This chapter discusses recycling processes used for metals, plastics, rubber, glass, and paper. Is also describes the advantages of recycled materials.

Improvement in processing, material substitution, light weighting, and recycling have contributed immensely to the cause of sustainability in the materials cycle. This chapter discusses some of the key indicators of sustainability that have direct relevance to advanced high-strength steels (AHSS) used in a vehicle. The discussion covers the major contributor to greenhouse gas emissions, production routes for manufacturing crude steel, and an optimized index guideline for selecting the best material. Details on the benefits of AHSS on the life cycle of vehicles are provided. The chapter also provides information on recycling and the economics of AHSS.

This chapter describes a process for recovering beryllium from industrial waste associated with beryllium-copper production. It presents several detailed flowsheets along with typical operating parameters such as flow rates, chemical concentrations, particle sizes, and compositional ranges.

This chapter first introduces the various factors that may alter the physical and mechanical properties of aluminum castings that are addressed in the other chapters in the book. Then, it presents the historical development of aluminum castings, followed by a discussion on the advantages and limitations of aluminum castings. Next, the chapter describes the major trends that are influencing the increased use of aluminum castings. Finally, it introduces the considerations involved in the selection of an appropriate aluminum alloy and casting process for a given application.

Casting is one of the most economical manufacturing processes for providing shape to components of machinery and is used in a wide range of industries. This chapter is a brief account of the advantages, applications, limitations, and market growth of aluminum casting. It also provides information on the process of conversion of steel and iron parts to aluminum.

This chapter discusses the engineering significance of steel and briefly describes its chemical composition, crystal structure, Fe-C phases, and associated characterization techniques.

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 rise of steel minimills in the late 1960s through the leadership of F. Kenneth Iverson and Gerald Heffernan. The discussion covers the development of processes for flat products, flanged beams, and railroad rails. The chapter also covers the growth of the minimill industry along with the consolidation of the industry into large corporations. The chapter ends by providing information on novel processes developed for making iron.

This chapter describes some of the chemical processes that have been developed to extract beryllium from different types of ore. It covers the Kjellgren-Sawyer sulfate method, the Degussa method, Copaux-Kawecki fluoride extraction, solvent extraction, and leaching and settling. It also provides information on electrolytic extraction and the use of electrorefining.

This chapter discusses the advantages, limitations, and applications of various aluminum casting processes, namely green sand casting process, air set or no-bake molding process, vacuum molding process, evaporative foam casting process, and die casting process. The processes covered also include gravity permanent molding, low-pressure permanent molding, counter pressure, squeeze casting, investment casting, rapid prototype casting, cast forge hybrid, and semisolid metal processes.

Most iron and steel castings are produced by casting into sand molds. Sand cores are needed primarily to form hollow cavities in castings for collapsibility and ease of cleaning. This chapter begins with an overview of the classification of molding and core-making systems. This is followed by a section discussing the process involved in shell molding, along with its applications. A brief description of the special casting processes is then presented. Next, the chapter discusses the processes involved in core making. Further, it provides an overview of casting manufacturing. Finally, the chapter provides information on the factors that influence a casting facility layout.

This chapter discusses the effect of fiber length and orientation on the strength and stiffness of discontinuous-fiber composites. It also describes several fabrication processes, including spray-up, compression molding, reaction injection molding, and injection molding.

This chapter is a brief account of the composition, microstructures, heat treatment, deformation mechanisms, mechanical properties, formability, and special attributes of austenitic stainless steels.

This chapter discusses the use of phase diagrams in alloy design, processing, and performance assessment. The examples cover both ferrous and nonferrous metals and a variety of goals and objectives. The chapter also identifies limitations and pitfalls associated with the use of phase diagrams.

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.

Engineers have many materials to choose from when dealing with weight-related design constraints. The list includes aluminum, beryllium, magnesium, and titanium alloys as well as engineering plastics, structural ceramics, and polymer-, metal-, and ceramic-matrix composites. This chapter provides a brief overview of these lightweight materials, discussing their primary advantages along with their properties, behaviors, and limitations.