This chapter discusses the setup and use of a transmission electron detector in a typical scanning electron microscope (SEM). It describes the arrangement and function of the primary components in the detector, following the signal path from the sample to a micromirror array where it is directed by the user to either a CMOS sensor (to record diffraction patterns) or a photomultiplier tube (to observe real-space images). The chapter discusses some of the nuances of digital imaging and diffraction and includes examples in which transmission electron detectors are used to analyze gold films, carbon nanotubes, zeolite sheets, and monolayer graphene. It also describes emerging techniques, including four-dimensional STEM, thermal diffuse scattering, energy filtering, aberration correction, and atomic resolution imaging.

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.

This chapter discusses the advantages and limitations of 3D printing technology for the production of batteries and supercapacitors. It explains how 3D printing methods facilitate the build of microdevices with hierarchical nanoarchitectures and controlled microstructure. It also reviews recent progress in fabricating electrodes and electrolytes using 3D-printed functional materials.

This chapter, presented in a question-and-answer format, covers many practical aspects of high-entropy alloys (HEAs). It provides clear and concise answers to more than 50 questions, imparting knowledge on alloying elements, heat treatments, diffusion mechanisms, phase formation, lattice distortion, crystal and grain structures, structure-property relationships, microstructure control, and characterization methods. It likewise explains how to calculate the effect of strengthening processes on the mechanical properties of HEAs and offers insights on how to balance strength, ductility, and density for specific applications. It also provides information on twinning behaviors, stacking faults, elastic properties, coating and film deposition methods, manufacturing challenges, and the use of computational techniques for alloy design.

This chapter discusses the growing role of powder metallurgy in the production of intermetallic, Heusler, and high-entropy alloys. It reviews the challenges of producing these materials by conventional methods and the advantages of sinter-based PM techniques. It explains why PM processes are better suited for complex materials than casting and compares the properties of intermetallic, Heusler, and high-entropy alloys prepared by casting and powder-metal techniques.

This chapter describes the properties and attributes of various classes of metalworking lubricants, including mineral oils; natural oils, fats, derivatives, and soaps; synthetic fluids (olefins, esters, polyglycols, ionic liquids); compounded lubricants (oils, greases, fats); aqueous lubricants (emulsions, synthetics, solutions); and a wide range of coatings and carriers. It also discusses solid-film lubricants (oxide films, polymer films, layer-lattice compounds) and environmental and safety concerns.

This chapter provides an overview of sintering techniques and the microstructures and properties that can be achieved in different material systems. It covers conventional furnace sintering, microwave and laser sintering, hot and hot-isostatic pressing, and spark plasma sintering. It describes the advantages and disadvantages of each method, the mechanisms involved, and the effect of sintering parameters on the density, grain size, and mechanical properties of titanium and tungsten heavy alloys, stainless steel, cemented carbides, ceramics, composites, and rare earth magnets.

Rolling is unique in that it cannot be conducted without friction. Friction draws the workpiece into the roll gap and facilitates its passage through the deformation zone. This chapter provides an overview of the mechanics and tribology of flat rolling processes and explains how various aspects of the theory apply to shape rolling as well. It derives numerous equations and models to help quantify the forces, torque, and power involved in rolling operations and the associated heating, slip, strain distribution, and deformation in both the workpiece and rolls. It describes the friction and wear that occur in hot and cold rolling under hydrodynamic and mixed-film lubrication; the influence of viscosity, film thickness, rolling speed, interface pressure, pass reduction, and lubricant breakdown; and the effect of surface finish and defects. The chapter also provides best practices for evaluating, applying, and treating lubricants for industrially important materials including iron-base, nickel-base, and aluminum alloys.

This chapter covers the mechanics and tribology of sheet metalworking processes, including shearing, bending, spinning, stretching, deep drawing, ironing, and hydroforming. It explains how to determine friction, wear, and lubrication needs based on process forces, temperatures, and strains and the effects of strain hardening on workpiece materials. It presents test methods for evaluating process tribology, describes lubrication and wear control approaches, and discusses the factors, such as surface roughness, lubricant breakdown, and adhesion, that can lead to galling and other forms of wear. It also provides best practices for selecting, evaluating, and applying lubricants for specific materials, including steels, stainless steels, and aluminum and magnesium alloys.

In contrast to most plastic deformation processes, the shape of a machined component is not uniquely defined by the tooling. Instead, it is affected by complex interactions between tool geometry, material properties, and frictional stresses and is further complicated by tool wear. This chapter covers the mechanics and tribology of metal cutting processes. It discusses the factors that influence chip formation, including tool and process geometry, cutting forces and speeds, temperature, and stress distribution. It reviews the causes and effects of tool wear and explains how to predict and extend the life of cutting tools based on the material of construction, the use of cutting fluids, and the means of lubrication. It presents various methods for evaluating workpiece materials, chip formation, wear, and surface finish in cutting processes such as turning, milling, and drilling. It also discusses the mechanics and tribology of surface grinding and other forms of abrasive machining.