Contents. General Information... 1

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1 Editor(s): J.R. Davis All rights reserved. Contents General Information... 1 Glossary of Terms and Engineering Data Glossary of Metallurgical and Metalworking Terms... 3 Engineering Data Density of Metals and Alloys Linear Thermal Expansion of Metals and Alloys Thermal Conductivity of Metals and Alloys Electrical Conductivity and Resistivity of Metals and Alloys Approximate Melting Temperatures of Metals and Alloys Physical Properties of Common Gases and Liquids Approximate Equivalent Hardness Numbers for Nonaustenitic Steels (Rockwell C Hardness Range) Approximate Equivalent Hardness Numbers for Nonaustenitic Steels (Rockwell B Hardness Range) Approximate Equivalent Hardness Numbers for Austenitic Stainless Steel Sheet (Rockwell C Hardness Range) Approximate Equivalent Hardness Numbers for Austenitic Stainless Steel Sheet (Rockwell B Hardness Range) Approximate Brinell-Rockwell B Hardness Numbers for Equivalent Austenitic Stainless Steel Plate in the Annealed Condition Hardness of Some Alloy Constituents and Various Minerals.. 75 Approximate Equivalent Hardness Numbers for Wrought Aluminum Products Approximate Equivalent Hardness Numbers for Wrought Coppers (>99% Cu, Alloys C10200 through C14200) Strength Versus Density for Various Engineered Materials Approximate Equivalent Hardness Numbers for Cartridge Brass (70% Cu, 30% Zn) Guide to the Unified Numbering System SI Prefixes--Names and Symbols Base, Supplementary, and Derived SI Units Fracture Toughness Versus Strength for Various Engineered Materials Conversion Factors Classified According to the Quantity/Property of Interest Alphabetical Listing of Common Conversion Factors Conversion Factors for Corrosion Rates Fundamental Physical Constants Greek Alphabet Structure and Properties of Metals The Chemical Elements Names and Symbols for the Elements Atomic Weights of the Elements The Periodic Table Crystal Structure of Metallic Elements Crystallographic Terms and Basic Concepts Crystal Defects and Plastic Flow Alloy Phase Diagrams and Mierostrueture Common Terms Unary Diagrams Binary Diagrams Ternary Diagrams Thermodynamic Principles Thermodynamics and Phase Diagrams Reading Phase Diagrams Examples of Phase Diagrams Appendix 1: Melting and Boiling Points of the Elements Appendix 2: Allotropic Transformations of the Elements Properties of Metals Physical Properties Chemical Properties Mechanical Properties Design Considerations and Materials Selection Introduction and Overview Key Considerations in Design 122 Key Considerations in Materials Selection Concurrent Engineering Design Factors Functional Requirements in Design Statistical Aspects of Design Total Life Cycle in Design Other Major Factors in Design Factors in Materials Selection Materials Properties Manufacturing Process Considerations Fabricability Other Major Factors in Materials Selection Irons, Steels, and High-Performance Alloys Structure/Property Relationships in Irons and Steels Basis of Material Selection Role of Microstmcture Ferrite Pearlite Ferrite-Peadite Bainite... ~ Martensite Austenite Ferrite-Cementite Ferrite-Martensite Ferrite-Austenite Graphite Cemenfite Steelmaking Practices and Their Influence on Properties Ironmaking Steelmaking Secondary Steelmaking Processing of Special-Quality Steels Casting Hot Rolling Specialized Processing Routes Analytical Techniques for Liquid Steel

2 Editor(s): Carbon J.R. and Davis Alloy Steels Classification and Designations of Carbon and AHoy Steels 203 Mechanical Properties of Carbon and Alloy Steels Steel Sheet, Strip, and Plate Low-Carbon Steel Sheet and Strip Alloy Steel Sheet and Strip Precoated Steel Sheet Steel Sheet for Porcelain Enameling Carbon and Low-Alloy Steel Plate Steel Bar, Rod, and Wire Hot-Rolled Steel Bar and Shapes Cold-Finished Steel Bars Steel Wire Rod Steel Wire Steel Tubular Products Closed-Die Steel Forgings Steel Castings Bearing Steels High-Strength Structural and High-Strength Low-Alloy Steels Ultrahigh-Strength Steels Wear-Resistant Austenitic Manganese Steels Hardenahility of Carbon and Alloy Steels Service Characteristics of Carbon and Alloy Steels Wear Resistance of Steels Elevated-Temperature Properties of Steels Fatigue Resistance of Steels Embrittlement