This article presents fractographs that show evidence of overload and fatigue in gray cast irons. The overload failure section illustrates a fractured motor housing, valve body, and bracket with microvoid coalescence (dimpled rupture) in the metal matrix between graphite flakes. The fractographs of fatigue failures illustrate a gearbox housing with fatigue striations and pearlitic microstructure.

This article presents fractographs that show evidence of overload in white cast irons. Images illustrate brittle fracture with cleavage facets and fracture at carbide boundaries, as well as cracks caused by shear stress and the tensile stress due to rebounding.

This article describes the general factors that can influence fracture appearances. The focus is on the general practical relationships of fracture appearances, with factors presented in some broad categories, including: material conditions (e.g., crystal structure and microstructure); loading conditions (stress state, strain rate, and fatigue); manufacturing conditions (casting, metal-working, machining, heat treatment, etc.); and service and environmental factors (hydrogen embrittlement, stress corrosion, temperature, and corrosion fatigue).

X-ray radiography and computed tomography (CT) are nondestructive testing (NDT) tools particularly well suited to additive manufacturing (AM). A brief overview of NDT for AM is presented in this article, including other NDT methods, followed by identifying the key advantages and requirements for x-ray radiography and CT in AM. Less widely known applications of CT are also presented, including powder characterization, the evaluation of lattice structures, surface roughness measurements, and four-dimensional CT involving interrupted (before-after) CT scans of the same parts, or even in situ scans of the same part subjected to some processing or loading conditions. The article concludes with a discussion on the limits and some guidelines for the use of x-ray and CT for various AM materials.

This article provides a detailed account of the basic concepts of Rutherford backscattering spectrometry (RBS). It begins with a description of the principles of RBS, as well as the effect of channeling in conjunction with backscattering measurements and the effect of energy loss under this condition. This is followed by a section on equipment used in RBS analysis. Channel-energy conversion, energy-depth conversion, and separation of the dechanneling background are then discussed as the main steps of RBS data analysis. The article also discusses the applications of RBS—including composition of bulk samples, thin-film composition and layer thickness, impurity profiles, damage depth profile, and surface peak—as well as the various codes developed to simulate it.

This article provides a detailed account of extended x-ray absorption fine structure (EXAFS). It begins with a description of the fundamentals of EXAFS, providing information on the physical mechanism, single-scattering approximation, and multiple-scattering effects. This is followed by a discussion on the use of synchrotron radiation as an X-ray source for EXAFS. Data-reduction procedures used to extract EXAFS signals are then described. The article also provides information on the analysis of x-ray absorption near-edge structure spectrum and ends with a discussion on the unique features and applications of EXAFS.

This article describes the methods of X-ray diffraction analysis, the types of information that can be obtained, and its interpretation. The discussion covers the basic theories of X-rays and various types of diffraction experiments, namely single-crystal methods for polychromatic and monochromatic beams, powder diffraction methods, and the Rietveld method.

This article provides a detailed account of the concepts of single-crystal x-ray diffraction (XRD). It begins with a historical review of XRD methods, followed by a description of the various factors involved in crystal symmetry. The article then focuses on the phase problem in x-ray structural analysis and validation of the structural model. Some of the factors to be considered for performing experimental procedure are provided. The article presents several examples of applications of single-crystal XRD. The following sections cover the crystallographic problem in terms of structural analysis, software programs for crystal structure solution and refinement, and visualization of crystal structures. The article ends with a discussion on various databases available for single-crystal XRD analysis.

X-ray topography is the general term for a family of x-ray diffraction imaging techniques capable of providing information on the nature and distribution of imperfections. This article provides a detailed account of x-ray topography techniques, providing information on the historical background and development trends in x-ray diffraction topography. The discussion covers the general principles, components of systems, and applications of x-ray topography techniques, namely conventional X-ray topographic techniques and synchrotron x-ray topographic techniques.

This article discusses the techniques and applications of synchrotron x-ray diffraction, providing information on x-ray generation, monochromation, and crystallography. X-ray diffraction techniques covered include single-crystal and powder diffraction. Some of the factors involved in the construction and development of macromolecular x-ray crystallography are also described.

The electron backscatter diffraction (EBSD) technique has proven to be very useful in the measurement of crystallographic textures, orientation relationships between phases, and both plastic and elastic strains. This article focuses on backscatter diffraction in a scanning electron microscope and describes transmission Kikuchi diffraction. It begins with a discussion on the origins of EBSD and the collection of EBSD patterns. This is followed by sections providing information on EBSD spatial resolution and system operation of EBSD. Various factors pertinent to perform an EBSD experiment are then covered. The article further describes the processes involved in sample preparation that are critical to the success or usefulness of an EBSD experiment. It also discusses the applications of EBSD to bulk samples and the development of EBSD indexing methods.

