Plastic deformation can occur in metals from various mechanisms, such as slip, twinning, diffusion creep, grain-boundary sliding, grain rotation, and deformation-induced phase transformations. This article emphasizes on the mechanism of slip and twinning under cold working conditions. It discusses the factors on which the structures developed during plastic deformation depend. These factors include crystal structure, amount of deformation, composition, deformation mode, and deformation temperature and rate. The article illustrates the microstructural features that appear after substantial deformation when revealed through metallographic investigation.

This article defines crystallographic terms and concepts, including crystal structure, unit cell, structure symbols, lattice, space-group notation, and atom position. It schematically illustrates the atom positions, prototypes, structure symbols, space-group notations, and lattice parameters for some of the simple metallic crystals. A table that lists the crystal structures of various metal elements is presented. The crystal structures are described by the Pearson symbols for crystal system, space lattice, total number of atoms per unit cell, and prototype structure. The article tabulates the assorted structure types of metallurgical interest arranged according to Pearson symbol. It also provides information on crystal defects, explaining some significant ones, such as point defects, line defects, stacking faults, and twins.

Carbon arc welding (CAW) utilizes a nonconsumable electrode, made of carbon or graphite, to establish an arc between itself and either a workpiece or another carbon electrode. This article describes the operation modes of the CAW process: single-electrode operation and twin-electrode operation. It presents a schematic representation of typical arrangements for single-electrode and twin-electrode carbon arc welding. Recommended current ranges for carbon and graphite electrodes are listed in a table. The article concludes with information on the applications of the CAW process.

This article, to develop an understanding of the underlying mechanisms governing deformation at elevated temperatures, discusses the phenomenological effects resulting from temperature-induced thermodynamic and kinetic changes. It describes the deformation behavior of engineering materials using expressions known as constitutive equations that relate the dependence of stress, temperature, and microstructure on deformation. The article reviews the characteristics of creep deformation and mechanisms of creep, such as power-law creep, low temperature creep, power-law breakdown, diffusional creep, twinning during creep deformation, and deformation mechanism maps. It discusses the creep-strengthening mechanisms for most structural engineering components. The article provides a description of the microstructural modeling of creep in engineering alloys.

This article discusses different forms of ingot and explains molten-metal processing. It describes ingot casting processes, namely, open-mold casting and direct chill (DC) process. The process variations and solidification in the DC process are summarized. The article describes continuous processes, namely, twin-roll strip casting, slab casting, and wheel-belt processes. It concludes with information on postsolidification processes, including stress relief and scalping.

This article reviews some concepts considered important for an understanding of processes used for preparing cobalt-chromium alloy implants, the microstructures resulting from this processing, and the resulting material properties. The review includes the solidification of alloys, diffusionless (martensitic) phase transformation as occurs with face-centered cubic to hexagonal close-packed transformation in cobalt-chromium alloys, stacking faults and twins and their role in this transformation. It also includes strengthening mechanisms that are responsible for the mechanical properties of cast and wrought cobalt alloys. The article contains tables that list the commonly used cobalt alloys and their biomedical applications and chemical compositions. It discusses the mechanical and corrosion properties of cobalt alloys, and provides a description of the microstructure of cobalt alloys.

This article describes the extrusion process, which converts soft, plastic material into a particular form using an extruder, or screw conveyer. It discusses the two main types of plastic extruders, twin-screw and single-screw, estimation of extruder capacity, and design and operations (heating, cooling, downstream sizing, corrugating, and crossheading) of the screw, the most important component of any extruder. It discusses the shapes produced by screw extrusion and the types of extrusion products produced by extrusion processes, including blown-film extrusion, flat-film or sheet extrusion, chill-roll film extrusion, pipe or tube extrusion, wire and cable coverings, extrusion coating, and profile extrusion, and provides some discussion on multiple-screw extruders. The article describes the dimensional accuracy of extrusion products, and lists common defects that occur frequently in the extrusion process.

Crystal structure is the arrangement of atoms or molecules in the solid state that involves consideration of defects, or abnormalities, in idealized atomic/molecular arrangements. The three-dimensional aggregation of unit cells in the crystal forms a space lattice or Bravais lattice. This article provides a brief review of the terms and basic concepts associated with crystal structures. It also discusses some of the significant defects obstructing plastic flow in real crystals, namely point defects, line defects, stacking faults, twins, and cold work. Several tables in the article provide information on the crystal structures and lattice parameters of allotropes of metallic elements.

