An advanced, patented probe sensor provides early detection of water infrastructure problems caused by corrosion and harsh atmospheric conditions. Designed to detect graphitization in active pipelines, it identifies areas at risk of major failures early on. By using indirect methods like GIS mapping, in-situ soil resistivity testing, and structure-to-soil potential measurements, high-risk zones can be pinpointed. Once these areas are identified, the probe assesses the severity and depth of graphitization, providing a comprehensive evaluation of the pipeline’s condition. This allows for the implementation of effective corrosion management strategies, including cathodic protection systems, to prevent critical failures. This article describes the sensor system and provides a case study of its use. The technology received the 2024 Engineering Materials Achievement Award from ASM International.

Automotive designers and heat treaters have many choices when it comes to the materials and processes that will meet their overall needs. This article reviews some of the major trends affecting automotive heat treating.

Automotive die OEMs throughout Europe are using laser heat treatment (LHT) to deliver parts fast, with superior quality, at lower cost. This article presents a basic technical introduction to LHT and the results of a case study of LHT cost savings in automotive trim/form dies.

Advances in software algorithms and design enable automation of microstructure image analysis, leading to cost savings, reduction in measurement variability, and access to important metrics.

This article provides an overview of cracking and fracture mechanisms in heritage gold, silver, low-tin bronze, and wrought iron alloys. Understanding these mechanisms can be important for restorers, and possibly for conservators and curators as well. Metallography is widely used (when sampling is permitted) for studying archaeometallurgical artifacts in detail. However, fracture surface examinations and analysis (i.e., fractography) can often provide even greater insight. Case studies demonstrate the benefits of employing fractographic analysis to study cracking and fracture mechanisms in heritage alloys.

By effectively mitigating the historical paradox between strength and ductility, a new advanced high strength steel with a mixed microconstituent structure enables automotive sheet steel to meet automobile efficiency requirements.

Many broken parts look similar at a glance, but examination of the failed part using advanced equipment and methods such as scanning electron microscopy (SEM) reveals much more about the origins of the failure. This article presents a case history involving SEM analysis of a trailer hitch fatigue failure.

Selecting materials for high-pressure hydrogen systems requires balancing technical understanding of hydrogen embrittlement and business considerations. While the direct effect of hydrogen on materials is usually manifested as ductility loss under tension stress, the most concerning failure in a hydrogen system is fatigue. Although no material is immune to property degradation caused by hydrogen, Type 316 stainless steel is among the best in resisting hydrogen embrittlement.

During the past 30 years, enormous research has been devoted to developing titanium-base intermetallics for use in gas turbine engines as lightweight alternative to nickel-base superalloys. This article presents a brief history of Ti 2 AlNb and efforts to mature this material for commercial component production. The article includes processing experience insights gained from a current R&D program in China.

This article describes Shear-Assisted Processing and Extrusion (ShAPE), an emerging extrusion technology being developed at the Pacific Northwest National Laboratory. One application of the ShAPE process is recycling post-consumer scrap without adding primary aluminum, which reduces embodied energy and carbon output. Scientists at PNNL won an R&D 100 Award in 2020 for their work in developing the ShAPE process.

A new fusion cladding process that uses high-intensity arc lamps can produce pinhole free, smooth, uniform coatings as thick as 15 mm from various feedstock materials. This article briefly describes the process and the corrosion, wear, and high-temperature behavior of fusion claddings designed for oil and gas pipelines and related components.

Affordable bulk production of a newly developed nanostructured bainitic steel is possible without using severe deformation or complex heat treatments. This article discusses the characteristics and significance of nanostructured bainite in terms of the transformation mechanism.

A look at how bifilms are created during casting may offer clues to eliminating cracks, tensile fracture, fatigue failure, pitting, and stress corrosion cracking failures.

Throughout metal making history, nothing has exceeded the technical importance, scientific complexity, and human curiosity involved in the hardening of steel. After the bustling 1890s, with its exciting and productive discoveries around steel metallography, a period of quiet consolidation occurred in the early 20th century. This article describes the breakthroughs in steel metallurgy that occurred after this period by such pioneers as William Chandler Roberts-Austen, Adolf Martens, Henry Marion Howe, and Edgar C. Bain.

A new high-strength steel developed for cold stamping addresses the challenges presented by materials traditionally used to manufacture electric vehicle components.

Conventional manufacturing from wrought bar stock typically involves extensive machining, creates significant material waste (scrap metal), and requires numerous steps to obtain the final part geometry. As a more efficient alternative, powder metallurgical (PM) processes are now available to cost effectively fabricate both simple and complex shapes with minimal material waste. Combustion driven higher pressure powder compaction (CDC) for near-net or net shape manufacturing was recently developed. It offers a unique way of forming near-net or net shape high-density powder metal components both cost effectively and at relatively higher compaction pressures than other PM processes.

A recent metallographic and historical analysis of two parts from the Buenos Aires to Pacific Railroad railway looked at possible manufacturing techniques of the parts in question. The information collected is useful for comparison with techniques and materials used at that time as well as with current techniques. The analysis questioned whether the material itself has varied or evolved from the metallurgical point of view, and confirmed the quality of raw material used to construct the historic railway line.

Significant advancements in metallurgy were highlighted at a special symposium presented at the Materials Science & Technology 2016 conference in Salt Lake City. This article summarizes the topics presented. All six speakers shared examples of the importance of understanding how the specific manufacturing process affects microstructure development in metals. The fundamental understanding of microstructure allows metallurgists to select manufacturing processes and schedules to tailor the microstructure, and therefore mechanical properties and performance, for a particular component.

This article describes a planned three-year research project at the Center for Heat Treating Excellence (CHTE) at Worcester Polytechnic Institute (WPI) to help the heat treat industry better understand process parameters related to austempering of steels. This research will enable the industry to identify the potential strength, toughness, and cost benefits of bainitic steels over martensitic steels and provide guidance on the design, validation, and control of heat treating processes to produce bainitic microstructures in steels.

Chemical vapor deposition (CVD) of pyrolytic chromium carbide coatings (PCCCs) is proving to be a viable alternative to hard chrome plating used on cylinder piston group components. This article discusses the development and optimization of a CVD process for depositing PCCCs on piston rings and cylinder sleeves. It evaluates the coatings based on friction, wear, and adhesion properties in comparison with coatings produced by other methods.