of Steels Notch Toughness of Steels Fracture Toughness of Steels Corrosion Characteristics of Carbon and AHoy Steels Types of Corrosive Environments Atmospheric Corrosion Soil Corrosion Corrosion in Concrete Corrosion in Fresh Water Corrosion in Seawater Stress-Corrosion Cracking of Steels Protection of Steel from Corrosion Cast Irons Basic Metallurgy of Cast Iron Gray Iron Ductile Iron Compacted Graphite Iron Malleable Iron Alloy Cast Irons Ferrous Powder Metallurgy Materials Pressed-and-Sintered Parts Powder Production Compaction and Sintering Designation of Ferrous P/M Materials Properties of Ferrous P/M Materials High-Density Parts Powder Forging Metal Injection Molding Tool Steels Classification and Characteristics Properties of Tool Steels Effects of Surface Treatments on Properties Fabrication Characteristics Machining Allowances P/M Tool Steels Precision-Cast Tool Steels Specialty Tool Steels Stainless Steels Wrought Stainless Steels: Selection and Appfication Fabrication of Wrought Stainless Steels Corrosion of Wrought Stainless Steels... All rights 379 reserved. Cast Stainless Steels P/M Stainless Steels SuperaHoys General Background Processing Properties and Microstructure Environmental Effects References Selected References Nonferrous Alloys and Special-Purpose Materials Aluminum and Aluminum Alloys Introduction to Aluminum and Aluminum AHoys Alloy and Temper Designations for Aluminum Chemical Compositions and International Designations Physical Metallurgy of Aluminum Alloys Aluminum Wrought Products..., Properties of Wrought Aluminum Alloys Aluminum Foundry Products Properties of Aluminum Castings Aluminum P/M Products Corrosion Resistance of Aluminum and Aluminum Alloys Copper and Copper Alloys Introduction and Overview Copper Tubular Products Copper Wire and Cable Copper Alloy Castings Copper P/M Products Thermal Softening and Stress Relaxation in Copper Corrosion Characteristics of Copper and Copper Alloys Magnesium and Magnesium Alloys Selection and Application The Magnesium Industry Alloy and Temper Designations Casting Alloys Wrought Alloys Mechanical Properties Selection of Product Form Fabrication Characteristics Design and Weight Reduction Corrosion Resistance Metallurgical Factors Environmental Factors Sl~ess-Corrosion Cracking Galvanic Corrosion Protection of Assemblies Protective Coating Systems Titanium and Titanium Alloys Introduction and Overview Processing Corrosion Resistance Properties, Compositions, and Applications of Selected Alloys Selected References on Titanium Zinc and Zinc Alloys Zinc Industry Zinc Coatings Zinc Alloy Castings Wrought Zinc and Zinc Alloys Corrosion Resistance of Zinc Selected References Tin and Tin Alloys Tin Production

3 Editor(s): J.R. Tin Davis in Coatings Pure (Unalloyed) ~n Tin in Chemicals Tin-Base Alloys Other Alloys Containing Tin Corrosion Resistance Selected References Lead and Lead Alloys Lead Production Product Forms Compositions and Grades Properties of Lead Products and Applications Corrosion Resistance References Nickel and Nickel Alloys Mining and Extraction Uses of Nickel Categories of Nickel and Nickel Alloys Corrosion Resistance Selected References Cobalt and Cobalt Alloys Mining and Processing Uses of Cobalt Wear-Resistant Alloys High-Temperature Alloys Corrosion-Resistant Alloys Special-Purpose Alloys Zirconium and Hafnium Metal Processing and Fabrication Metallurgy of Zirconinm and Its Alloys Alloy Grades Corrosion Resistance Hafnium Precious Metals and Alloys The Precious Metals Industry Resources and Consumption Trade Practices Properties, Product Forms, and Applications Property Characteristics Product Forms Silver and Silver Alloys Gold and Gold Alloys Platinum-Group Metals Selected References Refractory Metals and Alloys Molybdenum and Molybdenum Alloys... ~ Tungsten and Tungsten Alloys Niobium and Niobium Alloys Tantalum and Tantalum Alloys Rhenium and Rhenium-Bearing Alloys Oxidation Resistance and Protective Coatings Selected References Cemented Carbides and Cermets Manufacture of Cemented Carbides Cemented Carbides for Machining Applications Classification of Cemented Carbides Properties of Cemented Carbides Coated Cemented Carbides Cemented Carbides for Nonmachining Applications Cermets Special-Purpose Materials Magnetically Soft Materials