This chapter discusses the processes involved in the heat treatment of steel, namely austenitizing, hardening, quenching, and tempering. It begins with an overview of austenitizing of steels by induction heating, followed by a discussion on the processes involved in transformation of the soft austenite into martensite or lower bainite in the hardening operation. The chapter provides information on various quenching systems and a description of quenching techniques, namely austempering, martempering, and patenting. Difficulties associated with hardening of steel are discussed. Further, the chapter describes the equipment used for and principal variables of tempering. It discusses the causes for various forms of embrittlement due to tempering. Information on multiple tempering, protective-atmosphere tempering, and selective tempering are also provided, along with processes involved in selection of tempering temperature. The chapter ends with a section discussing various effects, advantages, and disadvantages of precipitation hardening.

This chapter covers the early studies and various discoveries by metals researchers to study the internal structure of metals. The topics covered include light microscopy, phase diagrams, X-ray diffraction, principles of precipitation hardening, and dislocation theory.

This chapter addresses the general effects of composition, mechanical treatment, surface treatment, processing, and fabrication operations on the corrosion resistance of aluminum and its alloys. Different types of surface treatments covered include claddings, anodizing, and conversion coatings. The processing steps that can have relatively significant impact on corrosion resistance are homogenization, rolling, extrusion, quenching, aging, and annealing.

This chapter discusses the stress-strain response of ferritic microstructures and its influence on tensile deformation, strain hardening, and ductile fracture of carbon steels. It describes the ductile-to-brittle transition that occurs in bcc ferrite, the effects of aging and grain size on strength and toughness, continuous and discontinuous yielding behaviors, and dispersion and solid-solution strengthening processes.

This chapter describes the mechanical properties of fully pearlitic microstructures and their suitability for wire and rail applications. It begins by describing the ever-increasing demands placed on rail steels and the manufacturing methods that have been developed in response. It then explains how wire drawing, patenting, and the Stelmor process affect microstructure, and describes various fracture mechanisms and how they appear on steel wire fracture surfaces. The chapter concludes by discussing the effects of torsional deformation, delamination, galvanizing, and aging on patented and drawn wires.

Titanium alloys respond well to heat treatment be it to increase strength (age hardening), reduce residual stresses, or minimize tradeoffs in ductility, machinability, and dimensional and structural stability (annealing). This chapter describes the phase transformations associated with these processes, explaining how and why they occur and how they are typically controlled. It makes extensive use of phase diagrams and cooling curves to illustrate the effects of alloying and quenching on beta-to-alpha transformations and the conditions that produce metastable phases. It also examines several time-temperature-transformation diagrams, which account for the effect of cooling rate.

This chapter discusses the basic principles of precipitation hardening, an important strengthening mechanism in nonferrous alloys as well as stainless steel. It begins with a detailed review of the theory of precipitation hardening, then describes its application to aluminum alloys and nickel-base superalloys.

This chapter explains how the presence of intermediate phases affects the melting behavior of binary alloys and the transformations that occur under different rates of cooling. It begins by examining the phase diagrams of magnesium-lead and copper-zinc, noting some of the complexities associated with intermediate phases. It then discusses the difference between ordered and disordered phases and how they are accounted for on phase diagrams. It describes how the atoms in a disordered solution may arrange themselves into an ordered array, forming a superlattice in the process of cooling, and goes on to identify the most common superlattice structures and their corresponding alloy phases. It also discusses the factors that limit the formation of superlattices along with the kinetics of spinodal decomposition and its effect on microstructure development.

This chapter begins by presenting a generic eutectic phase diagram and identifying critical points, lines, and features. It then describes the composition and properties of aluminum-silicon and lead-tin eutectic systems, the characteristics of eutectic morphologies, the solidification and scale of eutectic structures, and the competitive growth of dendrites and eutectic colonies or cells. It also examines the different types of precipitation structures that form during slow cooling cycles.

This chapter provides a brief overview of phase diagrams, explaining what they represent and how and why they are used. It identifies key points, lines, and features on a binary nickel-copper phase diagram and explains what they mean from a practical perspective. It also discusses the concept of equilibrium, the significance of Gibb’s phase rule, the theorem of Le Chatelier, and the use of the lever rule.

