This article provides an overview of the classification system of coppers for conductors and for wires and cables, as well as wire rod fabrication techniques such as rolling and continuous casting. Wiredrawing and wire stranding operations, including the preparation of rod surface, drawing, production of flat rectangular wire, annealing, and coating, are discussed. The article also provides information on electrical insulation and jacketing techniques, including polymeric insulation, enamel insulation, and paper-and-oil insulation.

Wrought copper and copper alloys are produced in various mill-product forms for a variety of applications due to their high electrical conductivity, corrosion resistance, ease of fabrication, and good heat-transfer properties. This article describes the manufacturing processes used to produce wrought copper and copper alloys in the form of sheet and strip products, tubular products, and wire and cable. Common processes include melting, casting, hot and cold rolling, milling or scalping, annealing, cleaning, slitting, cutting, and leveling. In addition, the article discusses stress-relaxation characteristics of copper alloys.

This article discusses the properties, primary and secondary production, product forms and applications of various grades of lead and lead-base alloys with the aid of several tables and illustrations. It lists the Unified Numbering System (UNS) designations for various pure lead grades and lead-base alloys grouped according to nominal chemical composition. The properties of lead that make it useful in a wide variety of applications are also discussed. The largest use of lead is in lead-acid storage batteries. Other applications include ammunition, cable sheathing, cast products such as type metals, terneplate, foils, and building construction materials. Lead is also used as an alloying element in steel and in copper alloys to improve machinability. The article concludes with information on the principles of lead corrosion, corrosion resistance of lead in water, atmospheres, underground ducts, soil and chemicals.

This article discusses the processing, properties, and applications of various grades of lead and lead-base alloys with the aid of several tables and illustrations. It lists the Unified Numbering System (UNS) designations for various pure lead grades and lead-base alloys grouped according to nominal chemical composition. The properties of lead that make it useful in a wide variety of applications are also discussed. The largest usage of lead is in the lead acid storage batteries (in the grid plates, posts, and connector straps). Other applications include ammunition; cable sheathing; cast products such as type metals, terneplates, and foils; and building construction materials. Lead is also used as an alloying element in steel and in copper alloys to improve machinability and other characteristics. In many applications, lead is combined with stronger materials to make structures that have the best qualities of both materials such as the plumbum series.

Niobium-titanium alloys (NbTi) became the superconductors of choice in the early 1960s, providing a viable alternative to the A-15 compounds and less ductile alloys of niobium-zirconium. This can be attributed to the relative ease of fabrication, better electrical properties, and greater compatibility with copper stabilizing materials. This article discusses the ramifications of design requirements, selection criteria and processing methods of superconducting fibers and matrix materials. It provides information on the various steps involved in the fabrication of superconducting composites, including assembly, welding, isostatic compaction, extrusion, wire drawing, twisting, and final sizing. The article also provides a detailed account of the properties and applications of NbTi superconducting composites.

This article reviews the phase diagrams, alloy with third element additions, layer growth, critical current density, and matrix materials of A15 superconductors. It describes the production methods of tape conductors (chloride deposition, and surface diffusion) and multifilamentary wires (rod process, modified jelly roll process, niobium tube process, in-situ process, powder metallurgy process, and jelly roll method). The article focuses on reaction heat treatment, which is required at the end of wire processing to convert the ductile components to the desired, but brittle, superconductor. Finally, it discusses the applications of A15 superconductors in commercial magnets, power generation, power transmission, high-energy physics, and fusion.

This article focuses on the corrosion and deterioration of components on recreational and small workboats. It discusses the materials selection and corrosion control for the components. These components include hulls, fittings, fasteners, metal deck gear, winches, backing plates, lifeline supports, inboard engines, cooling systems, propulsion systems, electrical and electronic systems, plumbing systems, masts, spars, and rigging.

Copper and copper alloys constitute one of the major groups of commercial metals due to their excellent electrical and thermal conductivities, corrosion and fatigue resistance, ease of fabrication, and good strength. This article lists the types, properties, fabrication characteristics, corrosion ratings, temper designations, and applications of wrought copper and copper alloys. It also presents an outline of the most commonly used mechanical working and heat treating processes. The copper industry in the United States is broadly composed of two segments: producers (mining, smelting, and refining companies) and fabricators (wire mills, brass mills, foundries, and powder plants). The article discusses copper production methods and describes major changes in the structure of the U.S. copper and copper alloys industry.

The rate and form of corrosion that occur in a particular situation depend on many complex variables. This article discusses the rate of corrosion of lead in natural and domestic water depending on the degree of water hardness caused by calcium and magnesium salts. Lead exhibits consistent durability in all types of atmospheric exposure, including industrial, rural, and marine. The article tabulates the corrosion of lead in various natural outdoor atmospheres and the corrosion of lead alloys in various soils. It explains the factors that influence in initiating or accelerating corrosion: galvanic coupling, differential aeration, alkalinity, and stray currents. The resistance of lead and lead alloys to corrosion by a wide variety of chemicals is attributed to the polarization of local anodes caused by the formation of a relatively insoluble surface film of lead corrosion products. The article also provides information on the corrosion rate of lead in chemical environments.

Roll welding (ROW) is a process in which two or more sheets or plates are stacked together and then passed through the rolls until sufficient deformation has occurred to produce solid-state welds. This article begins with a process description of two modes of roll welding, including pack rolling. It describes a patented roll welding process for fabrication of heat exchangers. The article presents a table showing the typical properties of common roll welded clad laminates. The relative weldability of selected dissimilar metals and alloys roll welded into clad-laminate form are also tabulated. The article concludes with information on cladding of metals by strip roll welding.

Ultrasonic welding (USW) is effectively used to join both similar and dissimilar metals with lap-joint welds. This article describes procedure considerations for the ultrasonic welding of specific material types. It reviews difficult-to-weld alloys, such as carbon and low-alloy steels, high-strength steels, and stainless steel, and provides information on the applications of weldable alloys such as aluminum alloys and copper alloys. The article concludes with a discussion on welding of dissimilar metal (nonferrous-to-nonferrous) combinations and its applications.

This article focuses on microbiologically influenced corrosion (MIC) of military assets. It discusses the mechanisms of MIC in hydrocarbon fuels and atmospheric, immersion, and buried environments with specific examples. The article describes the behavior of metals and alloys, namely, copper alloy, nickel alloy, titanium and titanium alloys, aluminum alloys, stainless steels, and carbon steel in immersion environments.

This article provides a historical review of corrosion problems in military electronic equipment. It describes the importance of design for corrosion control of an electronic black box used to contain electrical equipment that provides various functions. The article illustrates corrosion control aspects, such as the position of printed circuit boards (PCBs) and proper location of connectors for insertion of the PCBs. It discusses various materials and alloys considered for connectors, PCB contacts, and circuits. The article concludes with a discussion on the effects of contaminants on the electronic black box.

This article describes the principles of operation, operating techniques, equipment selection, and important process variables of air-carbon arc cutting. It also provides information on the safety practices to be followed during the air-carbon arc cutting process.

Copper and copper alloys are used extensively in structural applications in which they are subject to moderately elevated temperatures. At relatively low operating temperatures, these alloys can undergo thermal softening or stress relaxation, which can lead to service failures. This article is a collection of curves and tables that present data on thermal softening and stress-relaxation in copper and copper alloys. Thermal softening occurs over extended periods at temperatures lower than those inducing recrystallization in commercial heat treatments. Stress relaxation occurs because of the transformation of elastic strain in the material to plastic, or permanent strain.