This article presents a general overview of outdoor weather aging factors, their effects on plastic materials, and the accelerated test methods that can be used to estimate the reaction of a plastic component during actual use. Weather and radiation factors that contribute to degradation in plastics include temperature variations, moisture, sunlight, oxidation, microbiologic attack, and other environmental elements. The article also describes the tests used to predict the behavior of a plastic material to outdoor exposure, discussing the use of xenon arc lamp for the weatherometer and fadeometer and the use of fluorescent sunlamp in test devices.

This article describes the mechanisms of moisture-induced damage in polymeric materials, covering the characteristics of important structural plastics; the effects of moisture on glass transition temperature, modulus, creep, and stress relaxation of plastic materials; and moisture-induced fatigue failure in composites. The effect of moisture on the mechanical properties of thermoset resins and thermoplastics are also discussed.

This chapter instructs the metallographer on the basic skills required to prepare a polished metallographic specimen. It is organized in a chronological sequence starting with the information-gathering process on the material being investigated, then moving on to sectioning, mounting, grinding, and polishing processes, and ending with methods used to properly store metallographic specimens. The discussion covers the preparation procedures, the materials being investigated, and equipment used to perform these procedures.

This chapter explains how to join beryllium parts using adhesive bonding and mechanical fastening techniques and discusses the advantages and disadvantages of each method. It describes the stresses that need to be considered when designing adhesive bonds, the benefits and limitations of different adhesives, and surface preparation requirements. It explains how adhesives are applied and cured and how curing times and temperatures affect bonding strength. It also discusses the use of bolts and rivets and the different types of joints that can be made with them.

Organic coatings (paints and plastic or rubber linings), metallic coatings, and nonmetallic inorganic coatings (conversion coatings, cements, ceramics, and glasses) are used in applications requiring corrosion protection. These coatings and linings may protect substrates by three basic mechanisms: barrier protection, chemical inhibition, and galvanic (sacrificial) protection. This chapter begins with a section on organic coating and linings, providing a detailed account of the steps involved in the coating process, namely, design and selection, surface preparation, application, and inspection and quality assurance. The next section discusses the methods by which metals, and in some cases their alloys, can be applied to almost all other metals and alloys: electroplating, electroless plating, hot dipping, thermal spraying, cladding, pack cementation, vapor deposition, ion implantation, and laser processing. The last section focuses on nonmetallic inorganic coatings including ceramic coating materials, conversion coatings, and anodized coatings.

This article covers the thermal analysis and thermal properties of engineering plastics with respect to chemical composition, chain configuration, and/or conformation of the base polymers. The thermal analysis techniques covered are differential scanning calorimetry, thermogravimetric analysis, thermomechanical analysis, and rheological analysis. The basic thermal properties covered include thermal conductivity, temperature resistance, thermal expansion, specific heat, and the determination of glass-transition temperatures. The article further describes various factors influencing the determination of service temperature of a material. Representative examples of different types of engineering thermoplastics are discussed in terms of structure and thermal properties. The article also discusses the thermal and related properties of thermoset resin systems.

This article presents best practices for the metallographic preparation of specimens produced via thermal spray coating methods. It outlines typical metallographic preparation process flow, highlighting important considerations for obtaining a clear and representative specimen suitable for characterization via examination techniques, such as optical or electron microscopy. The process flow includes preliminary resin infiltration, sectioning, mounting, grinding, and polishing. To aid in the identification and resolution of common issues during subsequent specimen analysis, the article presents common issues, along with causes and mitigation strategies. It describes the processes involved in the interpretation of the thermal spray coating microstructure.

This chapter explains how to prepare metallographic samples for light microscopy and how to anticipate and avoid related problems. It describes standard practices and procedures for sectioning, mounting, grinding, and polishing and identifies common defects along with their causes and cures. It also provides recommendations for handling specific materials and addresses safety concerns.

This chapter focuses on various factors to be considered at design stage to minimize corrosion. It begins by providing information on design considerations and general corrosion awareness. This is followed by a description of several factors influencing materials-component failure. Details on design and materials selection, which assist in controlling corrosion, are then provided. The chapter ends with a discussion on the design factors that influence corrosion.

