This article discusses the role of alloying in the production and use of titanium. It explains how alloying elements affect transformation temperatures, tensile and creep strength, elasticity, hardness, and corrosion behaviors. It provides composition and property data for commercial grades of titanium, addresses processing issues, and identifies operating environments where certain titanium alloys are susceptible to stress-corrosion cracking.

Titanium is a lightweight metal used in a growing number of applications for its strength, toughness, stiffness, corrosion resistance, biocompatibility, and high-temperature operating characteristics. This chapter discusses the applications, metallurgy, properties, compositions, and grades of commercially pure titanium and alpha and near-alpha, alpha-beta, and beta titanium alloys. It describes primary and secondary fabrication processes, including melting, forging, forming, heat treating, casting, machining, and joining as well as powder metallurgy and direct metal deposition. It also compares and contrasts the properties of wrought, cast, and powder metal titanium products and discusses corrosion behaviors.

This chapter discusses various factors pertinent to the prevention of corrosion in alloys for petroleum applications and reviews the selection of stainless steels for petroleum applications, including oil country tubular goods, line pipe, offshore platforms, liquefied natural gas vessels, and refinery equipment.

Magnesium, by volume, is two-thirds the weight of aluminum and one-quarter the weight of steel. It also has good damping capacity, giving it an edge over other metals in high-vibration environments. This chapter discusses the basic metallurgy, alloy designations, compositions, and mechanical properties of cast and wrought magnesium alloys. It also describes the processes used to produce magnesium parts, the causes and effects of corrosion, and the use of protective coatings and treatments.

This chapter provides basic engineering information on aluminum alloys with an emphasis on their use in applications where weight is a significant design factor. It discusses the advantages and limitations of various types of aluminum along with their compositions, designations, and achievable strengths. It explains how some alloys are hardened through solution strengthening and cold working, while others are strengthened by precipitation hardening. It also describes production and fabrication processes such as melting, casting, rolling, forging, forming, extruding, heat treating, and joining, and includes a section on the causes and effects of corrosion and how they are typically controlled.

This article discusses the role of alloying in the production and use of carbon and low-alloy steels. It explains how steels are defined and selected based on alloy content and provides composition and property data for a wide range of designations and grades. It describes the effect of alloying on structure and composition and explains how alloy content can be controlled to optimize properties and behaviors such as ductility, strength, toughness, fatigue and fracture resistance, and resistance to corrosion, wear, and high-temperature creep. It also examines the effect of alloying on processing characteristics such as hardenability, formability, weldability, machinability, and temper embrittlement. In addition, the article provides an extensive amount of engineering data with relevance in materials selection.

This chapter discusses the metallurgy, phase structure, thermal processing, and applications of martensitic stainless steels. The phenomenon of martensite formation is explained. A table listing the compositions of martensitic stainless steels is also presented.

This chapter covers a wide range of finishing and coating operations, including cleaning, honing, polishing and buffing, and lapping. It discusses the use of rust-preventative compounds, conversion coatings, and plating metals as well as weld overlay, thermal spray, and ceramic coatings and various pack cementation and deposition processes. It also discusses the selection and use of industrial paints and paint application methods.

This chapter covers basic machining and assembly operations, with an emphasis on hole preparation for mechanical fasteners. It describes manual, power feed, and automated drilling techniques as well as reaming and countersinking. It discusses various types of fasteners, including rivets, pins, and bolts, along with selection factors and special considerations for composite joints. It also includes information on interference-fit and blind fasteners as well as trimming operations, general assembly considerations, and sealing and painting procedures.

Superalloys are susceptible to damage from a variety of surface contaminants. They may also require special surface finishes for subsequent processing steps such as coating applications. This chapter describes some of the cleaning and finishing procedures that have been developed for superalloys and how they work. It discusses the effect of metallic contaminants, tarnish, oxide, and scale and how they can be detected and removed. It also discusses chemical and mechanical surface finishing techniques and where they are used, and presents several application examples.

This chapter consists of three parts. The first part provides data and guidelines for selecting materials and processing routes. It compares the basic properties of metals, ceramics, and polymers, identifies important measures of performance, and discusses manufacturing processes and their compatibility with specific materials. The chapter then presents general guidelines for selecting lightweight materials, and concludes with a review of lightweight metals, plastics, and composites used in automotive applications.

In forgings of both ferrous and nonferrous metals, the flaws that most often occur are caused by conditions that exist in the ingot, by subsequent hot working of the ingot or the billet, and by hot or cold working during forging. The inspection methods most commonly used to detect these flaws include visual, magnetic particle, liquid penetrant, ultrasonic, eddy current, and radiographic inspection. This chapter provides a detailed discussion on the characteristics, process steps, applications, advantages, and limitations of these methods. It also describes the flaws caused by the forging operation and the principal factors that influence the selection of a nondestructive inspection method for forgings.

This chapter discusses the types of fibers and matrix materials used in ceramic matrix composites and the role of interfacial coatings. It describes the methods used to produce ceramic composites, including powder processing, slurry infiltration and consolidation, polymer infiltration and pyrolysis, chemical vapor infiltration, directed metal oxidation, and liquid silicon infiltration.

Ceramics normally have high melting temperatures, excellent chemical stability and, due to the absence of conduction electrons, tend to be good electrical and thermal insulators. They are also inherently hard and brittle, and when loaded in tension, have almost no tolerance for flaws. This chapter describes the applications, properties, and behaviors of some of the more widely used structural ceramics, including alumina, aluminum titanate, silicon carbide, silicon nitride, zirconia, zirconia-toughened alumina (ZTA), magnesia-partially stabilized zirconia (Mg-PSZ), and yttria-tetragonal zirconia polycrystalline (Y-TZP). It also provides information on materials selection, design optimization, and joining methods, and covers every step of the ceramic production process.

This chapter provides an overview of the possible mechanisms of failure for heat treated steel components and discusses the techniques for examining fractures, ductile and brittle failures, intergranular failure mechanisms, and fatigue. It begins with a description of the general sources of component failure. This is followed by a section on the stages of a failure analysis, which can proceed one after the other or occur at the same time. These stages of analysis are collection of background data, preliminary visual examination, nondestructive testing, selection and preservation of specimens, mechanical testing, macroexamination, microexamination, metallographic examination, determination of the fracture mechanism, chemical analysis, exemplar testing, and analysis and writing the report. The chapter ends with a discussion on various processes involved in the determination of the fracture mechanism.

This chapter describes sheet metal forming operations, including cutting, blanking, piercing, and bending as well as deep drawing, spinning, press-brake and stretch forming, fluid forming, and drop hammer and electromagnetic forming. It also discusses the selection and use of die materials and lubricants along with superplastic forming techniques.