aspectsofstandardsmar2012-120308161514-phpapp02.ppt

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March 6, 2012 Aspects of StandardsMarch 6, 2012 Aspects of Standards

Aspects of StandardsWhy are they important?

And, examples in Metallurgical Testing

John M. Tartaglia, Ph.D.Senior Metallurgical Engineer & Engineering Manager

Element Wixom


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Webinar Schedule

Begin lecture at 1 pm

Lecture for about 50 minutes

Questions & Answers

During webinar and directly after webinar

Ask questions using the GoToWebinar question box

These questions will be answered in the remaining 10

minutes

After the webinar is posted, send me an email at

[email protected]

Aspects of Standards


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Presentation Requests & Materials

Supplied materials

1. PowerPoint slides You may download a copy of this webinar from our website within 48 hours

You may separately download a pdf copy of this presentation from thewebsite, without my voice

2. Element Materials Technology marketing information and scopes areavailable on our website: www.element.com

Topical Coverage

I picked topics based on my/our experience with these standards

Ill try to keep your interest

I wont cover all the notes; some of them are for reference only. Thismay be a good reason to download the pdf copy of the presentation.

I will cover and omit topics partly based on time expenditure

This presentation contains some of the presenters personal opinions.

Some parties may consider these assertions to be controversial.

The opinions do not represent ASTM, ASM, JIS, ISO or Element policy.



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Questions that will be (at least) partially

answered in this webinar

How are ASTM standards developed?

How often are ASTM & SAE test methods and other standards

revised?

What are the strengths and weaknesses of various types ofspecifications?

What are some guidelines for citing open specifications and testmethods in industrial part prints and contractual documents

What are some implications of using domestic standards forproducts produced in foreign locations?

What are some key differences between the metallurgicalstandards published by various organizations, e.g., SAE, ASTM,JIS, DIN, EN, ISO, etc.?



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Aspects of Standards Topics

Definition of standards

ASTM society description

ASTM collections and nomenclature

Types of ASTM committees & standards

Other standards organizations

ASTM standards numbering

ASTM standard revision timing

ASTM versus SAE test methods and specifications

Why bother and a sad story

Test method standards, including ASTM vs. other types Hardness and Mechanical Test Standards

Quantitative Metallography Standards



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What is ASTM?

Originally known as the American Society fo rTesting andMaterials (ASTM).

Begun in 1898 when engineers and scientists gathered to address

frequent rail breaks in the burgeoning railroad industry.

Now known asASTM International, which isone of the largestvoluntary standards development organizations in the world.

ASTM standards make products and services safer, better and morecost-effective.

Information on this and subsequent ASTM slides was obtained fromwww.astm.organd the ASTM Blue book

http://www.astm.org/http://www.astm.org/http://www.astm.org/


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ASTM vs. ASM

Note that ASTM and ASM are very different

ASTM is a standards-making organization ASM International:

Is the former American Society for Metals,

IsThe Materials Info rmation Soc iety,

Only supplies information about materials, Issues no standards, but

Publishes handbooks that are an excellent source for cross-referencing various metals and alloy specifications



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7 Categories of ASTM Committees

andStandards

A. Ferrous Metals

B. Nonferrous Metals

C. Ceramics, Glass, Concrete, InsulatorsD. Plastics, Paint, Rubbers, Wood, Packages

E. Miscellaneous Subjects (mostlytesting)

F. Fasteners, Electronics, Hazards,Amusement Rides

G. Corrosion, Wear, Erosion



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ASTM standards facts

12,000 standards Delivered by PDF file download, CD, or

77 book volumes of standards

Two digit section number precedes a period

Two digit volume number follows the period Example:

Section 3: Metals Test Methods and Analytical Procedures

Volume 03.01: MetalsMechanical Testing; Elevated and Low-Temperature Tests; Metallography

With the advent of computerized standard delivery, the ASTMbook volumes are becoming less significant and less used.

However, they are still extremelyvaluable for several specializedreasons like subject matter searches and alloy groupings because theASTM website does not quite give you this key wording perfection.



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Volume 03.01Metals

(most common in metals labs)1. Volume 03.01 includes tests and practices that

outline the standard procedures needed to

perform mechanical testing

2. Some standards define terms and explain

procedures related to fatigue testing and loading

3. Also featured are metallography tests and

practices



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ASTM standard is a

generic description standard, nas used in ASTM International, a

document that has been developed and

established within the consensus principles of

the Society and that meets the approval

requirements of ASTM procedures and

regulations.

The term standard is also used as a genericadjective in thetitle of documents, such as test methods or specifications. The

various types of standard documents are prescribed by the

ASTM committees.



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Primary types of

ASTM standards

1. specification, nan explicit set of

requirements to be satisfied by a

material, product, system, or service.

2. test method, na definitive procedure

that produces a test result.



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Other types of ASTM standards

3. guide, na compendium of information or series ofoptions that does not recommend a specific course ofaction.

4. practice, na definitive set of instructions for performingone or more specific operations that does not produce atest result. This is not really true; many practices doproduce a test result.

5. terminology standard, na document comprising

definitions of terms; explanations of symbols,abbreviations, or acronyms.



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Other standards-making

organizations

In this webinar, I mostly discuss ASTM and SAE

because they are the organizations that are

arguably most predominant in North Americaand Detroit, respectively, where Element

Wixom mostly operates.

However, there are many organizations that

issue standards.

To the left of this slide is an example, from a

survey, of all the organizations that issue

aerospace standards:


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JIS Background

The Japanese Standards Association is an organization thatformed in December 6, 1945.