This chapter discusses the advantages and disadvantages of sandwich and integral cocured structures, and the methods by which they are made. It begins by explaining where and how sandwich construction is used and why it is so efficient. It then describes the design and fabrication of honeycomb panels and foam cores along with their respective applications and unique attributes. The chapter also discusses the cocuring process and its use in fabricating unitized structures.

This chapter discusses corrosion prevention methods used with aluminum and its alloys. The methods range from relatively straightforward measures, such as proper handling and storage, to advanced early warning corrosion monitoring systems for military aircraft. The chapter summarizes the basic factors that influence design for corrosion resistance and discusses the use of conversion coatings, organic coatings, porcelain enameling, and electroplating. It also discusses corrosion monitoring methods used in chemical processing and refining industries.

This introductory article describes the various aspects of chemical structure and composition that are important to an understanding of polymer properties and their eventual effect on the end-use performance of engineering plastics, namely thermoplastics and thermosets. The most important properties of polymers and the most significant influences of structure on those properties are covered. The article also includes some general information on the classification and naming of polymers and plastics.

This article focuses on characterization techniques used for analyzing the physical behavior and chemical composition of thermoset resins, namely chromatography and infrared spectroscopy. The main purpose is to give sufficient detail to permit the reader understand a particular test technique and its value to the thermoset resin field. Epoxy resins are emphasized in the examples because they dominate the airframe and aerospace industries. The article also provides information on two categories of characterization of the processing behavior of thermoset. The first studies the thermal properties of reactive thermoset systems, while the second utilizes these thermal characteristics as the basis for monitoring and control during processing.

The design process is the first and most important step in corrosion control. Major savings in operating costs are possible by anticipating corrosion problems so as to provide proper design for equipment before assembly or construction begins. This chapter describes the role of the design team in producing a successful final design, general considerations in corrosion-control design, and design details that accelerate corrosion. The details that must be considered when attempting to control corrosion by design include plant/site location, plant environment, component/assembly shape, fluid movement, surface preparation and coating procedures, and compatibility, insulation, and stress considerations. Design solutions for specific forms of corrosion, namely crevice corrosion, galvanic corrosion, erosion-corrosion, and stress-corrosion cracking, are then considered. A brief section is devoted to the discussion on corrosion allowance used for steel parts subject to uniform corrosion. Finally, the chapter describes the design considerations for using weathering steels.

The chapter covers various aspects of biotribology in the context of dental care, orthopedic implants, haptics, eyewear, and stents and fixation devices. It also addresses the issue of biocompatibility and the effects of friction and contact pressure on skin.

This article discusses the effect of alloying on the composition, structure, properties, and processing characteristics of ordered intermetallic compounds, including nickel aluminides, iron aluminides, and titanium aluminides. It includes several data tables along with a list of typical applications.

This chapter describes the molecular structures and chemical reactions associated with the production of thermoset and thermoplastic components. It compares and contrasts the mechanical properties of engineering plastics with those of metals, and explains how fillers and reinforcements affect impact and tensile strength, shrinkage, thermal expansion, and thermal conductivity. It examines the relationship between tensile modulus and temperature, provides thermal property data for selected plastics, and discusses the effect of chemical exposure, operating temperature, and residual stress. The chapter also includes a section on the uses of thermoplastic and thermosetting resins and provides information on fabrication processes and fastening and joining methods.

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.

Corrosive environments can be broadly classified as atmospheric, underground/soil, water, acidic, alkaline, and combinations of these. Complicating matters is the fact that there are important variables, for example, pH, temperature, and the presence of biological organisms, that can significantly alter the response of the material in a given environment. This chapter provides a detailed account of all these types of corrosion affecting various industries, pointing out the connection between the characteristics of the corrosive environment that control corrosion behavior, the corrosion characteristics of various metals and materials systems, and the subsequent corrosion response.

This chapter discusses the most common causes and contributing factors for external corrosion and stress-corrosion cracking on oil and natural gas pipelines, as well as describes procedures for prevention, mitigation, detection, assessment, and repair. The forms of external corrosion covered include differential cell corrosion, microbiologically influenced corrosion, and stray current corrosion.