This chapter discusses the key findings of an investigation into the failure of an aircraft engine fuel pump. It explains how investigators came to the conclusion that metal slivers from a heavily worn spring may have interrupted the flow of lubricant to one of the slipper pads, causing adhesive wear and the welding of slipper pad material onto the surface of a mating cam plate. Excessive friction between the slipper pads and cam plate, in turn, created a torsional overload that caused the camshaft to break. The chapter presents SEM images showing the wear pattern on one of the springs along with photographs of the damaged slipper pads and cam plate. It also includes an image of a copper flake found in one of the pistons and discusses the results of qualitative x-ray chemical analysis.

This appendix lists plating solutions and procedures used in metallographic edge preparation.

This chapter discusses the failure of a first-stage compressor blade in an aircraft engine and explains how investigators determined that it was caused by fatigue, with a crack originating from corrosion pits that developed in the root transition region on the convex side of the airfoil.

Stainless steels have a wide variety of applications for household products, food-handling equipment, major appliances, medical equipment, and industrial equipment. Stainless is also featured in many architectural designs and monuments. Many of the most important applications of stainless steel can be found in the transportation industry, where both the cutlery martensitic and the chromium-nickel austenitic stainless steels have been used. This chapter provides a detailed discussion on these applications.

This chapter briefly reviews the history of brazing from ancient times to the early 20th century.

This chapter covers coatings and treatments that are used to improve the friction and wear behaviors of materials. It describes modifications that work by hardening contacting surfaces, including heat treating, vacuum coating, thermal spray, and plating, and those that separate or lubricate surfaces, including solid film, chemical conversion, and vacuum coatings, surface oiling and texturing, and lubricating platings. It compares and contrasts methods based on thickness and depth and their relative effect on friction, erosion, and wear.

This chapter covers the tribological properties of stainless steel and other corrosion-resistant alloys. It describes the metallurgy and microstructure of the basic types of stainless steel and their suitability for friction and wear applications and in environments where they are subjected to liquid, droplet, and solid particle erosion. It also discusses the tribology of nickel- and cobalt-base alloys as well as titanium, zinc, tin, aluminum, magnesium, beryllium, graphite, and different types of wood.

Stop-off coatings prevent nitriding of selected areas on components. This chapter discusses the processes, advantages, and disadvantages of stop-off techniques for gas nitriding, salt bath nitriding, and ion nitriding.

Beryllium has been successfully joined by fusion welding, brazing, solid-state bonding, and soldering. This chapter describes these processes in detail along with their advantages and disadvantages. It also addresses application considerations such as surface preparation, joint design, and testing.

This chapter discusses recycling processes used for metals, plastics, rubber, glass, and paper. Is also describes the advantages of recycled materials.

Titanium and its alloys are used chiefly for their high strength-to-weight ratio, but they also have excellent corrosion resistance, better even than stainless steels. Titanium, as the chapter explains, is protected by a tenacious oxide film that forms rapidly on exposed surfaces. The chapter discusses the factors that influence the growth and quality of this naturally passivating film, particularly the role of oxidizing and inhibiting species, temperature, and alloying elements. It also discusses the effect of different corrosion processes and environments as well as hydrogen, stress-corrosion cracking, liquid metal embrittlement, and surface treatments.

This chapter presents an overview of families of brazing alloys that one is likely to encounter in a manufacturing environment. It discusses the metallurgical aspects of brazing and includes a survey of brazing alloy systems. A discussion of deleterious and beneficial impurities is provided with examples. The chapter also describes the application of phase diagrams to brazing.

This chapter covers the friction and wear behaviors of copper alloys. It describes the compositions and forms of copper available and their suitability for applications involving friction, different types of erosion, and adhesive and abrasive wear.

This chapter discusses the compositions, properties, and applications of nonferrous metals, including zirconium, hafnium, beryllium, lead, tin, gold, silver, and platinum group metals. It also addresses fusible alloys and provides melting temperatures for several compositions.

Brazes for carat gold jewelry must meet or exceed the fineness/caratage of the component piece parts of the assembly in order for it to meet the national fineness/caratage standards and marking or hallmarking regulations for jewelry. This chapter concentrates on brazes for gold jewelry. It provides understanding of the metallurgy of gold jewelry alloys and includes a discussion of brazes for carat gold jewelry. The chapter also provides information on traditional gold jewelry brazes, the target properties of filler metals for carat gold jewelry and describes the characteristics of novel 22 carat gold solders.

This chapter presents several materials and processes related to soldering technology. It first provides information on lead-free solders, followed by sections devoted to flip-chip processes, diffusion soldering, and modeling. Scanning acoustic microscopy and fine-focus x-ray techniques are also discussed. The chapter describes several evaluation procedures and tests developed to measure solderability and standards for process calibration. The chapter also describes the characteristics of reinforced solders, amalgams used as solders, and other strategies to boost the strength of solders. Further, the chapter considers methods for quantifying the mechanical integrity of joints and predicting their dimensional stability under specified environmental conditions. It discusses the effects of rare earth elements on the properties of solders. The chapter concludes with information on advanced joint characterization techniques.

This chapter compares and contrasts surface-engineering processes based on process availability, corrosion and wear performance, distortion effects, penetration depth or attainable coating thickness, and cost. It provides both quantitative and qualitative information as well as measured property values.

The orientation of the devices within a package determine the best chosen approach for access to a select component embedded in epoxy both in package or System in Package and multi-chip module (MCM). This article assists the analyst in making decisions on frontside access using flat lapping, chemical decapsulation, laser ablation, plasma reactive ion etching (RIE), CNC based milling and polishing, or a combination of these coupled with optical or electrical endpoint means. This article discusses the general characteristics, advantages, and disadvantages of each of these techniques. It also presents a case study illustrating the application of CNC milling to isolate MCM leakage failure.

This article examines the role of alloying in the production and use of lead and tin. It describes the various categories and grades of lead and lead-base alloys along with their nominal compositions and corresponding UNS numbers. It also discusses the composition and properties of lead used in battery grids, type metals, and bearings. It, likewise, discusses the use of tin in various types of solder and in bearings and provides composition and property data for application-specific designations and grades. The article also discusses the effect of impurities in tin-lead solders and the amounts and combinations in which they are found.