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 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.

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

This chapter discusses the ambient-temperature corrosion characteristics of aluminum metal-matrix composites (MMCs), including composites formed with boron, graphite, silicon carbide, aluminum oxide, and mica. It also discusses the effect of stress-corrosion cracking on graphite-aluminum composites and the use of protective coatings and design criteria for corrosion prevention.

This chapter discusses the properties and behaviors of advanced high-strength steels used in the automotive industry, including dual- and complex-phase steels, transformation-induced plasticity steels, ferritic-bainitic steels, and quenched and partitioned steels. It explains how different manufacturing processes, including coating, affect the grain size, microstructure, and formability of these important steels.

This chapter discusses the basic principles of corrosion, explaining how and why it occurs and how it is categorized and dealt with based on the appearance of corrosion damage or the mechanism of attack. It explains where different forms of corrosion are likely to occur and identifies metals likely to be affected. It also discusses the selection and use of protective coatings and the tests that have been developed to measure their effectiveness.

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 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.

All materials are susceptible to corrosion or some form of environmental degradation. Although no single material is suitable for all applications, usually there are a variety of materials that will perform satisfactorily in a given environment. The intent of this chapter is to review the corrosion behavior of the major classes of metals and alloys as well as some nonmetallic materials, describe typical corrosion applications, and present some unique weaknesses of various types of materials. It also aims to point out some unique material characteristics that may be important in material selection, and discuss, where appropriate, the characteristic forms of corrosion that attack specific materials. The materials addressed in this chapter include carbon steels, weathering steels, and alloy steels; nickel, copper, aluminum, titanium, lead, magnesium, tin, zirconium, tantalum, niobium, and cobalt and their alloys; polymers; and other nonmetallic materials, including rubber, carbon and graphite, and woods.

This chapter discusses the effect of friction and lubrication on forgings and forging operations. The discussion covers lubrication mechanisms, the use of friction laws, tooling and process parameters, and the lubrication requirements of specific materials and forging processes. The chapter also describes several test methods for evaluating lubricants and explains how to interpret associated test data.

This chapter first covers some basic principles of electrochemical corrosion and then some of the various types of corrosion. Some of the more common types of corrosion discussed include uniform corrosion, galvanic corrosion, pitting, crevice corrosion, erosion-corrosion, cavitation, fretting corrosion, intergranular corrosion, exfoliation, dealloying corrosion, stress-corrosion cracking, and corrosion fatigue. The chapter discusses the processes involved in corrosion control by retarding either the anodic or cathodic reactions. The rate of corrosion is reduced by conditioning of the metal, by conditioning the environment, and by electrochemical control. Finally, the chapter deals with high-temperature oxidation that usually occurs in the absence of moisture.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.

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.