Analytical Characterization of Aluminum, Steel, and Superalloys

768 Pages·2005·39.31 MB·English

by  D. Scott MacKenzie

A C
NALYTICAL HARACTERIZATION
A , S ,
OF LUMINUM TEEL
S
AND UPERALLOYS

A C
NALYTICAL HARACTERIZATION
A , S ,
OF LUMINUM TEEL
S
AND UPERALLOYS
edited by
D. Scott MacKenzie
George E. Totten
Boca Raton London New York
A CRC title, part of the Taylor & Francis imprint, a member of the
Taylor & Francis Group, the academic division of T&F Informa plc.
DK1326_Discl.fm Page 1 Tuesday, July 12, 2005 2:55 PM
Published in 2006 by
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International Standard Book Number-10: 0-8247-5843-9 (Hardcover)
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Library of Congress Cataloging-in-Publication Data
Analytical characterization of aluminium, steel, and superalloys / edited by D. Scott MacKenzie and George
Totten.
p. cm.
Includes bibliographical references and index.
ISBN 0-8247-5843-9 (alk. paper)
1. Aluminum--Analysis. 2. Steel--Analysis. 3. Heat resistant alloys--Analysis. I. MacKenzie, D. Scott.
II. Totten, George E.
TA480.A6A65 2005
620.1'86'0287--dc22 2005043721
Visit the Taylor & Francis Web site at
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Preface
The Analytical Characterization of Aluminum, Steel, and Superalloys addresses the needs of
the practicing materials scientist and engineer,whether in an industrial or university setting,
andtheadvancedstudent. Thishandbookprovides afundamental overview ofawiderange
of characterization methodologies and does not provide an experimental guide for specific
techniques.
Wehaveenlistedthetopresearchersandpractitionersintheworldtowriteintheirareas
of expertise and to critically discuss the methodologies to quantitatively evaluate properties
and microstructures. The result is a unique and outstanding text that will be an invaluable
companion reference guide to many advanced laboratory techniques to characterize the
microstructure of many different alloys including aluminum, steel, and superalloys.
Whilethisbookhasafocusonaluminum,thebasicanalyticaltechniquesarevalidforall
materials. Specifically, critical evaluation methodologies are described for aluminum, steel,
and superalloys. Some of the topics included in this handbook are:
(cid:1) Metallography. This standard methodology for evaluating microstructure is
thoroughly explained. An emphasis on proper selection of mounting materials
for superior edge retention is provided, as well as a discussion of different etching
methods.
(cid:1) Atlas of Microstructures. Over 700 different high-quality photomicrographs are
provided for alloys of aluminum, steel, and superalloys. These photomicrographs
illustrate the effects of thermo-mechanical processing, heat treatment, metallo-
graphicpreparation,andetching.Thiscollectionofphotomicrographsshowsmany
microstructures that are unavailable anywhere else and were prepared by global
experts in the field.
(cid:1) Thermal Analysis. This powerful technique is described in detail, with methodol-
ogy to extract a wealth of information regarding precipitate mechanisms, kinetics,
and precipitate stability.
(cid:1) X-Ray Diffraction. Two chapters on x-ray diffraction are provided that describe
in detail an overview of this classically important technology in addition to
applications of these methods.
(cid:1) ResidualStressMeasurement. Residualstressmeasurementisbecominganincrea-
singly critical part of component manufacturing since they are being designed for
lighter weight and higher performance. A comprehensive treatment of the various
types of residual stress measurements and their application is provided.
(cid:1) Transmission Electron Microscopy (TEM). This classical research tool for the
evaluation of microstructure is described in detail. Different electron diffraction
techniques and their application are described. Case histories are provided to
illustrate the various TEM methods.
(cid:1) Electron Backscatter Diffraction and Texture Measurement. This relatively new
analytical technique utilizes diffraction information contained in backscatter
electrons and is a powerful method to determine crystallographic orientation of
individualgrains,micro-textureofmaterials(astheyareaffectedbyprocessingand
deformation), and unit cell identification of precipitates. Specimen preparation
techniques are described, as well as operating parameters.
(cid:1) Micro-SpectroscopyofSurfaces. Surfacemodificationorengineeredsurfacesisan
importantnewfield.Totakeadvantageoftheseengineeredsurfaces,itisimportant
that quantitative surface structural characterization surfaces be performed. This
chapter addresses methodologies to accomplish this task.
(cid:1) Advanced techniques of Electron Momentum Spectroscopy, Positron Annihilation,
and Atomic Probe Tomography are discussed.
Thepreparationofthisbookwasatremendouseffortthatoftentaxedthepatienceofour
contributors, our publisher, and us. We are deeply indebted to the long hours that each of
our contributors provided writing chapters for this one-of-a-kind text. We would like to
thank our spouses, Alice Totten and Patricia MacKenzie, for their patience throughout the
process of putting this book together. We especially acknowledge Houghton International
for their continued support.
D. Scott MacKenzie
George E. Totten
Editors
Scott MacKenzie was born on March 15, 1956, in Lafayette, Indiana. He attended Culver
MilitaryAcademyfrom1970to1974,andthenwentontotheOhioStateUniversityin1977,
graduating in 1981 with a B.S. in metallurgical engineering. He worked at the Emerson
Electric Electronics and Space Division from 1981 to 1983, as a failure analysis and quality
engineer. From 1983 to 1994, he worked for McDonnell Douglas in St. Louis, Missouri,
as a manufacturing engineer, being responsible for all the heat-treating activities (aluminum
and steel) at the St. Louis facilities. The heat-treating facility was primarily responsible
for heat-treating landing gear for the F/A-18, and heat-treating control surfaces and other
structural aluminum members for the F/A-18, F-15, and AV-8B.
Scott MacKenzie attended the University of Missouri at Rolla from 1993 to 1995, and
was awarded an M.S. in metallurgical engineering. His thesis topic was Design of a Small
Endothermic Generator for Laboratory Use. He worked at Boeing, St. Louis, Missouri (after
the Boeing/McDonnell Douglas merger) from 1994 to 2000, as a failure analysis engineer,
and was responsible for the failure analysis of components, assemblies, and systems on
aerospace hardware. He was awarded the Boeing Associate Technical Fellowship in 1999.
AttendingtheUniversityofMissouriagainfrom1997to2000,MacKenziewasawarded
a Ph.D. in metallurgical engineering in December 2000 for his dissertation, Quench Rate
Effects on the Aging of Al-Mg-Zn-Cu Aluminum Alloys.
MacKenzieiscurrentlyworkingatHoughtonInternational,ValleyForge,Pennsylvania,
as a technical specialist in heat-treating products. He was chairman of the ASM Failure
Analysis Committee in 2000-2001, and is now co-chairman of the ASM Quenching and
Cooling Committee. He and his wife, Pat, have two children, Tory and Ian.
George E. Totten is a research professor in the Department of Mechanical and Materials
EngineeringatPortlandStateUniversity,andispresidentofG.E.Totten&Associates,LLC,
in Seattle, Washington State. He is co-editor of the Handbook of Aluminum Metallurgy,
Volumes 1 and 2, the Handbook of Metallurgical Design, the Handbook of Mechanical Alloy
Design, the Steel Treatment Handbook (all titles, CRC Press Inc.), and of approximately
450 professional publications on quenching, heat treatment, hydraulics, and lubrication.
Dr. Totten is a fellow of ASM International, SAE International, and the International
Federation for Heat Treatment and Surface Engineering (IFHTSE), and a member of the
American Chemical Society, the Society of Tribologists and Lubrication Engineers, the
American Society of Mechanical Engineers, and the American Society for Testing and
Materials, among other professional organizations.
Dr. Totten is a past president of IFHTSE. He received his B.S. and M.S. degrees from
Fairleigh Dickinson University, Teaneck, New Jersey, and his Ph.D. from New York
University, New York.

