The basic concept for most methods of corrosion protection is to remove one or more of the electrochemical cell components so that the pure metal or metal alloy of interest will not corrode. Another widely used corrosion protection approach is to change the nature of the anode so that it becomes the cathode (cathodic protection). This chapter briefly reviews these methods of corrosion protection. The factors affecting corrosion behavior are covered. In addition, the chapter provides information on coatings and inhibitors, which are used in corrosion protection.

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 chapter covers a wide range of finishing and coating operations, including cleaning, honing, polishing and buffing, and lapping. It discusses the use of rust-preventative compounds, conversion coatings, and plating metals as well as weld overlay, thermal spray, and ceramic coatings and various pack cementation and deposition processes. It also discusses the selection and use of industrial paints and paint application methods.

This chapter discusses the use of coating methods and materials and their impact on corrosion and wear behaviors. It provides detailed engineering information on a wide range of processes, including organic, ceramic, and hot dip coating, metal plating and cladding, and the use of weld overlays, thermal spraying, and various deposition technologies.

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 chapter presents the history of stainless steel and provides an overview of the key concepts discussed in this book. This book covers a broad spectrum of historical events, many of which have not been touched upon in other works on stainless steel. It includes the discoveries of the various metallic elements that are used in the various alloys of stainless steel and discusses numerous experiments conducted during the 19th century with iron-base alloys containing chromium and carbon.

The case for using stainless steel in appliances of all types, whether they are commercial or residential, relates to it being able to provide the best value over the intended service life. This chapter describes some of the qualities in any material considered for food contact, namely chemical neutrality, biological neutrality, and cleanliness. A vast majority of stainless steel applications in commercial and residential equipment are also discussed.

This chapter is a compilation of terms and definitions related to surface engineering for corrosion and wear resistance.

This chapter describes the formability and forming characteristics of low-carbon sheet steels, coated sheet steels, stainless steels, and aluminum and magnesium alloys. It provides property data as well as flow stress curves for numerous grades of each material and explains how composition, microstructure, and processing methods influence forming behaviors.

This chapter begins with a brief review of the different types of surface treatments and coatings used in industry and their effect on properties and performance. It then discusses the importance of corrosion and wear treatments and the consequences of failing to properly implement them in critical industries such as mining, energy production, transportation, and mineral and chemical processing. The chapter also describes basic approaches to dealing with corrosion and wear in steel.

This chapter concerns itself with the tribology of ceramics, cermets, and cemented carbides. It begins by describing the composition and friction and wear behaviors of aluminum oxide, silicon carbide, silicon nitride, and zirconia. It then compares and contrasts the microstructure, properties, and relative merits of cermets with those of cemented carbides.

Corrosion can be defined as a chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties. This chapter describes the effects and economic impact of corrosion in major industrial plants. The emphasis in this chapter, as well as in other chapters in this book, is on aqueous corrosion, or corrosion in environments where water is present. The chapter describes the classification of various forms of corrosion based on the nature of the corrodent, mechanism of corrosion, and appearance of the corroded metal. It discusses five primary methods of corrosion control, namely, material selection, coatings, inhibitors, cathodic protection, and design. Examples of the opportunities in corrosion control and the means to implement a program to capitalize on those opportunities are presented in a table. The chapter concludes with varied sources of information pertaining to corrosion and corrosion prevention.

This chapter discusses the important aspects that a metallographer should understand in order to effectively reveal a microstructure. It begins by exploring etching response and how it can be a tool for revealing various microstructural features. The next part of the chapter discusses methods for revealing microstructure in the as-polished (unetched) specimen, then guidelines for selecting and using etchants when needed. The chapter discusses different types of etchants in terms of their ingredients, etching procedure, and major uses. The etchants discussed include basic etchants (nital and picral and their variations) and tint etchants for carbon and low-alloy steels and cast irons, and basic etchants for stainless steels. Finally, information is provided on different illumination methods (differential interference contrast and dark-field illumination) that can be used to highlight certain features in microstructures.

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 addresses the implications for increased aluminum usage on major issues such as climate change and solid waste management. The chapter also considers three approaches for decarbonizing aluminum-product production.

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 presents definitions of terms related to the metallurgy and metallographic study of irons and steels.

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.