This chapter discusses the composition, properties, and uses of crystalline ceramics, glasses, clay, and concrete mixes. It also discusses the carbon structure of diamond, graphite, fullerenes, and nanotubes.

The properties of cast iron are determined primarily by the form of carbon they contain, which in turn, is controlled by modifying compositions and cooling rates during casting. Certain alloys (such as Si, Al, Ni, Co, and Cu) promote graphite formation, while others (such as S, V, Cr, Sn, Mo, and Mn) promote the formation of cementite. This chapter examines the relative potencies of these alloys and their effect on microstructure. It covers the five most common commercial cast irons, including white, gray, ductile, malleable, and compacted graphite, describing their compositional ranges, distinguishing features, advantages, limitations, and applications.

All materials are susceptible to corrosion or some form of environmental degradation. Although no single material is suitable for all applications, usually there are a variety of materials that will perform satisfactorily in a given environment. The intent of this chapter is to review the corrosion behavior of the major classes of metals and alloys as well as some nonmetallic materials, describe typical corrosion applications, and present some unique weaknesses of various types of materials. It also aims to point out some unique material characteristics that may be important in material selection, and discuss, where appropriate, the characteristic forms of corrosion that attack specific materials. The materials addressed in this chapter include carbon steels, weathering steels, and alloy steels; nickel, copper, aluminum, titanium, lead, magnesium, tin, zirconium, tantalum, niobium, and cobalt and their alloys; polymers; and other nonmetallic materials, including rubber, carbon and graphite, and woods.

This article discusses the composition and morphology of compacted graphite (CG) iron relative to that of gray and ductile iron. It explains that the graphite in CG iron is intermediate in shape between the spheroidal graphite found in ductile iron and the flake graphite in gray iron, giving it distinct advantages in a number of applications. The article also discusses the role of melt treatment elements and explains how alloying and heat treatment affect tensile strength, hardness, toughness, and ductility.

A spheroidized structure, which consists of spherically shaped cementite in a matrix of ferrite, is often desired in the production of steel, whether to improve properties, such as machinability and ductility, or accommodate subsequent hardening treatments. This chapter discusses the spheroidization of normalized and annealed steels by heating at subcritical temperatures. It explains how lamellar pearlite and proeutectoid cementite transform when heated and how deformation prior to heating affects both the mechanism and kinetics of spheroidization. It also explains how austenitizing contributes to the production of spheroidal transformation products and why secondary graphitization sometimes occurs.

This chapter discusses the ambient-temperature corrosion characteristics of aluminum metal-matrix composites (MMCs), including composites formed with boron, graphite, silicon carbide, aluminum oxide, and mica. It also discusses the effect of stress-corrosion cracking on graphite-aluminum composites and the use of protective coatings and design criteria for corrosion prevention.

In an attempt to explain the stresses encountered in the plastics industry, this article first defines the different types of internal stresses in amorphous polymers. Each type of thermal stress is then discussed in detail, with reference to the mechanism of generation and the effect on engineering properties. Methods of detecting and measuring internal stresses are also presented. The article then describes the combined effects of thermal stresses and orientation that result from processing conditions. Finally, it discusses numerous aspects of physical aging and the use of high-modulus graphite fibers in amorphous polymers.

This chapter focuses on some of the facts of mechanical properties of metals that must be understood to successfully undertake the task of failure analysis. The discussion begins by describing the causes and effects of elastic and plastic deformation followed by a section describing the effects of temperature variations on mechanical properties, both in tension and in compression. The nonlinear behavior of gray cast iron caused by the graphite flakes is then described. Finally, the effect of stress concentrations on high-strength metals is considered.

The commercial relevance of cast irons is best understood in the context of the iron-carbon phase diagram, where their composition places them near the eutectic point, which sheds light on why they melt at lower temperatures than steel and why they can be cast into more intricate shapes. This chapter examines these unique properties and how they are derived. It begins by describing the basic metallurgy of cast iron, focusing on the eutectic reaction. It explains how to control the reaction and thus properties of cast iron by overcooling and inoculation. The chapter also discusses composition, microstructure, heat treatments, and the classification and casting characteristics of white, gray, ductile, malleable, compacted graphite, and special cast irons.