Permanent Magnet Materials Superconducting Materials Electrical Resistance Alloys Electrical Contact Materials All rights reserved. Thermocouple Materials Low-Expansion Alloys Shape Memory Alloys Fusible Alloys Hardfacing Alloys Metal-Matrix Composites Structural Intermetallics Beryllium Very High Density Metals Materials for Sliding Bearings Biomaterials Processing Extractive Metallurgy Mining of Minerals and Ores Mineral Processing Flow Diagrams of Extraction Processes Pyrometallurgical Processes Hydrometailurgical Processes Electrometallurgical Processes Casting General Introduction Casting Flow Chart Casting Alloys Solidification of Metals and Alloys Pure Metals Alloys Eutectic Phases Imperfections Gating and Risering Molding Methods Classification of Molding Methods Sand Molds Ceramic Molds Metallic Molds Melting Methods Induction Melting Cupola Melting Arc Furnaces Crucible Melting Reverberatory Furnaces Reaction Melting... : Vacuum Melting Molten Metal Treatment Foundry Practice for Ferrous Alloys General Considerations for Cast Irons Gray Irons Ductile irons Compacted Graphite Irons Malleable Irons High-AHoy White Irons Steels Foundry Practice for Nonferrous Alloys Aluminum Alloys Copper Alloys Zinc Alloys Magnesium Alloys Superalloys Titanium Alloys Cast Metal-Matrix Composites Casting Design and Quality Assurance Design Considerations Casting Tolerances Solidification Simulation Programs Rapid Prototyping Quality Assurance in the Foundry

4 Editor(s): Forming J.R. Davis Forming of Sheet, Strip, and Plate Presses and Auxiliary Equipment for Forming Sheet Metal 782 Selection of Die Materials for Sheet Metal Forming Selection and Use of Lubricants in Forming Sheet Metal Blanking of Low-Carbon Steel Piercing of Low-Carbon Steel Fine-Edge Blanking and Piercing Blanking and Piercing of Electrical Steel Sheet Press Bending of Low-Carbon Steel Press-Brake Forming.., Press Forming of Low-Carbon Steel Press Forming of High-Carbon Steel Press Forming of Coated Steel Forming of Steel Slrip in Multiple-Slide Machines Deep Drawing Stretch Forming Spinning Rubber-Pad Forming Three-Roll Forming Contour Roll Forming Drop Hammer Forming Explosive Forming Electromagnetic Forming Superplastic Forming (SPF) Forming of Bars, Tube, and Wire Wire, Rod, and Tube Drawing Bending of Bars and Bar Sections Bending and Forming of Tubing Tube Spinning Straightening of Bars, Shapes, and Long Parts Straightening of Tubing Wire Forming Shearing, Slitting, and Cutting Sheafing of Plate and Flat Sheet Slitting and Sheafing of Coiled Sheet and Strip Sheafing of Bars and Bar Sections Oxyfuel Gas Cutting Plasma Arc Cutting Air Carbon Arc Cutting and Gouging Oxygen Arc Cutting Laser BeamCutting Forming of Stainless Steel and Heat-Resistant Alloys Forming of Stainless Steel Forming of Heat-Resistant Alloys Forming of Ret~actory Metals Forming of Nonferrous Metals Forming of Aluminum Alloys Forming of Beryllium Forming of Copper and Copper Alloys Forming of Magnesium Alloys Forming of Nickel Alloys Forming of Titaninm Alloys Forming of Platinum Metals Selected References on Forming Forging Forging Machinery, Dies, and Processes Hammers and Presses for Forging Die Design and Materials Forging Processes Forging of Specific Metals and Alloys Forging of Carbon and Alloy Steels Forging of Stainless Steels Forging of Heat-Resistant Alloys Forging of Aluminum Alloys Forging of Copper and Copper Alloys Forging of Magnesium Alloys Forging of Titanium Alloys... All rights 873 reserved. Powder Metallurgy P/M Definitions Powder Characteristics Powder Production Processes Powder Treaanents Powder Consolidation Secondary Operations Machining..., General Introduction Elements of the Machining Process The Mechanics of Chip Formation Tool Wear in Metal Cutting Machining Parameters Forces and Power Cutting Tool Materials Cutting Fluids Surface Finish and Surface Integrity Microstructure and Machinability Cast Irons Steels Aluminum Alloys Machining Data Recommendations Speeds and Feeds for Turning, Face Milling, End Milling, Drilling, Reaming, and Tapping Tool Geometry Cutting Fluids Grinding Nontraditional Machining Processes Heat Treating Basic Principles and Design Guidelines for Heat Treating of Steel Principles of Heat Treating of Steel Design for Heat Treatment of Steel Heat Treating