Strain-range partitioning is a method for assessing the effects of creep fatigue based on inelastic strain paths or strain reversals. The first part of the chapter defines four distinct strain paths that can be used to model any cyclic loading pattern and describes the microstructural damages associated with each of the four basic loading cycles. The discussion then turns to fatigue life prediction for different types of materials and more realistic loading conditions, particularly those in which hysteresis loops have more than one strain-range component. To that end, the chapter considers two cases. In one, the relationship between strain range and cyclic life is established from test data. In the other, a rule is required to determine the damage of each concurrent strain and the total damage of the cycle is used to predict creep-fatigue life. The chapter presents several such damage rules and discusses their applicability in different situations.

This chapter gives an overview of how steel castings may be effectively adapted to modern concurrent engineering processes. The chapter discusses computer aided design programs, solid modeling, solidification simulation programs, and rapid prototyping.

This chapter discusses the progress that has been made in the development of superalloy operating temperatures, properties, and performance. It also provides forward-looking projections based on advances in process modeling, alloying, and production techniques.

This article discusses the steps in the primary processing of stainless steels: melting, refining, remelting, casting, and hot rolling. It provides information of the major categories of defects in hot rolled stainless steels, namely hot mill defects, inclusion-related defects, and hot ductility-related defects.

This chapter traces the history of steelmaking over three millennia, from the discovery of martensite in a mining tool dating from the twelfth century B.C. to the nineteenth century development of the Bessemer and Siemens processes. It also describes the work of early metallographers who discovered many phases and microstructures associated with steel and gave them their now familiar names. The chapter concludes with a brief discussion on the emergence of continuous casting and the subsequent development of strip casting production techniques.

Oxidation usually dominates high-temperature corrosion reactions, but under certain conditions, some alloys may be affected by nitridation as well. This chapter explains why nitridation occurs and how it attacks various metals, in some cases, penetrating deeper than oxidation. It provides images and data describing the nitridation process and its effects on metals and alloys in high-temperature air as well as NH3-H2O, NH3 and H2-N2-NH3, and N2 environments. It also includes test data showing that nitridation is more severe in a nitrogen atmosphere than an ammonia environment at 1090 °C (2000 °F).

Joining comprises a large number of processes used to assemble individual parts into a larger, more complex component or assembly. The selection of an appropriate design to join parts is based on several considerations related to both the product and the joining process. Many product design departments now improve the ease with which products are assembled by using design for assembly (DFA) techniques, which seek to ensure ease of assembly by developing designs that are easy to assemble. This chapter discusses the general guidelines for DFA and concurrent engineering rules before examining the various joining processes, namely fusion welding, solid-state welding, brazing, soldering, mechanical fastening, and adhesive bonding. In addition, it provides information on several design considerations related to the joining process and selection of the appropriate process for joining.

This article explains how alloying elements affect the properties and behaviors of electrical contacts. It describes the composition, strength, hardness, and conductivity of a wide range of contact alloys and composites based on silver, copper, gold, platinum, palladium, tungsten, and molybdenum, and related oxides and carbides.

This chapter explains how polymeric adhesives are applied to composite as well as metal parts, forming bonded structures. It describes surface preparation practices and techniques, epoxy selection and use, and bonding procedures.

Metallurgy, as discussed in this chapter, focuses on phases normally encountered in stainless steels and their characteristics. This chapter describes the thermodynamics and the three basic phases of stainless steels: ferrite, austenite, and martensite. Formation of the principal intermetallic phases is also covered. In addition, the chapter provides information on carbides, nitrides, precipitation hardening, and inclusions.

This chapter discusses the alloy composition, metallurgy, mechanical behavior, stabilization, texture, anisotropy, high-temperature properties, and corrosion and oxidation resistance of ferritic stainless steels.

The modeling and simulation activities in the field of high-pressure cold spray can be divided into two main parts: solid mechanics and fluid dynamics. This chapter focuses on these parts of modeling work in cold spray research. The discussion covers the objective, principal concepts, methods, and outcome of modeling and simulation of particle impact and of in-flight history of particles in cold spraying. The concept of integration of particle impact and fluid flow modeling to optimize cold spray deposition for a given material is also explained.

This chapter discusses the typical compositional ranges of superalloys, the role of major base metals (iron, cobalt, and nickel), and the effects of common alloying additions. It describes how chromium, aluminum, and titanium as well as refractory elements, grain-boundary elements, reactive elements, and oxides influence mechanical properties and behaviors. It also discusses the effect of trace elements.

This chapter reviews the basic chemistry of beryllium metals and compounds, including beryllium hydroxide, beryllium carbonates, beryllium fluoride, and beryllium chloride. It discusses the uses as well as application challenges of various forms of beryllium and includes information on their chemical properties and reactions.

This chapter presents the theory and practice associated with the application of thin films. The first half of the chapter describes physical deposition processes in which functional coatings are deposited on component surfaces using mechanical, electromechanical, or thermodynamic techniques. Physical vapor deposition (PVD) techniques include sputtering, e-beam evaporation, arc-PVD, and ion plating and are best suited for elements and compounds with moderate melting points or when a high-purity film is required. The remainder of the chapter covers chemical vapor deposition (CVD) processes, including atomic layer deposition, plasma-enhanced and plasma-assisted CVD, and various forms of vapor-phase epitaxy, which are commonly used for compound films or when deposit purity is less critical. A brief application overview is also presented.

This chapter explains how decarburization can occur during carburizing processes and how to limit the severity of its effects. It describes the reactions and conditions that result in a loss of carbon atoms and how they vary with changes in the physical metallurgy of the affected material and the processing environment. It examines the characteristic features of decarburized microstructures and assesses their influence on hardness, residual stresses, and fatigue and fracture behaviors. It also discusses corrective measures and practical considerations regarding their use.

This article presents best practices for the metallographic preparation of specimens produced via thermal spray coating methods. It outlines typical metallographic preparation process flow, highlighting important considerations for obtaining a clear and representative specimen suitable for characterization via examination techniques, such as optical or electron microscopy. The process flow includes preliminary resin infiltration, sectioning, mounting, grinding, and polishing. To aid in the identification and resolution of common issues during subsequent specimen analysis, the article presents common issues, along with causes and mitigation strategies. It describes the processes involved in the interpretation of the thermal spray coating microstructure.

Aluminum has many outstanding properties, leading it to be used for a wide range of applications. It offers excellent strength-to-weight ratio, good corrosion and oxidation resistance, high electrical and thermal conductivity, exceptional formability, and relatively low cost. This chapter examines the metallurgy, composition, processing, and mechanical properties of aluminum and its alloys, both cast and wrought forms. It also covers heat treating and basic temper designations, including annealed, work hardened, solution heat treated, and solution heated treated and aged. The chapter concludes with information on corrosion and oxidation resistance.