturing with Thermoplastic2Matrix284 Manufacturing Process Simulation 289 Merging Technologies 294 Structural Health Monitoring 294 Adaptive Structures 297 Further Reading 298 References 300 Metal Matrix Composites 303 Maider Garda de Cortazar, Pedro Egizabal, Jorge Barcena, and Yann Le Petitcorps General Aspects ofMMCs 306 Structural Applications 310 Thermal Management Applications312 Relevant MMC Systems 312 Discontinuously Reinforced Metal Matrix Composites and Associated Processes 313 Continuously Reinforced Metal Matrix Composites and Associated Processes 316 SiC Monofilament Cost Reduction319 Development of Preprocessing Concepts 319 Simplified Manufacturing Methods319 Case Study 1: Aluminum Matrix Composites for IGBTs 319 Reąuirements and MaterialsSelection320 Manufacturing Process,Design, and Performance Analysis322 Case Study 2: Aluminum Matrix Composites for Automotive Brake Disks 324 Reąuirements and MaterialsSelection325 Manufacturing Process,Design, and Performance Analysis326 Case Study 3: TitaniumMatrix Composites (TMCs) for Aerospace Reąuirements and MaterialsSelection329 Manufacturing Process,Design, and Performance Analysis330 Further Reading 335 Acknowledgments 336 References 336 Polymer Nanocomposites 339 James Njuguna and Krzysztof Pielichowski 10.1Introduction 339 Fiber-Reinforced Nanocomposites 341 Natural Fiber-Reinforced Nanocomposites 341 Polyamide/Layered Silicates Nanocomposites 344 Epoxy/Layered Silicates Nanocomposites348 Epoxy/CNT Nanocomposites 351 Sandwich Structures 355 High-Temperature Fiber-Reinforced Nanocomposites 358 Age and Durability Performance 362 ciated Part IV Cellular Materials 371 Eusebio Solórzano and Miguel A. Rodriguez-Perez References 374 Polymeric Foams 375 Eusebio Solórzano and Miguel A. Rodriguez-Perez Blowing Agents for Polymer Foams 375 Thermoplastic Foams: Conventional Processing Technologies 378 Injection Molding 378 Extrusion Foaming 381 Compression Molding 382 Gas Dissolution Foaming 383 Thermoplastic Foams: New Trends, Materials and Technologies 384 Microcellular Foams 384 Nanofoams 386 BrakeBioplastic and Biodegradable Foams 388 Thermosets Foams: Conventional Processing Technologies 390 Flexible PU Foams 391 Rigid PU Foams 393 Thermosets Foams: New Trends, Materials and Technologies 394 paceEpoxy Foams 394 Environmentally Friendly Blowing Agents for PU396 Nanocomposite Foams 397 Structural Applications: Sandwich Cores and Structural Foams 400 Comfort and Security 403 Combustion and Flammability 403 Fogging and Volatiles 404 Thermal Insulation 405 Sound Proofing and Vibration Damping 405 Environmental Issues 406 Energy Saving and Raw Materials Reduction 406 Recyclability and Biodegradability 407 Further Reading 409 Acknowledgments 410 References 410 Metal Foams 415 Joachim Baumeister and Jorg Weise Foams Produced by Means of Melt Technologies 419 Foams Produced by Means of Powder Metallurgy (P/M)423 Porous Structures for Structural Applications Produced from Wires and Other Half-Finished Parts 429 Automotive Passenger Cars439 Commercial Vehicles 439 Railway Transportation440 Marinę Transport 440 Aeronautical Transport440 Further Reading 441 Acknowledgments 443 References 443 Part V Modeling and Simulation 445 Kambiz Kayvantash Advanced Simulation and Optimization Techniques for Composites 447 Jorg Hohe Multiphysics Homogenization Analysis 448 Concept of the Representative Volume Element 448 Equivalence Conditions 449 Probabilistic Homogenization Approaches 453 Assessment of Materiał Uncertainties 453 Statistical Assessment of theHomogenization Results455 Probabilistic Materiał Models 457 Optimization An Artificial-Intelligence-Based Approach forCeneralizedMateriał Modeling 463 Kambiz Kayvantash 14.1 Strain Measures 464 Stress Measures 467 One-Diraensional Materiał Models 469 General Materiał Models in Three Dimensions471 A Generalized Materiał Model 472 Reliability and Robustness 474 Machinę Learning Techniąues and Rule 475 How to Extract the Generalized Materiał Law Extraction Initio Guided Design of Materials 481 Martin Fńdk, Dierk Raabe, and Jórg Neugebauer Top-Down and Bottom-Up Multiscale Modeling Strategies 481 Ab Initio Based Multiscale Modeling of Materials484 Modeling of Ultralightweight Mg-Li Alloys 486 Ternary bcc MgLi-X Alloys 489 Further Reading 492 Acknowledgments 492 References 493 Part VI Higher Level Trends 497 Dirk Lehmhus Hybrid Design Approaches 499 Daniele Bassan Motivation 499 From Monomaterial to Hybrid Multi-Material Design Approach in the Automotive Sector 502 ULSAB AVC Project/FSV Futurę Steel Vehicle Project502 S-in Motion - Steel BiW Project 503 Multi-Material Hybrid Design Approach 504 Optimum Multi-Material Solutions: The Reason for Hybrid Design Approach 504 SuperLIGHT-Car Project 505 Hybrid Solutions: Overview of Current Automotive Production 506 Trends in Automotive Materials and Structural Design512 Hybrid Solutions in Aircraft, Raił, and Ship Market 513 General Aspects on Joining Technologies for Multi-Material Mix 514 Sensorial Materials 517 Dirk Lehmhus, Stefan Bossę, and Matthias Busse Components519 Sensors 520 Component Integration 522 Data Processing: Algorithms and Hardware Architectures 525 Energy Supply and Management 531 Further Reading 542 Acknowledgment 544 References 544 Additive Manufacturing Approaches549 Juan F. Isaza P. and Claus Aumund-Kopp Metal Materials 554 Titanium Alloys 557 Stainless Steel 557 Aluminum 557 Cobalt-Based Alloys557 Nickel-Based Alloys557 Nonmetal Materials558 Secondary Processes 560 Hydraulic Crossing561 Wing Profile 562 Series Production ofIndividual Parts-Dental Restorations 563