This article reviews high strain rate compression and tension test methods with a focus on the general principles, advantages, and limitations of each test method. The compression test methods are cam plastometer test, drop tower compression test, the Hopkinson bar in compression, and rod impact (Taylor) test. The flyer plate impact test, expanding ring test, split-Hopkinson bar in tension, and a test using a rotating wheel used for high strain rate tension are also discussed.

This article reviews the dynamic factors, experimental methods and setup, and result analysis of different types of high strain rate shear tests. These include high strain rate torsion testing, double-notch shear testing and punch loading, drop-weight compression shear testing, thick-walled cylinder testing, and pressure-shear plate impact testing.

This article outlines the basic steps to be followed and the range of techniques available for failure analysis, namely, background data assembling, visual examination, microfractography, chemical analysis, metallographic examination, electron microscopy, electron microprobe analysis, X-ray techniques, and simulations. It also describes the steps for analyzing the data, preparing the report, preservation of evidence, and follow-up on recommendations.

Induction heating for hardening of steels has advantages from the standpoint of quenching because parts are individually processed in a controlled manner. This article provides information on the effect of agitation, temperature, hardening, residual stresses, and quenching media, on quenching. It also describes various quenching methods for steel induction heat treating, namely, spray quenching, immersion quenching, self or mass quenching, and forced air quenching. The article also reviews quench system design and quenchants and their maintenance.

This article presents the primary considerations and mechanisms for corrosion and explains how they are involved in the selection of materials for process equipment in refineries and petrochemical plants. It discusses the material selection criteria for a number of ferrous and nonferrous alloys used in petroleum refining and petrochemical applications. The article reviews the mechanical properties, fabricability, and corrosion resistance of refinery steels. It describes low- and high-temperature corrosion, hydrogen embrittlement, and cracking such as stress-corrosion, sulfide stress, and stress-oriented hydrogen-induced cracking. The article considers hydrogen attack, corrosion fatigue, and liquid metal embrittlement and the methods of combating them. It explains the causes of velocity-accelerated corrosion and erosion-corrosion. The article summarizes some corrective measures that can be implemented to control corrosion. The applicable standards for materials used in corrosive service conditions in upstream and downstream petroleum service are presented in a tabular form.

Measurement and analysis of fracture behavior under high loading rates is carried out by different test methods. This article provides a discussion on the history and types of notch-toughness tests and focuses exclusively on notch-toughness tests with emphasis on the Charpy impact test. It reviews the requirements of test specimens, test machine, testing procedure and machine verification, application, and determination of fracture appearance and lateral expansion according to ASTM A370, E 23, and A 593 specifications. In addition, the article includes information on the instrumentation, standards and requirements, and limitations of instrumented Charpy impact test, which is carried out in specimens with induced fatigue precrack. The article concludes with a review of the requirements of drop weight testing and the specimens used in other notch-toughness tests.

This article provides an overview of two major classes of bearings: rolling bearings and sliding, or plain, bearings. It reviews the experimental data resulted from testing of rolling and sliding bearing materials with illustration. The article presents a table that summarizes rolling contact fatigue test methods that ASTM published in STP 771. It also describes the role of lubrication in the bearings.

Filament winding is a process for fabricating a composite structure in which continuous reinforcements, either previously impregnated with a matrix material or impregnated during winding, is placed over a rotating form or mandrel in a prescribed way to meet certain stress conditions. This article describes the advancements in filament winding and lists the advantages and disadvantages of filament winding. It discusses the effects of fiber tension in filament winding and the selection of fibers, resins, and materials for filament winding. The article emphasizes the three basic filament-winding patterns, such as helical, polar, and hoop. It presents information on the applications of filament winding, including rocket motors, natural gas vehicle (NGV) tanks, and sporting goods. The article presents recommendations for the basic design guidelines for filament-winding design/manufacturing process and concludes with a discussion on fabrication recommendations.

Independent verification of coating system performance can be based on laboratory testing and/or field exposure. Qualification testing is a critical component to coating system selection. This article focuses on performance evaluations that are used to prequalify coating systems, namely, facility-specific, industry-specific, coating-type-specific, or a combination of these. It describes the standard laboratory tests used to generate performance data, namely, physical, compositional, chemical exposure, and application characteristics tests. The pros and cons of using manufacturer-generated data versus independently generated data are discussed. The article provides information on accelerated corrosion/weathering testing and nuclear level 1/level 2 service coatings qualification. It also describes the procedures for establishing minimum performance requirements and for determining when requalification testing may be required.

In high-iron-tonnage operations, the cupola remains the most efficient source of continuous high volumes of iron needed to satisfy high production foundries or the multiple casting machines of centrifugal pipe producers. This article explores successful improvement technologies in cupola equipment, including preheated air blast, recuperative hot blast systems, and duplex electric holders. It discusses the shell, intermittent or continuous tapping, tuyere and blower systems, refractory lining, water-cooled cupolas, emission-control systems, and storage and handling of the charge materials. The article provides a discussion on the control tests for cupola, including the chill test and mechanical test. It concludes with information on specialized cupolas such as the cokeless cupola and the plasma-fired cupola.

