This chapters discusses the considerations involved in the qualification and analysis of induction hardening treatments. The discussion covers material selection and prior heat treatment, hardness and case depth, frequency selection, power density and heating time, part and process tolerances, geometrical effects, quenchant selection, coil design, and work-handling equipment. The chapter also presents several examples, walking readers though each step, and discusses the development of setup instructions and operating procedures.

Casting quality and consistency need to be carefully controlled. This chapter discusses the procedures that describe the process and product quality controls. In addition, it provides information on quality assurance programs.

Root cause of failure in automotive electronics cannot be explained by the failure signatures of failed devices. Deeper investigations in these cases reveals that a superimposition of impact factors, which can never be represented by usual qualification testing, caused the failure. This article highlights some of the most frequent early life failure types in automotive applications. It describes some of the critical things to be considered while handling packages and printed circuit board layout. The article also provides information on failure anamnesis that shows how to use history, failure signatures, environmental conditions, regional failure occurrences, user profile issues, and more in the failure analysis process to improve root cause findings.

This appendix provides reference tables listing weldability of cast irons, steels, and nonferrous metals. A process selection table for arc welding carbon steels is included, and recommended preheat and interpass temperature tables are also presented. This appendix includes information on qualification codes and standards.

The tensile test provides a relatively easy, inexpensive technique for developing mechanical property data for the selection, qualification, and utilization of metals and alloys in engineering service. The tensile test requires interpretation, and interpretation requires a knowledge of the factors that influence the test results. This chapter provides a metallurgical perspective for such interpretation. The topics covered include elastic behavior, anelasticity, damping, proportional limit, yield point, ultimate strength, toughness, ductility, strain hardening, and yielding and the onset of plasticity. The chapter describes the effects of grain size on yielding, effect of cold work on hardness and strength, and effects of temperature and strain-rate on the properties of metals and alloys. It provides information on true stress-strain relationships and special tests developed to measure the effects of test/specimen conditions. Finally, the chapter covers the characterization of tensile fractures of ductile metals and alloys.

This chapter covers the basics of weldability of cast steels such as carbon and low alloy steels, corrosion-resistant high alloy steels, nickel-base alloys, heat-resistant high alloy steels, and wear-resistant high austenitic manganese steels. It provides an overview of weld overlay and hard facing; cast-weld construction; and plasma arc cutting and plasma arc welding. The chapter discusses different types of welding processes. These include shielded metal-arc welding, air carbon arc cutting process, gas tungsten-arc welding, gas metal-arc welding process, flux-cored arc welding, submerged arc welding, and electroslag and electro-gas welding.

This chapter describes how ultrasonic testing came to be a viable method for evaluating intergranular stress-corrosion cracking (SCC) in large-diameter stainless steel pipe welds in boiling water reactor service. Intergranular SCC can be difficult to detect using nondestructive evaluation (NDE) techniques because of its treelike branching pattern and its location in the heat-affected zone within the weld. As the chapter explains, by optimizing excitation and reflected waveforms, switching to dual-element sensing, properly orienting the scanning path, and using crack-tip diffraction and amplitude-drop techniques, the height, length, and location of intergranular cracks can be accurately determined anywhere along the walls of the pipe as well as in weld areas.

This chapter discusses the role of standards and specifications for steel castings. It defines specifications and discusses how certification, testing, examination, methods, practices, procedures, compositions, properties, facilities, statistical process control, and documentation relate to codes and standards. The chapter describes processes involved in the selection of specifications for steel castings. Further, it provides information on the cost of specifications.

After pouring, castings are allowed to solidify and cool. They are later removed from the molds in the shakeout operation. A series of activities then follow, which are generally referred to as finishing and heat treatment. These activities can be broadly categorized as shakeout, abrasive blast cleaning, removal of risers, ingates, and discontinuities, rough inspection, removal of discontinuities, finishing welding, heat treatment, and final visual, dimensional, and NDT inspection. This chapter provides a detailed discussion on these activities.

This chapter examines the stress-corrosion cracking (SCC) failure of stainless steel pipe welds in boiling water reactor (BWR) service. It explains where most of the failures have occurred and provides relevant details about the materials of construction, fabrication techniques, environmental factors, and cracking characteristics. It includes a model that accounts for the primary factors involved in intergranular SCC, namely, tensile stresses above the yield stress of the base material, a sensitized microstructure, and reactor cooling water. The chapter also provides proven remedies and mitigation techniques corresponding to a wide range of issues related to stress, sensitization, and operating conditions.

This chapter concentrates almost exclusively on inspection techniques related to pressure vessels and pipework. The discussion covers the general aspects associated with inspection and the key factors relevant to it. In addition, the chapter addresses processes involved in data collection and management, namely data acquisition, reporting, trending, reviewing, and auditing. Capabilities and limitations of in-service inspection techniques are discussed in the Appendix to this chapter.

This article addresses critical aspects in bond testing of thermal spray coatings and provides step-by-step guidance for obtaining representative and reproducible test results based on ASTM C633 and other applicable industry standards. It clarifies details of ASTM C633 requirements and provides examples of the best practice confirmed by hundreds of tests performed worldwide, adopted by numerous industrial standards, and requested to comply with international technical standardization and certification organizations such ISO, AS, SAE, and Nadcap.

This chapter focuses on high-pressure cold spray applications pertaining to repair and refurbishment in the aerospace, oil and gas, and power-generation industries, the last specifically involving repair of gas turbine components. Advantages of cold spray coating in the repair and refurbishment of structural engineering components are also discussed.

This chapter discusses the processes and guidelines for selecting a supplier and for specifying and purchasing steel castings. It details the information that is most useful to the casting supplier and purchaser.

The management of a failure analysis (FA) laboratory requires a broad range of activities to optimize the efficiency of the operation. The purpose of this article is to stimulate readers to consider the various aspects of FA laboratory operations and their respective business management requirements. The various aspects include: staffing, laboratory organization, lab design and operations, strategic development, financial management, and metrics and measurements. References for further reading and examples of resource materials are also included.

This chapter discusses quality control programs and procedures for induction heat-treating systems and includes related forms and checklists.