Metals achieve engineering importance because of their abundance, variety, and unique properties as conferred by metallic bonding. The two most abundant metallic elements, iron (5.0%) and aluminum (8.1%), are also the most commonly used structural metals. Iron is the most-used metal, in part because it can be extracted from its frequently occurring, enriched ores with considerably less energy penalty than aluminum, but also because of the very wide range of mechanical properties its alloys can provide (as will be seen below). The cost of metals is strongly affected by strategic abundance as well as secondary factors such as extraction/processing cost and perceived value. Plain carbon steels and cast irons, iron alloys with carbon, are usually most cost- effective for ordinary mechanical applications. These alloys increase in cost with alloying additions. This bonding is different from other types of solids in that the electrons are free to acquire energy, and the metallic ions are relatively mobile, and quite interchangeable with regard to their positions in the crystal lattice, the three- dimensional repeating arrangement of atoms in a solid. Metals are good conductors of heat and electricity because thermal and electrical energy can be transferred by the free electrons. As a broad generalization, metallic elements with an odd number of valence electrons tend to be better conductors than those with an even number. Metals are opaque to and reflective of light and most of the electromagnetic spectrum, because electromagnetic energy is transferred to the free electrons and immediately retransmitted. Metals are almost always crystalline solids with a regular repeating pattern of ions. A number of atomic-level defects occur in this periodic array. A number of atomic-level defects occur in this periodic array. A large number of atomic sites are “vacancies” (point defects) not occupied by atoms The number and mobility of vacant sites increase rapidly with temperature. At a slightly larger level, linear atomic packing defects known as dislocations, give rise to the ability of metallic materials to deform substantially under load. Such a dislocation can break and remake bonds relatively easily in a metal and thereby shift an atomic distance Many dislocations moving in this fashion can give rise to significant shape change in the material at moderate stresses. The interaction of deformation, alloying elements, temperature, and time can cause a wide variety of microstructures in a solid metal down to near atomic levels with mechanical (and other) properties which can vary over a very wide range. It is possible to manipulate the properties of a single metal composition over a very wide range in the solid state — a behavior which can be used to mechanically form a particular metal and then use it in a demanding load-bearing application. One of the important technological advantages of metals is their ability to incorporate a wide variety of secondary elements in a particular metal and thereby create alloys of the metal. Alloying can increase the strength of a metal by several orders of magnitude and permit the strength and ductility to be varied over a wide range by thermal and/or mechanical treatment, resulting in ease of mechanical forming or resistance to deformation. Casting methods include expendable mold casting (investment/precision, plaster mold, dry sand, and wet sand casting), permanent mold casting (ingot, permanent mold, centrifugal, and die casting), and continuous casting (direct chill and “splat” casting). As cooling rate increases, the grain (crystal) size tends to be smaller and the strength increases while compositional segregation decreases, providing more uniform properties. Alloying additions can have profound consequences on the strength of me- tals. Major alloying additions can lead to multiphase materials which are stro- nger than single-phase materials. Small alloying additions may also sub- stantially increase strength by so-lute strengthening as solid solution sub- stitutional or interstitial atoms and or by particle strengthening as dispersion or precipitation hardening alloys. As the amount of an alloying element in solution increases, the strength in- creases as disloctions are held in place by the “foreign” atoms. The greater the ionic misfit (difference in size — Sn is a much larger ion than Ni), the greater the strengthening effect. Interstitial solid solution carbon contri- butes to the strength of iron and is one contributor to strength in steels and cast irons. Steels, perhaps the most important of all engineering metals, are alloys of iron and carbon usually containing about 0.02 to 1.0 w/o carbon. Steel strengthening treatments require heating into the austenite region (above the Ac3) and then quenching. Steel forming and heat treatment center on the transformation from austenite, γ phase, at elevated temperature to ferrite (α phase) plus cementite (iron carbide, Fe3C) below 727°C (1340°F), the Ac1 temperature, a eutectoid transformation.