This article describes manufacturing procedures that produce aluminum foams and have since become industrially important and successful. It discusses the foaming of melts by blowing agents and foaming of melts by gas injection. The article focuses on aluminum foams based on the Foaminal technology, because those foams dominate the technical applications of aluminum foams. It also discusses the mechanical properties of metal foams, such as general compression behavior, elastic behavior, strain-rate sensitivity, tensile behavior, ductility, fatigue, and mechanical damping. The article concludes with information on the applications of highly porous metal structures.

This article discusses the methods of pulp production, pulp processing, pulp bleaching, and paper manufacturing. It describes various types of digesters, their construction materials, the corrosion problems encountered, and methods to protect these digesters from corrosion. The article examines the corrosion problems in high-yield mechanical pulping, sulfite process, neutral sulfite semichemical pulping, chemical recovery, tall oil plants, wastewater treatment, and recovery boilers. It explains the stages of chlorine-based and nonchlorine bleaching, process water reuse for elemental chlorine-free and nonchlorine bleaching stages, selection of material for bleaching equipment, developments in oxygen bleaching, and the use of highly corrosion-resistant materials for bleach plant equipment. The article reviews the materials used in the construction of paper machine components and specific corrosion problems that affect them. It discusses the composition and corrosive nature of white water. The article also addresses the corrosion and chemical recovery associated with kraft pulping liquors.

This article discusses the general formability considerations of aluminum alloys. To conduct a complete analysis of a formed part, the required mechanical properties, as determined by several standard tests, must be considered. The article describes tension testing and other tests designed to simulate various production forming processes, including cup tests and bend tests, which help in determining these properties. It provides information on the equipment and tools, which are used in the forming of aluminum alloys. The article presents a list of lubricants that are most widely used in the forming. It also analyzes the various forming processes of aluminum alloys. The processes include blanking and piercing, bending, press-brake forming, contour roll forming, deep drawing, spinning, stretch forming, rubber-pad forming, warm forming, superplastic forming, explosive forming, electrohydraulic forming, electromagnetic forming, hydraulic forming, shot peening, and drop hammer forming.

Pumps and compressors are representative fluid machineries, which are indispensably important industrial equipment for water supply systems, chemical processing and reactions, and fluid power systems. This article addresses friction, lubrication, and wear of components in several types of machines such as positive displacement pumps including hydraulic pumps, turbo-pumps including centrifugal pumps, vacuum pumps, and compressors including the positive displacement type and turbo type.

Certain metal products can be produced only by powder metallurgy; among these products are materials whose porosity is controlled. Successful production by powder metallurgy depends on the proper selection and control of process variables: powder characteristics; powder preparation; type of compacting press; design of compacting tools and dies; type of sintering furnace; composition of the sintering atmosphere; choice of production cycle, including sintering time and temperature; and secondary operations and heat treatment. When the application of a powder metallurgy part requires high levels of strength, toughness, or hardness, the mechanical properties can be improved or modified by infiltration, heat treatment, or a secondary mechanical forming operation such as cold re-pressing or powder forging. The article also discusses the effect of the secondary processes on P/M mechanical properties.

This article briefly reviews the forming of steel tailor-welded blanks (TWB) with a discussion on the effects of welding on forming. It presents the parameters that are monitored to control the stamping operation for tailor-welded blanks. The article discusses weld factors such as the orientation of weld relative to metal movement in dies, the formability of TWB materials, die and press considerations, and specific factors for the drawing, stretching, and bending of steel tailor-welded blanks.

This article describes the characteristics of tubing of heat exchangers with respect to general corrosion, stress-corrosion cracking, selective leaching, and oxygen-cell attack, with examples. It illustrates the examination of failed parts of heat exchangers by using sample selection, visual examination, microscopic examination, chemical analysis, and mechanical tests. The article explains corrosion fatigue of tubing of heat exchangers caused by aggressive environment and cyclic stress. It also discusses the effects of design, welding practices, and elevated temperatures on the failures of heat exchangers.

Structural alloys are commonly subjected to a variety of thermal and thermomechanical loads. This article provides an overview of the experimental methods in thermal fatigue (TF) and thermomechanical fatigue (TMF) and presents experimental results on the structural materials that have been considered in TF and TMF research. Life prediction models and constitutive equations suited for TF and TMF are covered. The structural materials discussed include carbon steels, low-alloy steels, stainless steels, aluminum alloys, and nickel-base high-temperature alloys. The article explains crack initiation and crack propagation in TF and TMF. It describes thermal ratcheting and thermal shock behavior of structural metallic materials. The article concludes with information on life prediction of structural materials under TF and TMF.