CONTENTS. Preface to the 3rd Edition Acknowledgments

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1 CONTENTS Preface to the 3rd Edition Acknowledgments vii ix CHAPTER 1 INTRODUCTION Definition of materials degradation Definition and significance of surface engineering Classification of materials degradation by physical 5 mechanism 1.4 Economic and technical significance of materials degradation Summary 9 PART 1: MECHANISMS OF MATERIALS 11 CHAPTER 2 MECHANICAL CAUSES OF MATERIALS Introduction Wear Adhesive wear Abrasive and erosive wear Wear induced by mechanical fatigue of the worn 31 surface Melting wear, fretting wear and diffusive wear Analytical models of wear Wear resistant materials Fatigue, fracture and creep Mechanisms of fatigue and creep Fatigue and creep resistant materials Summary 64 xi

2 xii Materials Degradation and Its Control by Surface Engineering CHAPTER 3 CHEMICAL CAUSES OF MATERIALS Introduction Corrosion of metals in aqueous media Electrochemistry and aqueous corrosion Electrochemical corrosion of machinery and structures Corrosion inhibitors Materials factors in aqueous corrosion Oxidative reactions of metals with oxygen, sulphur 116 and other halogens Durability of corrosion product film and failure 125 of passivation 3.4 Softening and embrittlement of wood and polymers 134 in water and other media 3.5 Damage to cement and concrete, glass and engineering 138 ceramics 3.6 Dissolution of metals and ceramics in liquid metals, 148 alkalis and salts 3.7 Biochemical and biological modes of materials degradation Corrosion resistant materials Summary 160 CHAPTER 4 MATERIALS INDUCED BY 165 HEAT AND OTHER FORMS OF ENERGY 4.1 Introduction Thermal degradation of materials Materials degradation at very low temperatures Photochemical degradation of polymers High energy radiation damage of materials Summary 174 CHAPTER 5 DUPLEX CAUSES OF MATERIALS Introduction Wear in a corrosive or chemically active environment Corrosive and corrosive-abrasive wear Oxidative and corrosive effects on fretting Abrasive wear in liquid metals 183

3 Contents xiii 5.3 Corrosion fatigue and corrosion embrittlement (SCC) Summary 189 PART 2: SURFACE ENGINEERING 191 CHAPTER 6 DISCRETE COATINGS Introduction Coatings of organic compounds Utility of available organic coatings for different 197 conditions Methods of depositing organic coatings Corrosion problems of organic coatings Electrochemical coatings Electroplating of metals Anodizing, electroless coatings, chromating 204 and phosphating 6.4 Plasma and thermal spraying, plasma-transferred arc, 207 the D gun Plasma and thermal spraying Plasma transferred arc and the D-gun Vacuum-based coating methods Vacuum deposition Sputtering Ion plating and ion-beam assisted deposition Chemical vapor deposition (CVD) and plasma 226 enhanced CVD Arc evaporation Friction surfacing, weld overlays and explosive bonding Advanced coating techniques Diamond-like carbon Electron beam assisted physical vapor deposition Electrostatically assisted combustion chemical vapor 237 deposition 6.8 Summary 238 CHAPTER 7 INTEGRAL COATINGS AND MODIFIED 241 SURFACE LAYERS 7.1 Introduction Thermally or mechanically modified surface layers 242

4 xiv Materials Degradation and Its Control by Surface Engineering Induction hardening Laser and electron beam surface hardening Shot-peening Thermochemical methods of coating Galvanization and hot-dipping Carburizing, carbonitriding, nitriding, 258 nitrocarburizing & boronizing 7.4 Advanced surface modification technologies (ASMT) Plasma nitriding and plasma carburization Surface alloying by laser and electron beam Ion implantation Summary 285 CHAPTER 8 CHARACTERIZATION OF SURFACE 287 COATINGS 8.1 Introduction Measurement of surface roughness and coating thickness Surface roughness Coating thickness Hardness and microhardness analysis Adhesivity testing Microstructural evaluation Chemical analysis Comparison of surface analysis techniques Residual stress analysis Special techniques for dynamic testing conditions Analysis of service characteristics Corrosion testing Wear resistance tests Fracture testing of coatings Summary 331 PART 3: APPLICATION OF CONTROL TECHNIQUES 335 CHAPTER 9 CONTROL OF MATERIALS Introduction Methodology of analysing materials degradation Selection of optimal surface engineering technology Control of wear by surface engineering 340

5 Contents xv Principles of coating selection for wear resistance Selection of specific surface engineering techniques 343 for specific wear mechanisms 9.5 Control of corrosion by surface engineering Control of fatigue and fracture by surface engineering Discrete surface coatings Integral coatings and surface modified layers Summary 352 CHAPTER 10 FINANCIAL AND INDUSTRIAL ASPECTS 355 OF MATERIALS AND ITS CONTROL 10.1 Introduction Financial analysis of materials degradation control Options analysis of financial gain Modeling financial benefit in terms of reduced 361 depreciation Implications of behavioral finance Accounting accuracy and difficulties in reliable 363 measurement of savings in operating costs 10.3 Practical aspects of implementing new forms of surface 363 engineering 10.4 Evaluation of control of materials degradation in terms 364 of value to the company or institution 10.5 Summary 365 APPENDIX APPENDIX APPENDIX INDEX 401

Steels Processing, Structure, and Performance, Second Edition Copyright 2015 ASM International G. Krauss All rights reserved asminternational.

Steels Processing, Structure, and Performance, Second Edition Copyright 2015 ASM International G. Krauss All rights reserved asminternational.org Contents Preface to the Second Edition of Steels: Processing,