This article provides a description of the microscale models and mechanisms for deformation and fracture. Macroscale and microscale appearances of ductile and brittle fracture are discussed for various specimen geometries and loading conditions. The article reviews the general geometric factors and materials aspects that influence the stress-strain behavior and fracture of ductile metals. It highlights fractures arising from manufacturing imperfections and stress raisers. The article presents a root cause failure analysis case history to illustrate some of the fractography concepts.

This article illustrates equilibrium phase diagram for the aluminum-silicon system showing metastable extensions of the liquidus and solidus lines. It describes the classification and microstructure of the aluminum-silicon eutectic. The article presents the theories of solidification and chemical modification of the aluminum-silicon eutectic.

Self-consistent models are a particular class of models in continuum micromechanics, that is, the field concerned with making predictions of the properties and evolution of aggregates whose single-crystal deformation behavior is known. This article provides information on the measurement and representation of textures as well as prediction of texture evolution in single-phase materials and two-phase aggregates.

Martensite is a metastable structure that forms during athermal (nonisothermal) conditions. This article reviews the crystallographic theory, morphologies, orientation relationships, habit plane, and transformation temperature of ferrous martensite microstructures. It examines the stages of the tempering process involved in ferrous martensite. The article also describes the formation of the martensite structure in nonferrous systems. It concludes with a discussion on shape memory alloys.

This article provides an in-depth treatment on the deformation and recrystallization of titanium alloys. It provides information on the predominant mode of plastic deformation that occurs in titanium in terms of the most common crystallographic planes. The article explains the relationship of the recovery process to the recrystallization, grain-growth process, and the effects of time and temperature on stress relief. It describes the factors that influence the rate of recrystallization and the conditions required for neocrystallization to occur. The article explains the mechanism of strain hardening and its effects on the mechanical properties of titanium alloys. It also discusses the factors that influence the superplasticity of titanium alloys.

This article discusses the forging processes and equipment and forging practice associated with the forging of magnesium alloys. It describes the workability of magnesium alloys. The article concludes with a discussion on the inspection of magnesium alloy forgings.

This article focuses on characterizing the fracture-surface appearance at the microscale and contains some discussion on both crack nucleation and propagation mechanisms that cause the fracture appearance. It begins with a discussion on microscale models and mechanisms for deformation and fracture. Next, the mechanisms of void nucleation and void coalescence are briefly described. Macroscale and microscale appearances of ductile and brittle fracture are then discussed for various specimen geometries (smooth cylindrical and prismatic) and loading conditions (e.g., tension compression, bending, torsion). Finally, the factors influencing the appearance of a fracture surface and various imperfections or stress raisers are described, followed by a root-cause failure analysis case history to illustrate some of these fractography concepts.

The reflected light microscope is the most commonly used tool to study the microstructure of metals, composites, ceramics, minerals, and polymers. For the study of the microstructure of metals and alloys, light microscopy is employed in the reflected-light mode using either bright-field illumination, dark-field illumination, polarized light illumination, or differential interference contract, generally by the Nomarski technique. This article concentrates on how to reveal microstructure properly to enable the proper identification of the phases and constituents and, if needed, measuring the amount, size, and spacing of constituents, using the light optical microscope. The discussion covers the examination of microstructures using different illumination methods and includes a comparison between light optical images and scanning electron microscopy images of microstructure.

Engineering component and structure failures manifest through many mechanisms but are most often associated with fracture in one or more forms. This article introduces the subject of fractography and aspects of how it is used in failure analysis. The basic types of fracture processes (ductile, brittle, fatigue, and creep) are described briefly, principally in terms of fracture appearances. A description of the surface, structure, and behavior of each fracture process is also included. The article provides a framework from which a prospective analyst can begin to study the fracture of a component of interest in a failure investigation. Details on the mechanisms of deformation, brittle transgranular fracture, intergranular fracture, fatigue fracture, and environmentally affected fracture are also provided.

This article provides an overview of fractography and explains how it is used in failure analysis. It reviews the basic types of fracture processes, namely, ductile, brittle, fatigue, and creep, principally in terms of fracture appearances, such as microstructure. The article also describes the general features of fatigue fractures in terms of crack initiation and fatigue crack propagation.

This article focuses on the specimen preparation procedures of austenitic manganese steels: sectioning, mounting, and grinding. It provides information on macroexamination and microexamination of a fracture surface, the microstructure and special features of austenitic manganese steels, and the alloying elements used.

This article focuses on the specific aspects of nitinol that are of interest to medical device designers. It describes the physical metallurgy, physical properties, and tensile properties of the nitinol. The article discusses the factors influencing superelastic shape memory effects, fatigue, and corrosion in medical device design. It reviews the biocompatibility of nitinol based on corrosion behavior. The article describes the general principles, potential pitfalls, and key properties for manufacturing, heat treatment, and processing of nitinol.