Rust-preventive compounds are removable coatings used for the protection of the surfaces of iron, steel, coated or galvanized products, and other alloys. This article describes the basic parts of rust-preventive compounds, namely, carrier, film former, polar materials, and specialty additives. It explains types of rust-preventive compounds, including dry films and water-based dry films. The article also discusses the methods of application of various compounds, such as petrolatum compounds and emulsion compounds. It contains tables that provide information on the characteristics, applications, and physical properties of rust-preventive materials covered by military specifications. Finally, the article describes the various considerations and parameters for selecting rust-preventive materials.

This article describes the basic attributes of the most widely used metal surface cleaning processes to remove pigmented drawing compounds, unpigmented oil and grease, chips, cutting fluids, polishing and buffing compounds, rust and scale from steel parts, and residues and lapping compounds from magnetic particle and fluorescent penetrant inspection. The cleaning processes include emulsion cleaning, electrolytic alkaline cleaning, acid cleaning, solvent cleaning, vapor degreasing, alkaline cleaning, ultrasonic cleaning, and glass bead cleaning. The article provides guidelines for choosing an appropriate process for particular applications and discusses eight well-known methods for determining the degree of cleanliness of the work surface.

Metal surfaces must often be cleaned before subsequent operations to remove unwanted substances such as pigmented drawing compounds, unpigmented oil and grease, chips and cutting fluids, polishing and buffing compounds, rust and scale, and miscellaneous contaminants. The article describes common cleaning processes, including alkaline, electrolytic, solvent, emulsion, molten salt bath, ultrasonic and acid cleaning as well as pickling and abrasive blasting. It also explains how to select the appropriate process for a given soil type and surface composition.

A coating can be defined as a substance spread over a surface to provide protection or to serve decorative purposes. This article discusses two industrial coating components, namely, nonvolatile components such as the resin or binder, pigments, and any additives that may be incorporated into the formulation; and volatile components such as solvents, or water in emulsions and their composition. It provides general information on volatile organic compounds. The article describes the film-forming mechanisms of various coating types, namely, lacquers, chemically converting coatings, latex coatings, alkyds and other resins, which cure by oxidation, moisture-curing polyurethanes and inorganic zinc primers, and powder coatings. The article concludes with a discussion on the functions of the primer, intermediate coat, and topcoat in coating systems.

This article provides an overview of the interfacial interactions with a lubricant film between a die and a metal, lubricant mechanisms, chemistry, qualification testing, application methods, and property test methods. It focuses on sheet metal-forming operations, although the discussions are relevant to metal-forming operations in general. The article also deals with lubricant selection as influenced by the metal to be formed and particular sheet-metal forming operations. The article also discusses some aspects of microbiology and toxicity in lubricants.

Emulsion cleaning is an industrial cleaning process that uses an organic solvent as the main active agent. This article provides information on the applications, concerns and limitations, and process parameters of emulsion cleaning. It describes the processing variables and equipment for three main stages of emulsion cleaning: immersion cleaning, secondary cleaning, and spray cleaning. In addition, the classifications, composition, and selection criteria are also discussed.

This article discusses the functions and chemistry of metal cutting or grinding fluids. It reviews the choice of cutting or grinding fluids that is influenced by the workpiece material, fluid characteristics, and machining operation. The article describes two application methods of cutting or grinding fluids: flooding and misting. It discusses and lists the American Society for Testing and Materials standard test procedures used in establishing control of cutting and grinding fluids. The article provides information on the storage, distribution, cleaning, and disposal of cutting and grinding fluids. It concludes with information on the health implications and biology of cutting fluids.

Cutting fluids play a major role in increasing productivity and reducing costs by making possible the use of higher cutting speeds, higher feed rates, and greater depths of cut. After listing the functions of cutting fluids, this article then covers the major types, characteristics, advantages and limitations of cutting and grinding fluids, such as cutting oils, water-miscible fluids, gaseous fluids, pastes, and solid lubricants along with their subtypes. It discusses the factors considered during the selection of cutting fluid, focusing on machinability (or grindability) of the material, compatibility (metallurgical, chemical, and human), and acceptability (fluid properties, reliability, and stability). The article also describes various application methods of cutting fluids and precautions that should be observed by the operator.

Bitumen for coating usage can best be categorized as two fundamental but very different types: asphalts and coal tars. This article provides a detailed discussion on asphalt and coal tar hot-melt applications; asphalt and coal tar emulsions; asphalt and coal tar cutbacks; and coal tar epoxies. It reviews the similarities between asphaltic and coal tar coatings and discusses the health and environmental concerns of these materials.

This article provides an overview of surface contaminants that may affect the heat treatment processes and end-product quality. It presents information on the chemicals used to clean different surface contaminants of steels. The article discusses three types of cleaning methods, namely, mechanical, chemical, and electrochemical and their effectiveness and applicability. The mechanical cleaning methods include grinding, brushing, steam or flame jet cleaning, abrasive blasting, and tumbling. Solvent cleaning, emulsion cleaning, alkaline cleaning, acid cleaning, pickling, and descaling are chemical cleaning methods. The electrochemical cleaning methods include electropolishing, electrolytic alkaline cleaning, and electrolytic pickling. The article provides information on cleanliness measurement methods such as qualitative tests and quantitative tests to ensure product quality. Health hazards that may be associated with each cleaning method and the general control measures to be used for each hazard are tabulated.

