The microstructure of carbon steel is largely determined by the transformation of austenite to ferrite, cementite, and pearlite. This chapter focuses on the microstructures produced by diffusion-controlled transformations that occur at relatively low cooling rates. It describes the conditions that promote such transformations and, in turn, how they affect the structure of various phases and the rate at which they form. The chapter also discusses the concepts of transformation kinetics, minimum free energy, and nucleation and growth, and provides information on alloying, interphase precipitation, and various types of transformations.

This chapter discusses the basic principles of friction and the factors that must be considered when determining its effect on moving bodies in contact. It provides an extensive amount of friction data, including static and kinetic friction coefficients for numerous combinations of engineering materials and coatings. It also describes the causes and effects of the most common forms of wear, the conditions under which they occur, the role of lubrication, and wear testing methods.

Alloys containing elements that form volatile or low-melting-point halides are susceptible to high-temperature corrosion attack. This chapter explains how to determine whether such phases are likely to form, and the rate at which they occur, based on thermodynamic data and phase stability diagrams. It provides an extensive amount of high-temperature corrosion data for metals and alloys in gaseous environments containing chlorine and hydrogen chloride; fluorine and hydrogen fluoride; bromine and hydrogen bromide; and iodine and hydrogen iodide.

This chapter outlines the step-by-step processes by which materials are selected in order to prevent or control corrosion and includes information on materials that are resistant to the various forms of corrosion. The various forms of corrosion covered are general (uniform) corrosion, localized corrosion, galvanic corrosion, intergranular corrosion, stress-corrosion cracking, hydrogen damage, and erosion-corrosion. In addition, the economic importance of cost-effective materials selection is also considered.

This chapter covers a broad range of low-carbon steels optimized for structural applications. Low-carbon structural steels are generally considered the highest-strength steels that can be welded without undue difficulty, even in the field. They include mild steels, carbon-manganese and niobium- and vanadium-containing steels, and high-strength low-alloy steels. Chapter 5 discusses the composition, microstructure, and properties of these workhorse materials and explains how to identify the cause of production-related issues such as lamellar tearing and ferrite-pearlite banding. It also describes some of the alloying variations that have been developed to improve machinability and the mechanisms by which they work.

This chapter examines the effects of welding on the structure of metal, particularly the changes induced in the isothermal regions adjacent to the weld. It presents more than 150 images identifying structures and features associated with fusion and solid-state welding processes, including electroslag, TIG, gas, electron-beam, and arc welding as well as vacuum diffusion, forge, friction, electrical-resistance, and explosive welding. It also discusses the effect of welding temperature, pressure, and composition on the transformations that occur in and around the weld, and it includes a short section on brazing and braze welding.