This chapter describes the physical characteristics, properties, and behaviors of solid solutions under equilibrium conditions. It begins with a review of a single-component pure metal system and its unary phase diagram. It then examines the solid solution formed by copper and nickel atoms. It discusses the difference between interstitial and substitutional solid solutions and the factors that determine the type of solution that two metals are likely to form. It also addresses the development of intermediate phases, the role of free energy, transformation kinetics, liquid-to-solid and solid-state phase transformations, and the allotropic nature of metals.

This chapter explains how the principles of chemical thermodynamics are used in the construction and interpretation of phase diagrams. After a brief review of the laws of thermodynamics, it describes the concept of Gibbs free energy and its application to transformations that occur in single-component and binary solid solutions. It then examines the relationship between the free energy of a solution and the chemical potentials of the individual components. It also explains how to account for the heat of mixing using quasi-chemical models, discusses the effect of interatomic bond energies and chemical potentials, and shows how the equilibrium state of an alloy can be obtained from free-energy curves.

This chapter discusses the unique characteristics of isomorphous alloy systems. It begins with a review of the naming conventions for multi-component systems and the construction of a three-dimensional phase diagram for a two-component alloy system. It explains how phase diagrams can be constructed from time-temperature cooling curves and how they can be used to predict the phases present, their chemical compositions, and relative amounts. It also shows how phase diagrams can be modified to account for nonequilibrium cooling conditions.

This chapter discusses the phase transformations of peritectic alloy systems. It describes the processes involved with equilibrium and nonequilibrium freezing, the mechanisms of peritectic formation, and the resulting microstructures. It also discusses the formation of peritectic structures in iron-base alloys and multicomponent systems.

This chapter provides a brief overview of monotectic alloy systems and reactions. It begins by presenting a monotectic phase diagram and identifying important points, lines, and regions. It then describes the monotectic reactions that occur in copper-lead systems and the associated solidification structures. It also discusses the morphology of the microstructure produced during directional solidification and the classification criteria of low- and high-dome alloys.

This chapter discusses the characteristics of eutectoid transformations, a type of solid-state transformation associated with invariant reactions, focusing on the iron-carbon system of steel. It describes the compositions, characteristics, and properties of ferrite, eutectoid, hypoeutectoid, and hypereutectoid structures and how they are affected by the addition of various alloying elements. The chapter also discusses the formation of peritectoid structures in the uranium-silicon alloy system.

This chapter discusses the construction, interpretation, and use of ternary phase diagrams. It begins by examining a hypothetical phase space diagram and several corresponding two-dimensional plots. It then describes one of the most basic tools of metallurgy, the Gibbs triangle, and explains how to construct tie lines to analyze intermediate compositions and phases. It also discusses the use of three-dimensional temperature-composition diagrams, three- and four-phase equilibrium phase diagrams, and binary and ternary phase diagrams associated with the iron-chromium-nickel alloy system.

Gas-metal reactions can have a significant impact on metals and alloys, affecting their properties (during processing) and accelerating service failures, particularly in hot, corrosive environments. This chapter discusses the kinetics of gas-metal reactions and how they are driven by Gibbs energy changes. It plots the energy of formation for many important metal oxides and explains how to construct isothermal stability diagrams to analyze complex reactions involving metals, alloys, and gases containing more than one reactive component.

This chapter discusses some of the methods and measurements used to construct phase diagrams. It explains how cooling curves were widely used to determine phase boundaries, and how equilibrated alloys examined under controlled heating and cooling provide information for constructing isothermal and vertical sections as well as liquid projections. It also explains how diffusion couples provide a window into local equilibria and identifies typical phase diagram construction errors along with problems stemming from phase-boundary curvatures and congruent transformations.

This chapter provides an overview of a computational method, called CALPHAD, used for the study of phase equilibria in multicomponent systems. It describes the thermodynamic models and calculation techniques employed in the software and explains how it applies to complex alloys used in industry. It also provides examples showing how CALPHAD has been used to determine the formability of metallic glass, calculate the dilation of stainless steel during phase transformation, and predict the beta transus and approach curves of commercial titanium alloys.