Amtrak Acela trolley wire — Phelps Dodge vs. Rome NY supplier

Full development as the lecture's lead applied case. Tom's December consulting trip to Rome, NY; rejection of $4.5M product on December 23rd; arbitration in Old Saybrook, CT; FBI raid on the British supplier company; the elongation-spec upper bound (8–14% required, Phelps Dodge product was 18%); the orange-peel-effect mechanism revealed by Providence test-track sparking video.

I want to start showing you some types of flow you get from inhomogeneous deformation. Here's hot upsetting of steel with sticking friction. Sticking friction means the stuff under the tool doesn't move at all. The material is stuck to the workpiece — all you have to do is not put on the glass lubricant. For steel forging, like I showed you, you don't use any lubricant; you just let the oxide scale fall off. But for a nickel-based superalloy, you encase the whole thing in a glass frit, and when you get it hot, you have this syrupy layer of glass — the glass melts and gets thick, and if you pick the right glass for the forging temperature, it'll be a good lubricant.