Contributors
Leonid B. Ber K. Hono
All-Russia Institute of Light Alloys Materials Engineering Laboratory
Moscow, Russia National Institute for Materials
Science
Clive R. Clayton Tsukuba, Japan
Department of Materials Science and
Engineering Thomas Jaeger
State University of New York Institut fu¨r Energie und
Stony Brook, New York Automatisierungstechnik
Fachgebiet Elektrische Messtechnik
David P. Field Technische Universita¨t Berlin
Berlin, Germany
School of Mechanical and Materials
Engineering
Washington State University Anatoli Kheifets
Research School of Physical Sciences
Pullman, Washington
and Engineering
Institute of Advanced Studies
Dieter Filbert
Australian National University
Institut fu¨r Energie und
Canberra, Australia
Automatisierungstechnik
Fachgebiet Elektrische Messtechnik
Technische Universita¨t Berlin Mukul Kumar
Lawrence Livermore National
Berlin, Germany
Laboratory
Consuelo Garcı´a-Cordovilla Livermore, California
Flat Rolling Products
Alcoa Europe H. P. Leighly, Jr.
Department of Metallurgical Engineering
Alicante, Spain
University of Missouri
Rolla, Missouri
Pelagia Gouma
Department of Materials Science
Enrique Louis
and Engineering
Departamento de Fı´sica Aplicada and
State University of New York
Unidad Asociada de Consejo
Stony Brook, New York
Superior de Investigaciones Cientı´ficas
Universidad de Alicante
Gary P. Halada Alicante, Spain
Department of Materials Science
and Engineering D. Scott MacKenzie
State University of New York Houghton International
Stony Brook, New York Valley Forge, Pennsylvania