Any forming process that converts stored energy to plastic deformation in less than a few milliseconds is considered a high-velocity or impulse forming process. This chapter discusses the operating principles, equipment, and applications of the most common high-rate forming processes, including high-velocity hydroforming, high-velocity mechanical forming, and electromagnetic or energy-based forming.

This chapter addresses the basic concepts important to understanding corrosion of metals. It begins with an overview of the three types of behaviors that a metal exhibits when immersed in an environment and of the four requirements of a corrosion cell. The chapter then covers the important characteristics of metals with respect to corrosion, namely the metallurgical characteristics, the inherent tendency to corrode, and the tendency to form insoluble corrosion products. The important characteristics of aqueous solutions with respect to corrosion are then addressed. The characteristics include: conductivity of the solution, acidity and alkalinity, oxidizing power, degree of ionization, and solubility in the solution. These characteristics, in combination with the characteristics of the metal, will determine the corrosion behavior of a metal/environment combination. The chapter concludes with a section on the determination of corrosion rates and corrosion rate allowances.

The temperature and atmosphere conditions must be precisely controlled in order to achieve the desired metallurgical results during heat treating operations. In order to ensure the repeatability of operation, a heat treating system must have the necessary sensors, timers, and variable (temperature, atmosphere, etc.) controllers to hold the process within prescribed or specified limits. This chapter discusses temperature and atmosphere sensors used in a heat treating system. The temperature sensors covered are contact and noncontact types. The atmosphere sensors covered are oxygen probe, dew point, and infrared. The chapter concludes with an overview of the development of integrated control systems.

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.

This chapter provides a discussion of nitriding furnace equipment and control systems. The discussion covers the essential design criteria of the furnace, types of nitriding furnaces, insulation for the reduction of furnace heat losses, and factors influencing furnace configuration and design. It also covers the processes involved in the construction and maintenance of retorts, methods for sealing a retort to prevent ammonia leaks, and safety precautions to be taken while using ammonia. Further, the chapter provides information on the factors for choosing a heating medium and discusses the processes involved in controlling temperature, gas dissociation, oxygen probes, and nitriding sensors.

This chapter explores the behavior of stainless steel in media that promote corrosion. The forms of corrosion covered are uniform corrosion, atmospheric corrosion, localized corrosion, pitting corrosion, crevice corrosion, and grain boundary corrosion. The chapter discusses the influence of material and environmental variables on stress-corrosion cracking (SCC) and the mechanisms proposed for SCC in stainless steel, comparing the mechanism of SCC with hydrogen embrittlement. In addition, it provides information on biocorrosion and microbiologically induced corrosion in ambient aqueous environments.

Nonferrous metals are of commercial interest both as engineering materials and as alloying agents. This chapter addresses both roles, discussing the properties, processing characteristics, and applications of several categories of nonferrous metals, including light metals, corrosion-resistance alloys, superalloys, refractory metals, low-melting-point metals, reactive metals, precious metals, rare earth metals, and metalloids or semimetals. It also provides a brief summary on special-purpose materials, including uranium, vanadium, magnetic alloys, and thermocouple materials.

This chapter discusses three measurements parameters: temperature, strain, and magnetic field strength. It stresses the measurement of temperature because it is the primary variable in nearly all low-temperature material properties. The chapter contains information on methods and auxiliary materials. Areas of frequent concern, such as thermal contact, heat leak, thermal anchoring, thermal conductivity of greases, insulators, lead wires, ground loops, and feedthroughs are also reviewed. The chapter provides an overview and historical development of temperature scales because the practical use of all thermometers is associated with some approximation of the thermodynamic temperature scale. A short section is devoted to types of temperature measuring devices. The characteristics of commercially available resistance-type strain gauges at low temperatures are stressed.

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 discusses the selection, use, and integration of methods to control process variables in induction heating, including control of workpiece and processing temperature and materials handling systems. The discussion of temperature control includes a review of proportional controllers and heat-regulating devices. Integration of control functions is illustrated with examples related to heating of steel slabs, surface hardening of steel parts, vacuum induction melting for casting operations, and process optimization for electric-demand control. Distributed control within larger manufacturing systems is discussed. The chapter also covers nondestructive techniques for process control and methods for process simulation.

This appendix is a compilation of terms and definitions related to corrosion.

This chapter covers the corrosion behavior of beryllium in aqueous environments. It describes the chemical reactions that drive the corrosion process, the conditions required for equilibrium, and the factors that affect corrosion resistance. It discusses the stability of the native oxides that form on the surface of beryllium and their ability to withstand acids, bases, and corrosive agents found in rain and seawater. It explains how carbides, inclusions, ions, and impurities contribute to corrosion damage, particularly pitting, and how corrosion reduces the ductility and fracture strength of certain beryllium alloys.

This chapter provides a thorough introduction to the electrochemical thermodynamics that govern electrode reactions associated with corrosion. It begins with a review of the thermodynamic criteria for the stability of chemical reactions based on Gibbs free energy and explains how energies of formation are determined using the oxidation of iron as an example. It then considers how iron reacts with hydrochloric acid, explaining how it can be expressed as two half reactions modeled as electrodes in an electrochemical cell. It goes on to describe the chemical reactions occurring at each electrode, accounting for different variables, mechanisms, and electrochemical effects. The chapter concludes with an in-depth review of Pourbaix diagrams, explaining what they reveal about the stability of metal-water systems and the formation of corrosion products.

This chapter is a compilation of terms and definitions related to corrosion in the petrochemical industry.