2 Ferrous Metals and Their Alloys 59
2.1 Iron and Steels 59
2.1.1 Description and General Properties 59
2.1.2 Phase Transitions and Allotropism of Iron 64
2.1.3 Metallographic Etchants for Iron and Steels 66
2.1.4 History 66
2.1.5 Natural Occurrence,Minerals,and Ores 66
2.1.6 Mining and Mineral Dressing 70
2.1.7 Iron-and Steelmaking 71
2.1.8 Pure Iron Grades 73
2.1.9 The Iron-Carbon(Fe-C)and Iron-Cementite(Fe-Fe3C)Systems 73
2.1.10 Cast Irons 78
2.1.10.1 Gray Cast Iron or Graphitic Iron 79
2.1.10.2 White Cast Iron 79
2.1.10.3 Malleable Cast Irons 79
2.1.10.4 Ductile(Nodular)Cast Irons 79
2.1.10.5 High-Silicon Cast Irons 80
2.1.11 Carbon Steels(C-Mn Steels) 84
2.1.11.1 Plain Carbon Steels 85
2.1.11.2 Low-Alloy Steels 89
2.1.11.3 Cast Steels 95
2.1.12 Stainless Steels 95
2.1.12.1 Description and General Properties 95
2.1.12.2 Classification of Stainless Steels 96
2.1.12.3 Martensitic Stainless Steels 97
2.1.12.4 Ferritic Stainless Steels 97
2.1.12.5 Austenitic Stainless Steels 101
2.1.12.6 Duplex Stainless Steels 102
2.1.12.7 Precipitation-Hardening Stainless Steels 103
2.1.12.8 Cast Heat-Resistant Stainless Steels 103
2.1.12.9 Processing and Melting Process 103
2.1.12.10 Simplified Selection of Stainless Steels 108
2.1.12.11 Stainless Steel Application Guidelines 109
2.1.13 High-Strength Low-Alloy Steels(HSLA) 112
2.1.14 Ultrahigh-Strength Steels 115
2.1.15 Tool and Machining Steels 115
2.1.16 Maraging Steels 120
2.1.17 Iron-Based Superalloys 121
2.1.18 Iron Powders 122
2.1.18.1 Water-Atomized Iron Powders 122
2.1.18.2 Gas-Atomized Iron Powders 123
2.1.18.3 Sponge-Reduced Iron 123
2.1.19 Further Reading 123
2.2 Nickel and Nickel Alloys 124
2.2.1 Description and General Properties 124
2.2.2 History 124
2.2.3 Natural Occurrence,Minerals and Ores 125
2.2.4 Processing and Industrial Preparation 126
2.2.5 Nickel Alloys 127
2.2.6 Nickel Alloys and Superalloys 128
2.2.7 Nickel-Titanium Shape Memory Alloys 139
2.2.7.1 History 139
2.2.7.2 Fundamental 139
2.2.7.3 Shape Memory Effect 140
2.2.7.4 Superelasticity 140
2.2.7.5 Fabrication 140
2.2.8 Major Nickel Producers 141
2.3 Cobalt and Cobalt Alloys 141
2.3.1 Description and General Properties 141
2.3.2 History 142
2.3.3 Natural Occurrence,Minerals and Ores 143
2.3.4 Processing and Industrial Preparation 144
2.3.4.1 Cobalt as a Byproduct of Nickel Processing 144
2.3.4.2 Electrowinning of Cobalt 144
2.3.5 Properties of Cobalt Alloys and Superalloys 145
2.3.6 Corrosion Resistance of Stellites 148
2.3.7 Industrial Applications and Uses 148
2.3.8 Major Cobalt Producers 149
2.4 Manganese and Manganese-Based Alloys 149
2.4.1 Description and General Properties 149
2.4.2 History 151
2.4.3 Natural Occurrence,Minerals,and Ores 152
2.4.4 Processing and Industrial Preparation 153
2.4.4.1 Mining and Beneficiation of Manganese Ores 153
2.4.4.2 Preparation of Pure Manganese Metal 153
2.4.4.3 Ferromanganese and Silicomanganese 155
2.4.5 Industrial Applications and Uses 156
2.4.5.1 Metallurgical Uses 156
2.4.5.2 Nonmetallurgical Uses 156
2.4.6 Major Manganese Producers 157
3 Common Nonferrous Metals 159
3.1 Introduction 159
3.2 Aluminum and Aluminum Alloys 159
3.2.1 Description and General Properties 159
3.2.2 History 164
3.2.3 Natural Occurrence,Minerals,and Ores 165
3.2.4 Processing and Industrial Preparation 166
3.2.4.1 The Bayer Process 166
3.2.4.2 The Hall-Heroult Process for Electrowinning Aluminum 168
3.2.4.3 Secondary Aluminum Production and Recycling of Aluminum Drosses 169
3.2.5 Properties of Aluminum Alloys 170
3.2.5.1 Aluminum Alloy Standard Designations 171
3.2.5.2 Wrought Aluminum Alloys 172
3.2.5.3 Cast Aluminum Alloys 172
3.2.6 Industrial Applications and Uses 176
3.2.7 Major Aluminum Producers and Dross Recyclers 177
3.2.8 Further Reading 178
3.3 Copper and Copper Alloys 179
3.3.1 Description and General Properties 179
3.3.2 Natural Occurrence,Minerals,and Ores 179
3.3.3 Processing and Industrial Preparation 180
3.3.4 Properties of Copper Alloys 181
3.3.4.1 UNS Copper-Alloy Designation 181
3.3.4.2 Wrought Copper Alloys 183
3.3.4.3 Cast Copper Alloys 183
3.3.5 Major Copper Producers 187
3.3.6 Further Reading 187
3.4 Zinc and Zinc Alloys 187
3.4.1 Description and General Properties 187
3.4.2 History 188
3.4.3 Natural Occurrence,Minerals,and Ores 188
3.4.4 Processing and Industrial Preparation 189
3.4.4.1 Beneficiation of Zinc Ore 189
3.4.4.2 The Roasting Process 190
3.4.4.3 Mercury Removal 191
3.4.4.4 Hydrometallurgical Process 191
3.4.4.5 Pyrometallurgical Process 192
3.4.4.6 Treatment of Ferrite Residue 193
3.4.5 Industrial Applications and Uses 195
3.4.6 Properties of Zinc Alloys 196
3.5 Lead and Lead Alloys 196
3.5.1 Description and General Properties 196
3.5.2 History 199
3.5.3 Natural Occurrence,Minerals,and Ores 199
3.5.4 Beneficiation and Mineral Dressing 199
3.5.5 Processing and Industrial Preparation 199
3.5.6 Industrial Applications and Uses 201
3.5.7 Properties of Lead Alloys 201
3.5.8 Further Reading 201
3.6 Tin and Tin Alloys 204
3.6.1 Description and General Properties 204
3.6.2 History 205
3.6.3 Natural Occurrence,Minerals,and Ores 205
3.6.4 Processing and Industrial Preparation 206
3.6.4.1 Mining and Beneficiation 206
3.6.4.2 Processing and Smelting 207
3.6.5 Industrial Applications and Uses 208
3.6.6 Properties of Tin Alloys 208
3.7 Low-Melting-Point or Fusible Alloys 209
3.7.1 Further Reading 211