This chapter discusses the important role of metallography and the metallographer in predicting and understanding the properties of metals and alloys. Examples are presented of a metallographer working as part of a team in a research laboratory of a large steel company and a metallographer working alone at a small iron foundry. The three basic areas in all metallography laboratories are discussed: the specimen preparation area, the polishing/etching area, and the observation/micrography area. Important safety issues in a metallographic laboratory are also considered.

This chapter provides an overview of key elements in controlling the casting process, systems to confirm the quality of outgoing components, and the steps needed to launch a novel product. The discussion also provides information on process control tools and techniques; incoming material control; process control of sand preparation and system maintenance; metallic charge materials; product quality control; and melting, metallurgical, and mechanical testing.

Cast irons, like steels, are iron-carbon alloys but with higher carbon levels than steels to take advantage of eutectic solidification in the binary iron-carbon system. Like steel, heat treatment of cast iron includes stress relieving, annealing, normalizing, through hardening, and surface hardening. This chapter introduces solid-state heat treatment of iron castings, covering general considerations for heat treatment and discussing the processes, advantages, and disadvantages of heat treatment of cast iron.

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 defines steel castings, explains when to use steel castings, gives an overview of casting processes, and gives examples of suitable applications for cast steel parts.

Pattern equipment is the tooling utilized to form the mold cavity of a casting. This chapter first discusses the following factors that should be considered for determining the type of pattern equipment: number of castings to be produced, mold processes to be employed, dimensional tolerances required, casting design, and pattern cost. It also discusses the factors that should be considered when engineering a pattern. The chapter then presents the types of materials used for pattern construction. It provides an overview of patternmaker's shrinkage allowance. Finally, the chapter presents the factors that govern the space requirements for pattern storage.

This chapter presents the history of Plummer's classification system of stainless steels. One classification of Plummer's system is tabulated. The example shows the code number, the trade names and the producer of each alloy.

Nickel-base castings are produced from a group of alloys with compositions that are typically greater than 50% Ni and less than 10% iron. This chapter presents the casting compositions of nickel-base alloys. It then provides an overview of heat treatment, mechanical properties, and applications of nickel-base castings.