ASTM and other standards organizations have developed a number of tests for evaluating stress-corrosion cracking (SCC) under various conditions. This appendix lists many of the SCC tests that have been approved for specific materials and operating environments.

Aluminum is the second most widely used metal in the world. It is readily available, offers a wide range of properties, and can be shaped, coated, and joined using a variety of methods. This chapter discusses some of the key attributes of wrought and cast aluminum alloys and the classifications, designations, and grades of available product forms. It also explains how aluminum alloys are used in aerospace, automotive, rail, and marine applications as well as in building and construction, electrical products, manufacturing equipment, packaging, and consumer durables such as appliances and furniture.

This chapter discusses the extrusion characteristics of relatively soft aluminum alloys. It begins by identifying alloy designations within the class and the types of extrusions made from them. It then explains how extruded shapes and cross-sections are defined and how to analyze and assess important process variables such as runout, extrusion pressure, ram speed, and butt thickness. It also provides best practices for various operations and explains how to identify and remedy common extrusion defects.

Nonferrous alloys are heat treated for a variety of reasons. Heat treating can reduce internal stresses, redistribute alloying elements, promote grain formation and growth, produce new phases, and alter surface chemistry. This chapter describes heat treatment processes and how nonferrous alloys respond to them. It provides information on aluminum, cobalt, copper, magnesium, nickel, and titanium alloys and their composition, microstructure, properties, and processing characteristics.

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.

This chapter discusses the extrusion characteristics of hard aluminum alloys, particularly those in the 5000 and 7000 series. It begins with a review of two studies, one showing how the extrudability of 7 xxx alloys varies with the presence and amount of different alloying elements, the other relating minimum wall thickness with circumscribing circle diameter. It then explains how oxides on either the billet or container complicate the control of extrusion as well as auxiliary processes and how material flow and the movement of trapped gasses in different regions of the extrusion can lead to defects and variations in strength. It also discusses the extrusion of aluminum matrix composites and explains how composite billets are made.

This article reviews weldability of aluminum alloys and factors that affect weld performance. It first addresses hot tears, which can form during the welding of various aluminum alloys. It then presents comparison data from different weldability tests and discusses the specific properties that affect welding, namely oxide characteristics; the solubility of hydrogen in molten aluminum; and its thermal, electrical, and nonmagnetic characteristics. The article addresses the primary factors commonly considered when selecting a welding filler alloy, namely ease of welding or freedom from cracking, tensile or shear strength of the weld, weld ductility, service temperature, corrosion resistance, and color match between the weld and base alloy after anodizing. A number of factors, both global and local, that influence the fatigue performance of welded aluminum joints are also covered.

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 composition, structures, properties, and behaviors of aluminum alloys and explains how they correspond to specific alloying elements. It begins with an overview of the general characteristics of wrought and cast aluminum alloys, the four-digit classification system by which they are defined, and the applications for which they are suited. It then explains how primary alloying elements, second-phase constituents, and impurities affect yield strength, phase formation, and grain size and how they induce structural changes that help refine certain alloys. The article also explains how primary alloying elements affect corrosion and wear behaviors and how they influence fabrication processes such as forming, forging, welding, brazing, and soldering.

This chapter discusses the characteristics, advantages, and disadvantages of nondestructive hardness testing methods for metals, including electromagnetic impulse testing, photothermal testing, scratch hardness testing, and ultrasonic contact impedance testing. It also discusses the use of ultrasound to determine the depth of hardening in a metal or alloy. The chapter reviews methods used to check and calibrate hardness testing machines and indenters and the use of hardness reference blocks for verification and calibration of test machines. It also addresses conversion of hardness values determined by one method to equivalent values for a different method.

The term heat treatable alloys is used in reference to alloys that can be hardened by heat treatment, and this chapter briefly describes the major types of heat treatable nonferrous alloys. The discussion provides a general description of annealing cold-worked metals and describes some of the common nonferrous alloys that can be hardened through heat treatment. The nonferrous alloys covered include aluminum alloys, cobalt alloys, copper alloys, magnesium alloys, nickel alloys, and titanium alloys.

This chapter describes some of the technological milestones of the early 20th century, including the invention of tungsten carbide tool steel, the use of age-hardening aluminum in the Wright Flyer , the development of a new heat treating process for aluminum alloys, and Ford’s pioneering use of weight-saving vanadium alloys in Model T cars. It explains how interest in chromium alloys spread throughout the world, spurring the development of commercial stainless steels. The chapter concludes with a bullet point timeline of early 20th century achievements and a brief assessment of more recent innovations.

Several limitations in achieving optimal gear performance with conventional nitriding have led researchers to work on a variety of novel and improved nitriding processes. Of these, ion/plasma nitriding offers some promising results, which are reviewed in this chapter. The chapter concludes with a case history describing the application of ion nitriding to an internal ring gear of an epicyclic gearbox.

This chapter describes the processes involved in alloy production, including melting, casting, solidification, and fabrication. It discusses the effects of alloying on solidification, the formation of solidification structures, supercooling, nucleation, and grain growth. It describes the design and operation of melting furnaces as well as melting practices and the role of fluxing. It also discusses casting methods, nonferrous casting alloys, and atomization processes used to make metal powders.

The formation of martensite is characterized by its athermal transformation kinetics, crystallographic features, and development of fine structure. This chapter describes the diffusionless, shear-type transformation of austenite to martensite and how it affects the morphology and microstructure of heat-treatable carbon steels. It also provides information on lath and plate martensite and how they differ in structure and deformation properties.

Induction heating, in most applications, is used to selectively heat only a portion of the workpiece that requires treatment. This chapter covers the basic principles, features, and metallurgical aspects of induction heating. The discussion includes the conditions required for induction heating and quenching, the use of magnetic flux concentrators to improve the efficiency of surface heating, and the quenching systems used for induction hardening. The discussion also provides information on time-temperature dependence in induction heating, workpiece distortion in induction surface hardening, residual stresses after induction surface hardening and finish grinding, and input and output control of steel for induction surface hardening of gears.