of Steel Slress-Relief Heat Treating of Steel Normalizing of Steel Annealing of Steel Austenitizing Temperatures for Steels Quenching of Steel Tempering of Steel Martempering of Steel Austempering of Steel Cold Treating and Cryogenic Treatment of Steel Heat Treating of Ultrahigh-Strength Steels Heat Treating of Maraging Steels Heat Treating of Powder Metallurgy Steels Case Hardening of Steel Gas Carburizing Pack Carburizing Liquid Carburizing and Cyaniding Vacuum Carburizing Plasma (Ion) Carburizing CarboniUiding Gas Nitriding Liquid Nitriding Plasma (Ion) Nitriding Ferritic Nitrocarburizing Methods of Measuring Case Depth Heat Processing Equipment Types of Heat Treating Furnaces Salt Bath Equipment Fluidized-Bed Equipment Heat Treating in Vacuum Furnaces and Auxiliary Equipment 997 Heat-Resistant Alloys for Furnace Parts, Trays, and Fixtures 999 Process Control Considerations Temperature Control xii

5 Editor(s): J.R. Furnace Davis Atmospheres Furnace Atmosphere Control 1003 Conlrol of Surface Carbon in Heat Treating of Steel Evaluation of Carbon Conlrol in Processed Parts Furnace Safety Localized Heat 1 eating Induction Hardening and Tempering Flame Hardening Laser Surface Transformation Hardening Electron-Beam Heat Treating Heat Treating of Cast Irons Introduction to Heat Treating of Cast Irons Heat Treating of Gray Irons Heat Treating of Ductile Irons Heat Treating of Malleable Irons Heat Treating of Austenitic Irons Heat 'l~reating of Tool Steels Heat Treating of Stainless Steels and Heat-Resistant Alloys 1025 Heat Treating of Stainless Steels Heat Treating of Superalloys Heat Treating of Refi:actory Metals and Alloys Heat Treating of Nonferrous Alloys Heat Treating of Aluminum Alloys Heat Treating of Copper Alloys Heat Treating of Magnesium Alloys Heat Treating of Nickel and Nickel Alloys Heat Treating of Titanium and Titanium Alloys Joining Introduction and Overview Joining Processes Joint Design and Preparation Arc Welding Shielded Metal Arc Welding Flux-Cored Arc Welding Submerged Arc Welding Gas Metal Arc Welding Gas Tungsten Arc Welding Plasma Arc Welding Plasma-MIG Welding Electroslag and Electrogas Welding Arc Welding of Hardenable Carbon and Alloy Steels Arc Welding of Cast Irons Arc Welding of Stainless Steels Arc Welding of Heat-Resistant Alloys Arc Welding of Aluminum Alloys Arc Welding of Copper and Copper Alloys Arc Welding of Magnesium Alloys Arc Welding of Nickel Alloys Arc Welding of Titanium and Titanium Alloys Resistance Welding Resistance Spot Welding Resistance Seam Welding Projection Welding Flash Welding Other Fusion Welding Processes Oxyfuel Gas Welding Electron Beam Welding Laser Beam Welding Stud Welding Percussion Welding High-Frequency Welding Thermite Welding 1103 Solid-State Welding Processes Diffusion Bonding Explosion Welding Friction Welding Ultrasonic Welding Upset Welding... All rights 1106 reserved. Deformation Welding Brazing Selection of Brazing Processes and Filler Metals Fumace Brazing of Steels Torch Brazing of Steels Induction Brazing of Steels Resistance Brazing Dip Brazing of Steels in Molten Salt Brazing of Cast Irons Brazing of Stainless Steels Brazing of Heat-Resistant Alloys Brazing of Aluminum Alloys Brazing of Copper and Copper Alloys Brazing of Titanium and Titanium Alloys Soldering Surface Engineering General Introduction Surface Cleaning Cleaning Process Selection Alkaline Cleaning Electrolytic Cleaning Solvent Cleaning Emulsion Cleaning Molten Salt Bath Cleaning Ultrasonic Cleaning Acid Cleaning of Iron and Steel Pickling of Iron and Steel Abrasive Blast Cleaning Finishing Methods Classification of Finishing Methods Abrasive Finishing Methods Electropolishing... : Mass Finishing Shot Peening Electrodeposition Processes Copper Plating Industrial (Hard) Chromium Plating Decorative Chromium Plating Nickel Plating Iron Plating Cadmium Plating Zinc Plating Indium Plating Tin Plating Lead Plating Silver Plating Gold Plating Alloy Plating Selective Plating Electroforming Nonelectrolytie Deposition Processes... US1 Electroless Nickel Plating Electroless Copper Plating Mechanical Plating Dip, Barrier, and Chemical Conversion Coatings Hot-Dip Coating of Steels Continuous Elecl~odeposited Coatings for Steel Strip Babbitting Phosphate Conversion Coatings Chromate Conversion Coatings Painting Rust-Preventative Compounds Weld-Overlay Coatings Thermal Spray Coatings Porcelain Enameling Ceramic Coatings xiii