Transmission electron microscopy (TEM) approach enables essentially simultaneous examination of microstructural features through imaging from lower magnifications to atomic resolution and the acquisition of chemical and crystallographic information from small regions of the thin specimen. This article discusses fundamentals of the technique, especially for solving materials problems. Background information is provided to help understand basic operations and principles, including instrumentation, the physics of signal generation and detection, image formation, electron diffraction, and spectrometry techniques with data analysis.

This article is intended to provide the reader with a good understanding of the underlying science, technology, and the most common applications of focused ion beam (FIB) instruments. It begins with a survey of the various types of FIB instruments and their configurations, discusses the essential components, and explains their function only to the extent that it helps the operator obtain the desired results. An explanation of how the components of ion optical column shape and steer the ion beam to the desired target locations is then provided. The article also reviews the many diverse accessories and options that enable the instrument to realize its full potential across all of the varied applications. This is followed by a detailed analysis of the physical processes associated with the ion beam interacting with the sample. Finally, a complete survey of the most prominent FIB applications is presented.

Low-energy electron diffraction (LEED) is a technique for investigating the crystallography of surfaces and overlayers adsorbed on surfaces. This article provides a brief account of LEED, covering the principles and measurements of diffraction from surfaces. Some of the processes involved in sample preparation are described. In addition, the article discusses the limitations of surface-sensitive electron diffraction and the applications of LEED with examples.

Heat treatment of aluminum alloys frequently refers to the heat treatable aluminum alloys that can be strengthened by solution treatment, quenching, and subsequent hardening. This article introduces the general metallurgy of strengthening aluminum alloys by heat treatment. It discusses various heat treatable alloying elements, such as copper, chromium, iron, magnesium, silicon, zinc, and lithium. The article describes the age-hardening treatments and generalized precipitation sequence for aluminum alloys. It reviews the solution heat treatment in terms of solution heating time and temperature, as well as high-temperature oxidation. The article also discusses quench sensitivity, vacancy loss, grain-boundary precipitates, and quench delay for the heat treatment of aluminum. It concludes with a discussion on the deformation of aluminum alloys prior to aging.

Transition metal dichalcogenides (TMD) are solid lubricant materials, specifically, intrinsic solid lubricants, whose crystal structure facilitates interfacial sliding/shear to achieve low friction and wear in sliding contacts and low torque in rolling contacts. This article provides information on sliding friction and wear behavior of unbonded, bonded, and vapor-deposited pure and composite MoS 2 and WS 2 coatings. It discusses the rolling-torque behavior and applications of vapor-deposited pure and composite MoS 2 and WS 2 coatings. The article concludes with information on various forms of TMD lubrication, namely, oils, greases, microparticle and nanoparticle additives.

This article begins by describing the designations of cast and wrought aluminum alloys. It explains the effects of main alloying elements in aluminum alloys: boron, chromium, copper, iron, lithium, magnesium, manganese, nickel, phosphorus, silicon, sodium, strontium, titanium, and zinc. The article describes the microstructure of cast and wrought aluminum alloys and the various strengthening mechanisms, including solid solution, grain refinement, strain or work hardening, precipitation (or age) hardening, and dispersoid strengthening. The article explicates the tribological behavior of aluminum alloys, aluminum-base composites, and metal-matrix composites. It presents the effect of material-related parameters and external factors on wear behavior and transitions of aluminum-silicon alloys. The article also presents the most important factors affecting the dry sliding wear behavior of particle-reinforced aluminum-base composites against a steel counterface.

Solidification of cast iron alloys brings about volumetric changes. This article describes direct measurements of volume changes with an illustration of the analysis of volumetric changes during solidification of cast iron with the use of a specially designed riser combined with a furnace. It provides a discussion on the dilatometer analysis that is generally used to measure linear displacement as a function of temperature for all types of materials, and the problems associated with volume-change measurements. The article presents a graphical representation of a consequence of the anisotropy, where the calculated volume change is illustrated as a function of temperature. It concludes with a review of kinetic of graphite expansion.

The solidification of hypoeutectic cast iron starts with the nucleation and growth of austenite dendrites, while that of hypereutectic iron starts with the crystallization of primary graphite in the stable system or cementite in the metastable system. This article begins with a discussion on the nucleation and growth of austenite dendrites. It describes the nucleation of lamellar graphite, spheroidal graphite, and austenite-iron carbide eutectic. The article reviews three main graphite morphologies crystallizing from the iron melts during solidification: lamellar (LG), compacted or vermicular (CG), and spheroidal. It discusses the metastable solidification of austenite-iron carbide eutectic and concludes with information on gray-to-white structural transition of cast iron.