Chapter 9 Processing Steel to Finished Products. . . 172 9.1 Cold-Working Steel. . . . . . . . 174 9.2 Joining Steel Parts . . . . . . . . 183 9.3 Cutting, Grinding, and Polishing . . . 191 9.4 Controlling Corrosion . . . . . . . 192 Chapter 10 Phase Diagrams: The Road Map to Phases and Structures. . . . . . . . 198 10.1 Solutions and Mixtures You Know—Water and Antifreeze . . . 201 10.2 The Iron-Carbon Phase Diagram . . . 203 10.3 Transformations of Diff erent Steel Compositions . . . . . . . . 206 10.4 Eff ect of Cooling Rate on Structure and Properties . . . . . . . . . . 211 10.5 Additional Thermal Processing to Improve Properties . . . . . . . . 216 Chapter 11 Heat-Treating Steels for Strength, Toughness, and Ductility . . . . . . . 222 11.1 Heat Treatment—Metallurgical Eff ects and Equipment . . . . . . 224 11.2 Thermal Processing— Moderate Cooling Rate . . . . . . 230 11.3 Thermal Processing— Rapid Cooling. . . . . . . . . . . 235 11.4 Eff ects of Process Variations. . . . 240 11.5 Tempering Martensite . . . . . . 242 11.6 Heat-Treating Procedures Summarized . . . . . . . . . . . 243 11.7 Interrupted Quenching . . . . . . 244 11.8 Applications of Heat-Treated Steels. . . . . . . . . . . . . . 245 11.9 Drawbacks of Tempered Martensitic Steels. . . . . . . . . 247 Chapter 12 Heat-Treating Heavy Sections . . . . . 252 12.1 Heating and Quenching Heavy Sections . . . . . . . . . . . . . 254 12.2 Hardenability . . . . . . . . . . 259 12.3 Heat-Treating Equipment . . . . . 264 12.4 Precise Processing for Consistent Properties . . . . . . . . . . . . 266 Chapter 13 Surface Heat Treatment and Specialty Alloys. . . . . . . . . . . . 270 13.1 Surface Hardening of Carbon Steels . . . . . . . . . . 272 13.2 Stainless Steels . . . . . . . . . . 280 13.3 Tool Steels . . . . . . . . . . . . 286 13.4 High-Strength Low-Alloy (HSLA) Steels . . . . . . . . . . . . . . . 291 13.5 High-Performance Steels (HPS) . . . 293 Chapter 14 Production of Cast Iron . . . . . . . . 296 14.1 Cast Iron Compositions and Basic Properties . . . . . . . . . . . . 299 14.2 Basic Types of Cast Iron . . . . . . 302 14.3 Manufacture of Cast Iron Products . . . . . . . . . . . 306 SECTION 4 Nonferrous Metallurgy Chapter 15 Introduction to Nonferrous Metals. . . . 320 15.1 Atomic Structures in Metal Drive Unique Properties . . . . . . . . 322 15.2 Developing Desirable Properties by Working Metal . . . . . . . . . . 326 15.3 Strengthening through Alloying . . . 328 15.4 Reactions of Nonferrous Metals during Refi ning and Use . . . . . . 332 15.5 Processing Used in Nonferrous Metallurgy . . . . . . . . . . . . 333 15.6 Applications That Use Multiple Metals . . . . . . . . . . . . . . 346 Chapter 16 Aluminum . . . . . . . . . . . . . . 352 16.1 Extracting and Refi ning Aluminum from Ore and Scrap . . . 353 16.2 Aluminum Alloy Classifi cations . . . 355 16.3 Bulk Deformation of Aluminum. . . 357 16.4 Casting Aluminum . . . . . . . . 361 16.5 Strengthening Aluminum. . . . . 362 16.6 Properties of Aluminum Alloys. . . 366 16.7 Joining Aluminum. . . . . . . . . 367 16.8 Finish Processing of Aluminum. . . 370 ix