Zinc and zinc alloys require surface engineering prior to coating or use to improve adhesion and corrosion resistance. Die-cast zinc parts, in addition, must be trimmed and finished to remove flash and parting lines. This article covers zinc cleaning procedures as well as coating and finishing processes. It explains how to remove parting lines and presents several mechanical finishing methods, including surface polishing, brushing, controlled shot peening, and buffing. It also provides information on solvent cleaning, emulsion cleaning, aqueous detergent or alkaline cleaning), electrocleaning, acid dipping, and zinc conversion coating treatments.

This article discusses coating products available for use in the aerospace industry that are compliant with regulations requiring reductions in emissions from organic solvents. The coating products addressed include primers, topcoats, and chemical milling maskants. It describes their characteristics and limitations compared to conventional noncompliant materials. The article addresses the methods and products commonly used achieve regulatory compliance: waterborne coatings, exempt-solvent-based coatings, high-solids coatings, powder coating, and electro-deposition.

This article provides background information on the chemistry, coating properties, resin types, applications techniques, and performance characteristics of fluoroethylene vinyl ether (FEVE) resins. It describes the formulation methods of FEVE resins, namely, solvent-based coating formulations, water-based coating formulations, and powder coating formulations. The basic concerns to be addressed when formulating and using FEVE coatings are also discussed. The article concludes with a section on health and related safety regulations.

Rolling is the process of reducing the thickness or changing the cross section of a workpiece by compressive forces applied through a set of rolls. This article emphasizes flat rolling and illustrates basic flat-rolling process used to reduce the thickness of a rectangular cross section. It provides a discussion on hot rolling, cold rolling, and warm rolling, as well as lubrication in rolling. The article reviews the lubrication for iron-base and nickel-base materials, light metals, copper-base alloys, and titanium alloys. It discusses the wear mechanism in rolling: abrasion, adhesion, and fatigue, as well as oxidative and corrosive wear. Surface modification techniques, such as hardening by induction heat treating, weld overlay, thermal spray coating, coating via physical vapor deposition (PVD), and laser surface treatment, are also discussed for improving roll service life.

The selection of surface treatments for copper and copper alloys is generally based on application requirements for appearance and corrosion resistance. This article describes cleaning, finishing, and coating processes for copper and copper alloys. These processes include pickling and bright dipping, abrasive blast cleaning, chemical and electrochemical cleaning, mass finishing, polishing and buffing, electroless plating, immersion plating, electroplating, passivation, coloring, and organic coatings.

This article focuses on lubricants classified as either internal combustion engine or nonengine lubricants, and the lubricant additives. The functional groups of chemically active and inert additives, as well as friction modifiers and other additives, are described in detail. The chemically active additives include dispersants, detergents, antiwear, and extreme-pressure agents, oxidation inhibitors, and rust and corrosion inhibitors. The chemically inert additives include emulsifiers, demulsifiers, pour-point depressants, foam inhibitors, and viscosity improvers. The article also discusses the multifunctional nature of additives and concludes with information on lubricant formulation.

This article focuses on those areas of coatings technology where silicon-based technology (SBT) is the primary enabling technology and where SBT is used as an additive to provide unique properties to the coating film. It describes the chemistry and the uses of alkoxy silanes. The uses of silicates, siliconates, silicone fluids, and silicone resins in coatings are reviewed. The article discusses the various applications of SBT, namely, primers, heat-resistant coatings, industrial maintenance coatings, hygienic coatings, and abrasion-resistant coatings, and for marine biofouling control. It also provides information on the benefits of silicon-base additives.

This article describes the presses that are mechanically or hydraulically powered and used for producing sheet, strip, and plate from sheet metal. It also presents the JIC standards for presses, compares the presses based on power source, details the selection criteria and provides information on the various drive systems and the auxiliary equipment. It describes the selection of die materials and lubricants for sheet metal forming and provides information on the lubrication mechanisms and selection with a list of lubricant types for forming of specific sheet materials of ferrous or nonferrous metals. The article reviews the various types of forming processes such as blanking, piercing, fine-edge blanking, press bending, press forming, forming by multiple-slide machines, deep drawing, stretch forming, spinning, rubber-pad forming, three-roll forming, contour roll forming, drop hammer forming, explosive forming, electromagnetic forming, and superplastic forming.

This article discusses the coating systems categorized by the generic type of binder or resin and grouped according to the curing or hardening mechanism inherent within that generic type. It focuses on the properties, advantages, and limitations of various autooxidative cross-linked resins, thermoplastic resins, and cross-linked thermosetting resins. The autooxidative cross-linked resins include alkyd resins and epoxy esters. The article examines the two types of coatings based on thermoplastic resins: those deposited by evaporation of a solvent, commonly called lacquers, and those deposited by evaporation of water, a class of coatings called water-borne coatings. The coatings that chemically cross link by copolymerization, including epoxies, unsaturated polyesters, urethanes, high-temperature curing silicones, and phenolic linings, are also described.