Casting is the most economical processing route for producing titanium parts, and unlike most metals, the properties of cast titanium are on par with those of wrought. This chapter covers titanium melting and casting practices -- including vacuum arc remelting, consumable electrode arc melting, electron beam hearth melting, rammed graphite mold casting, sand casting, investment casting, hot isostatic pressing, weld repair, and heat treatment -- along with related equipment, process challenges, and achievable properties and microstructures. It also explains how titanium parts are produced from powders and how the different methods compare with each other and with conventional production techniques. The methods covered include powder injection molding, spray forming, additive manufacturing, blended elemental processing, and rapid solidification.

Boiler tubes operating at high temperatures under significant pressure are vulnerable to stress rupture failures. This chapter examines the cause, effect, and appearance of such failures. It discusses the conditions and mechanisms that either lead to or are associated with stress rupture, including overheating, high-temperature creep, graphitization, and dissimilar metal welds. It explains how to determine which mechanisms are in play by interpreting fracture patterns and microstructural details. It also describes the investigation of several carbon and low-alloy steel tubes that failed due to stress rupture.

This chapter covers the tribological properties of stainless steel and other corrosion-resistant alloys. It describes the metallurgy and microstructure of the basic types of stainless steel and their suitability for friction and wear applications and in environments where they are subjected to liquid, droplet, and solid particle erosion. It also discusses the tribology of nickel- and cobalt-base alloys as well as titanium, zinc, tin, aluminum, magnesium, beryllium, graphite, and different types of wood.

This chapter discusses the effect of composition and cooling rate on the microstructure and properties of cast irons and explains how they differ from steel. It describes the conditions under which white, gray, mottled (chilled), and nodular (ductile) cast irons are produced, and examines the growth mechanisms and structural details that set them apart. It also discusses the formation of compacted (vermicular) graphite and malleable iron, and compares and contrasts the composition, properties, and heat treatment of whiteheart and blackheart malleable types.

This article discusses the metallurgy and properties of ductile cast iron. It begins with an overview of ductile or spheroidal-graphite iron, describing the specifications, applications, and compositions. It then discusses the importance of composition control and explains how various alloying elements affect the properties, behaviors, and processing characteristics of ductile iron. The article describes the benefits of nickel and silicon additions in particular detail, explaining how they make ductile iron more resistant to corrosion, heat, and wear.

This article explains how malleable iron is produced and how its microstructure and properties differ from those of gray and ductile iron. Malleable iron is first cast as white iron then annealed to convert the iron carbide into irregularly shaped graphite particles called temper carbon. Although malleable iron has largely been replaced by ductile iron, the article explains that it is still sometimes preferred for thin-section castings that require maximum machinability and wear resistance. The article also discusses the annealing and alloying processes by which these properties are achieved.

This appendix lists the designations, commercial sources, and suppliers of different types of fibers and resins.

This chapter discusses the composition, properties, microstructure, grain formation, and fracture behavior of gray, white, ductile, and malleable cast iron and how these critical factors are affected when iron is heated to different temperatures prior to or during solidification.

This chapter covers the friction and wear behaviors of cast irons. It describes the microstructure and metallurgy of gray, white, malleable, and ductile cast irons, their respective tensile properties, and their suitability for applications involving friction, various types of erosion, and adhesive and abrasive wear.

This chapter discusses ferrous metals, including low-carbon steels, stainless steels, and cast irons. It also provides information on hardening and hardenability and the tempering process.

This chapter introduces the metallographer to the various types of steels and cast irons and explains how they are classified and defined. Classification and designation details are provided for plain carbon steels, alloy steels, and gray, white, ductile, and malleable cast irons.