This chapter provides the definitions of fundamental wear mechanisms. The chapter describes the properties and applications of materials used for wear resistance. It discusses the processes involved in screening tests for wear resistance. In addition, the practical application of wear-resistant principles is covered.

This chapter discusses radiography methods using x-rays, gamma rays, and neutrons. It begins with a discussion on the applications and principles of radiography followed by sections providing information on the sources of radiation, classifications, and characteristics of x-ray tubes. Three primary attenuation processes of electromagnetic radiation, namely photoelectric effect, Compton scattering, and pair production, are covered. The chapter then discusses the principles of shadow formation, the process involved in the conversion of radiation into a form suitable for observation, and the characteristics of x-ray film. It provides information on various exposure factors in film radiography. The chapter provides a description of the characteristics that differentiate neutron radiography from x-ray or gamma ray radiography. The application of neutron radiography is described in terms of its advantages for improved contrast on low atomic number materials, discrimination between isotopes, or inspection of radioactive specimens.

This chapter surveys both basic quality and basic reliability concepts as an introduction to the failure analysis professional. It begins with a section describing the distinction between quality and reliability and moves on to provide an overview of the concept of experiment design along with an example. The chapter then discusses the purposes of reliability engineering and introduces four basic statistical distribution functions useful in reliability engineering, namely normal, lognormal, exponential, and Weibull. It also provides information on three fundamental acceleration models used by reliability engineers: Arrhenius, Eyring, and power law models. The chapter concludes with information on failure rates and mechanisms and the two techniques for uncovering reliability issues, namely burn-in and outlier screening.

This chapter discusses composite testing procedures, including tension, compression, shear, flexure, and fracture toughness testing as well as adhesive shear, peel, and honeycomb flatwise tension testing. It also discusses specimen preparation, environmental conditioning, and data analysis.

This appendix is a compilation of terms and definitions associated with the processing, microstructure, and properties of powder metal stainless steels.

This chapter provides a brief account of galvanic corrosion, which occurs when a metal or alloy is electrically coupled to another metal or conducting nonmetal in the same electrolyte. It begins by describing the galvanic series of metals and alloys useful for predicting galvanic relationships, followed by a brief section on polarization of metals or alloys. The effects of area, distance, and geometric shapes on galvanic-corrosion behavior are then discussed. Various alloys susceptible to galvanic corrosion are briefly reviewed. The chapter also discusses various modes of attack that lead to galvanic corrosion, along with methods for predicting and controlling galvanic corrosion.

The low-pressure permanent molding (LPPM) and semipermanent molding (LPSPM) processes are versatile, and they meet the quality requirements of a variety of high-integrity, large-sized, and thin-walled aluminum castings for various industries. This chapter presents the major features, operation sequence, advantages, and applications of LPPM, LPSPM, and counter-pressure casting.

Ultrasonic inspection is a nondestructive method in which beams of high frequency acoustic energy are introduced into a material to detect surface and subsurface flaws, to measure the thickness of the material, and to measure the distance to a flaw. This chapter begins with an overview of ultrasonic flaw detectors, ultrasonic transducers, and search units and couplants. It then discusses the principles of operation, presentation, and interpretation of data of pulse echo and transmission methods. This is followed by sections providing information on general characteristics of ultrasonic waves and the factors influencing ultrasonic inspection. The advantages, disadvantages, and applications of ultrasonic inspection are finally compared with other methods of nondestructive inspection of metal parts.

This chapter details low-temperature test procedures and equipment. It discusses the role temperature plays in the properties of typical engineering materials. The effect that lowering the temperature of a solid has on the mechanical properties of a material is summarized for three principal groups of engineering materials: metals, ceramics, and polymers (including fiber-reinforced polymers). The chapter describes the factors that influence the selection of tensile testing procedures for low-temperature evaluation, along with a comparison of tensile and compression tests. It covers the parameters and standards related to low-temperature tensile testing. The chapter discusses the factors involved in controlling test temperature. Finally, the chapter discusses the safety issues concerning the use of cooled methanol, liquid-nitrogen, and liquid helium.

Fatigue life analysis and crack growth life prediction require an accurate interpretation of the load spectrum. This appendix presents two methods for interpreting load spectra and provides several data plots and tables comparing fatigue test data with analytically predicted values.

This chapter provides a detailed account of corrosion inhibitors for oil and gas production. It begins by discussing some of the demands of competitive industry on inhibitor formulations. It then describes the varying characteristics of oil wells, gas wells, water injection systems, and pipelines. The following sections provide information on the factors influencing corrosivity of produced fluids and the methods of inhibitor application. The chapter discusses the primary causes of corrosion problems and inhibition in waterfloods and provides an overview of bacteria-induced corrosion. Various laboratory testing methods of corrosion inhibitors and the methods used to monitor corrosion rates and inhibitor effectiveness are also presented. The chapter ends by providing information on quality control of inhibitors and computerization of inhibitor treating programs.

The Nuclear Waste Management Organization (NWMO) investigates approaches for managing Canada's used nuclear fuel. As part of a larger program investigating concepts of copper coatings, NWMO has begun exploring copper cold spray in collaboration with the National Research Council. Within the coating program, a large variety of copper coating sizes have been investigated, from small corrosion coupons to full-scale used-fuel containers/canisters (UFCs). This chapter demonstrates the successful application of copper coating technology to full-scale geometric representative Mark II UFC mock-up configurations through activities involving powder selection, general coating development, UFC coating optimization, and prototyping.

There are several analytical methods available that can be used in-line on whole wafers as well as off-line on de-processed products that are returned from the field. These techniques are surface analytical techniques that can be used to characterize the bulk of the material. The main six methods used in semiconductor industry are: Auger spectroscopy, dynamic secondary ion mass spectroscopy, time of flight static secondary ion mass spectroscopy (ToF-SIMS), X-ray photoelectron spectroscopy, scanning electron microscope-energy dispersive X-ray spectroscopy (SEM-EDX), and transmission electron microscope-EDX. This review specifically addresses ToF-SIMS and describes some typical examples of the application of Auger and SEM-EDX.

This chapter discusses various factors pertinent to the applications of low-pressure permanent mold casting process, namely decorative automotive wheels, critical safety structural components, and chassis components.