This appendix provides a brief review of thin film deposition methods and their uses in a question and answer format. The questions deal with recommended practices, process conditions, terminology, and classifications.

This chapter presents the theory and practice associated with the application of thin films. The first half of the chapter describes physical deposition processes in which functional coatings are deposited on component surfaces using mechanical, electromechanical, or thermodynamic techniques. Physical vapor deposition (PVD) techniques include sputtering, e-beam evaporation, arc-PVD, and ion plating and are best suited for elements and compounds with moderate melting points or when a high-purity film is required. The remainder of the chapter covers chemical vapor deposition (CVD) processes, including atomic layer deposition, plasma-enhanced and plasma-assisted CVD, and various forms of vapor-phase epitaxy, which are commonly used for compound films or when deposit purity is less critical. A brief application overview is also presented.

This chapter discusses coating technologies that are applicable to beryllium, including physical and chemical vapor deposition, thermal evaporation, electroplating, sputtering, ion plating, and plasma arc spraying. It describes the advantages and disadvantages of each method and the effect of temperature, pressure, and other process variables on the microstructures and properties developed.

Aluminum generally has excellent resistance to corrosion and gives years of maintenance-free service in natural atmospheres, fresh waters, seawater, many soils and chemicals, and most foods. This chapter explains why aluminum and aluminum alloys are naturally resistant to corrosion and describes the conditions and circumstances under which their natural defenses break down. It discusses the causes and forms of corrosion observed in aluminum alloys and the effect of composition, microstructure, processing history, and environmental variables such as impurities, fluid flow, surface area, pressure, and temperature.

Magnesium, by volume, is two-thirds the weight of aluminum and one-quarter the weight of steel. It also has good damping capacity, giving it an edge over other metals in high-vibration environments. This chapter discusses the basic metallurgy, alloy designations, compositions, and mechanical properties of cast and wrought magnesium alloys. It also describes the processes used to produce magnesium parts, the causes and effects of corrosion, and the use of protective coatings and treatments.

This chapter covers the tribological properties of different types of oil, greases, solid lubricants, and metalworking and traction fluids. It explains how lubricants are made, how they work, and how they are applied and tested. It also discusses the fundamentals of lubrication and friction control, the relationship between viscosity and breakaway friction, and the factors that affect load-carrying capacity and service life.

This chapter begins with an overview of the history of ion nitriding. This is followed by sections that describe how the ion nitriding process works, glow discharge characteristics, process parameters requiring good control, and the applications of plasma processing. The chapter explores what happens in the ion nitriding process and provides information on its gas ratios. It describes the reactions that occur at the surface of the material being treated during iron nitriding and defines corner effect and nitride networking. Further, the chapter provides information on the stability of surface layers and processes involved in the degradation of surface finish and control of the compound zone formation. Gases primarily used for ion nitriding and the control parameters used in ion nitriding are also covered. The chapter also presents the philosophies and advantages of the plasma generation technique for nitriding. It concludes with processes involved in oxynitriding.

This chapter considers the materials and processing aspects of soldering and the manner in which these interrelate in the development of joining processes. It discusses the processes involved in eliminating or suppressing metallurgical and mechanical constraints as well as constraints imposed by the components.

This chapter provides an introduction to various forms of corrosion, namely uniform corrosion, localized corrosion, mechanically assisted degradation, environmentally induced cracking, microbiologically influenced corrosion, and metallurgically influenced corrosion.

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 discusses the effects of corrosion on boiler tube surfaces exposed to water and steam. It describes the process of corrosion, the formation of scale, and the oxides of iron from which it forms. It addresses the primary types of corrosion found in boiler environments, including general corrosion, under-deposit corrosion, microbially induced corrosion, flow-accelerated corrosion, stress-assisted corrosion, erosion-corrosion, cavitation, oxygen pitting, stress-corrosion cracking, and caustic embrittlement. The discussion is supported by several illustrations and relevant case studies.

Aluminum products are used extensively in natural atmospheres and in and around water. They are also widely used in building materials and as containers for chemicals and food and beverage products. This chapter discusses the corrosion mechanisms associated with these environments and the influence of various factors and prevention methods. It also includes an extensive amount of data of corrosion rates, corrosion resistance, and changes in mechanical properties.

This chapter covers the corrosion behavior of beryllium in aqueous environments. It describes the chemical reactions that drive the corrosion process, the conditions required for equilibrium, and the factors that affect corrosion resistance. It discusses the stability of the native oxides that form on the surface of beryllium and their ability to withstand acids, bases, and corrosive agents found in rain and seawater. It explains how carbides, inclusions, ions, and impurities contribute to corrosion damage, particularly pitting, and how corrosion reduces the ductility and fracture strength of certain beryllium alloys.

Pitting is the most common corrosion attack on aluminum alloy products. This chapter explains why pitting occurs and how it appears in different types of aluminum. It discusses pitting rates, pitting potentials, and pitting resistance as well as testing and prevention methods. It also discusses the problem of crevice corrosion and how it is influenced by crevice geometry and operating environment. The discussion covers the most common forms of crevice corrosion, including water staining, poultice corrosion, and filiform corrosion, along with related testing and prevention methods.

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.

Cleaning procedures serve to remove scale, tarnish films, and other contaminants that form or are otherwise deposited on the surface of titanium during processing operations such as hot working and heat treatment. This chapter explains what makes titanium susceptible to the formation of scale and how it can be removed via belt grinding, abrasive blasting, and molten salt descaling baths. It also discusses the role of acid pickling, barrel finishing, polishing, and buffing as well as the use of chemical conversion coatings and protective platings.

Water chemistry is a factor in nearly all boiler tube failures. It contributes to the formation of scale, biofilms, and sludge, determines deposition rates, and drives the corrosion process. This chapter explains how water chemistry is managed in boilers and describes the effect of impurities and feedwater parameters on high-pressure boiler components. It discusses deposition and scaling, types of corrosion, and carryover, a condition that occurs when steam becomes contaminated with droplets of boiler water. The chapter also covers water treatment procedures, including filtration, chlorination, ion exchange, demineralization, reverse osmosis, caustic and chelant treatment, oxygen scavenging, and colloidal, carbonate, phosphate, and sodium aluminate conditioning.

This chapter presents topics pertaining to resistance at cryogenic temperatures: measurement, the resistive mechanisms, and available data. The chapter also presents brief descriptions of the various mechanisms that are operative in producing resistance at low temperatures. The alloys discussed are the nondilute mixtures of metals. An introduction to low-temperature electrical properties of specific metals and alloys is included.

Beryllium is an extraordinary metal with an unusual combination of physical and mechanical properties. It has low density, high stiffness, and excellent dimensional stability. It is also transparent to x-rays and can be machined to extremely close tolerances. This chapter discusses the properties, compositions, and processing characteristics of beryllium and its alloys. It provides information on powder production and consolidation, commercial designations and grades, wrought products, and forming processes. It also discusses the issue of corrosion, the use of protective treatments and coatings, and health and safety concerns.