6 Editor(s): J.R. Davis Chemical Vapor Deposition and Related Processes Physical Vapor Deposition Surface Engineering of Stainless Steels and Heat=Resistant Alloys Surface Engineering of Stainless Steels... : 1170 Surface Engineermg of I-Ieat-Resistant Alloys Surface Engineermg of Nonferrous Metals Surface Engineering of Aluminum and Aluminum Alloys Surface Engineering of Copper and Copper Alloys Surface Engineering of Magnesium Alloys Surface Englneermg of Nickel and Nickel Alloys Surface Engmeermg of Zinc Alloys Surface Engmeermg of Titanium and Titanium Alloys Surface Engmeermg of Zirconium and Hafnium Surface Engineering of Refractory Metals and Alloys Recycling and Life-Cycle Analysis Recycling Recycling Basics Recycling of Iron and Steel Recycling of Stainless Steel, Superalloys, and Nickel Recycling of Aluminum Recycling of Copper Recycling of Precious Metals from Electronic Scrap Recycling of Lead Recycling of Magnesium Recycling of Tin Recycling of Titanium Recycling of Zinc Design for Recycling and Life-Cycle Analysis Design for Recycling Life-Cycle Analysis Testing, Inspection, Characterization, and Quality Control Failure Analysis Engineering Aspects of Failure and Failure Analysis General Practice in Failure Analysis An Introduction to Fracture Mechanics Failures from Various Mechanisms and Related Environmental Factors Identification of Types of Failures Ductile and Brittle Fractures Fatigue Failures Distortion Failures Wear Failures Corrosion Failures Stress-Corrosion Cracking Liquid-Metal Embrittlement Hydrogen-Damage Failures Corrosion-Fatigue Failures Elevated-Temperature Failures Fractography Principles and Procedures Preparation and Preservation of Fracture Specimens Photography of Fractured Parts and Fracture Surfaces Fractographic Features Revealed by Light Microscopy Interpretation of Optical Fractographs Interpretation of Scanning-Electron Microscope Fractographs Use of Fractography for Failure Analysis Aspects of Failure That Can Be Resolved by Fractography 1248 Discontinuities Leading to Fracture Nondestructive Testing Guide to Nondestructive Testing and Inspection Methods 1254 Leak Testing Visual Inspection Liquid-Penetrant Inspection All rights reserved. Magnetic-Particle Inspection Magnetic Field Testing Eddy-Current Inspection Microwave Inspection Ultrasonic Inspection Acoustic Emission Inspection Radiography Thermal Inspection Holography Mechanical, Wear, and Corrosion Testing Mechanical Testing Hardness Testing Tension Testing Compression Testing Dynamic Fracture Testing Fracture Toughness Testing Fatigue Life Testing Fatigue Crack Growth Testing Creep, Stress-Rupture, and Stress-Relaxation Testing Shear Testing Torsion Testing Formability Testing Wear Testing Corrosion Testing Tests for Slress-Corrosion Cracking Tests for Hydrogen Embrittlement Metallography Metallographic Practices Generally Applicable to All Metals Metallographic Methods Principles of Technique Selection in Mechanical Polishing 1364 Electrolytic Polishing Procedures and Precautions for Preparation and Handling of Etchants Metallographic Technique for Ferrous Metals Technique for Carbon and Alloy Steels Technique for Case Hardening Steels Technique for Steel Castings Technique for Cast Irons Technique for Tool Materials Technique for Ferrous Powder MetaLlurgy Alloys Technique for Wrought Stainless Steels Technique for Stainless Steel Casting Alloys Technique for Fe-Cr-Ni Heat-Resistant Casting Alloys "l~pical Microstructures of Iron-Base Alloys Metallographic Technique for Nonferrous Metals and Special-Purpose Alloys Technique for Aluminum Alloys Technique for Copper and Copper Alloys Technique for Lead and Lead Alloys Technique for Magnesium Alloys Technique for Nickel and Nickel Alloys Technique for Wrought Heat-Resistant Alloys Technique for Magnetic Alloys Technique for Tin and Tin Alloys Technique for Titanium and Titanium Alloys Technique for Refractory Metals and Alloys Technique for Zinc and Zinc Alloys Measurement of Microstructure Materials Characterization Introduction and Overview Bulk Elemental Analysis X-Ray Diffraction for Bulk Structural Analysis Microstructural Analysis Surface Analysis Index xiv