The objective of the association is "to educate the publicregarding the standardization and unification of industrialstandards, and thereby to contribute to the improvement oftechnology and the enhancement of production efficiency".

The primary activity of JSA is to publish and distribute JIS(Japanese Industrial Standards)

JSA also publishes books on industrial standardization, qualitymanagement (control), administrative management, science andtechnology, JIS Handbooks, and other books.

http://www.jsa.or.jp/default_english.asp



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ISO Background

ISO standards are developed similarly to ASTM and according to the followingprinciples:

Consensus

The views of all interests are taken into account: manufacturers, vendors and users,consumer groups, testing laboratories, governments, engineering professions andresearch organizations.

Industry wideGlobal solutions to satisfy industries and customers worldwide.

VoluntaryInternational standardization is market driven and therefore based on voluntaryinvolvement of all interests in the market-place.

Example: Element laboratories have A2LA Accreditation

International Standard ANS/ISO/IEC 17025 General requirements for thecompetence of testing and calibration laboratories

http://www.iso.org/iso/home.htm



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DIN and EN Background

The creation of German standards is the task of DIN, a self-governing institution of tradeand industry.

DIN represents Germany and fulfils an equivalent function in the European and

International (ISO) standards organization. An EN standard is a European standard, with the status of a DIN or BS (British) standard.

CEN develops EN standard s, in the same way as ASTM and ISO:

Standards are developed through a consensus process;

Participants in standards development represent all concerned interests: industry, authorities and

civil society, contributing mainly through their national standards bodies;

Draft standards are made public for consultation at large;

The final and formal vote is binding on all members;

The European Standards (ENs) must b e transposed into nat ional standards and c onf l ict ingstandards withdraw n.

http://www.din.de/cmd?level=tpl-home&languageid=en http://www.cen.eu/cen/Pages/default.aspx



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ASTM standards

Numbering

Revision and issuance

Test methods Specifications

The sad stories..



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Standards Numbering Volume 03.01 contains standards produced by the

following committee(s): E04 on Metallography

E08 on Fatigue and Fracture

E28 on Mechanical Testing

E30 and E58 on Forensic Sciences and Engineering, respectively

Im a member of these three committees for Element

Wixom and I vote on new and revised standards that are

issued by several subcommittees of these committees.

The standards themselves are preceded by their letter

category and a chronological number (which varies from

one to four digits).



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Standards Numbering Example

E1234M-99a(2004)1

1. The E signifies that it is a Miscellaneous Subjects standard, andthat it was probably published by an E committee andsubcommittee.

2. The 1234 signifies that it is the 1234th standard developed in the Ecategory.

3. The M means the standard version with metric units. Sometimesthis is in a separate document like this example

Usually it is in the same document with the English units and calledE1234(E1234M)a(2004)e1.

4. The 99 signifies that it was originally adopted or last revised in 1999.

5. Standards can be revised every day, but in reality, it takes a ratherlong process with one or more votes.

The a signifies that it was revised once in 1999 after it was adopted or arevision was published during that year.


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Standards Numbering Continued

E1234M-99a(2004)1 (with rules)

6. The 2004 signifies that it was reapproved with nochanges during 2004.

All ASTM standards must be reapproved or withdrawn

(after a vote) within seven years. ASTM will automatically withdraw the standard when/if the

(sub)committee does not act to submit the standard forreapproval, revision or withdrawal vote within the sevenyears.

7. The e1 ore1 signifies that it was revised editorially. These editorial revisions do not require a vote and are

usually used to correct clerical mistakes.



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ASTM Standard Footnotes & Chronology

The footnotes at the bottom of the left hand column of each standardgive more pedigree information.

Chronology: The current edition was approved on July 1, 2007.

The current edition was published in September 2007.

The standard was originally published as E3-21T, which was in 1921.This is the oldest surviving E standard!

The last previous edition was E3-01, or the 2001 version. The 2007 reapproval makes it a separate version!

Both a committee and a subcommittee are involved in issuance: Jurisdiction of ASTM (Main) Committee E04 on Metallography

Direct responsibility of Subcommittee E04.01 on Specimen Preparation.



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Are your ASTM standards updated in

a timely manner?

ASTM standards change at any time

Some changes occur multiple times throughout the year.

With standards in book form, you probably dont have the

latest standard. If you update once a quarter, you are more timely, but you

are still behind.

ASTM email notification service is available

when a standard of interest is updated and downloadable

as a pdf.

Often entities, and even ASTM, references obsolete or

withdrawn standards!



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Incorporating ASTM standard revisions At Element Wixom, I read the standard and see what has changed.

(For the major ASTM test methods, I know this because Ive voted

on the standard revisions during development.)

The subcommittee authors sometimes make this easy with aNotification of Changes section since the last revision.

I then notify the laboratory staff who will be affected, and its theirresponsibility to incorporate the revisions into their daily test orcertification practice.

A2LA and other accreditation bodies like Nadcap require a fullcitation on a report for the relevant standard. This must include theyear and revision designation. I am surprised at how often thatsmissing on many laboratory reports!



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Other documents reference ASTM standards

Besides ASTM, many companies and standardizing bodiesissue test methods.

Almost all of these organizations refer to ASTM standards,

but not all of them do so correctly!

The major examples ofincorrect (or at least inadvisable)reference are as follows:

Including a year for the reference (which is exactly oppositeto the

requirement forareport)

Abstracting data from the cited ASTM standard, e.g., an alloy

composition

Both of these references are potentially out-of-date as soon as they

are published.



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An example of a print exhibiting a

problematic specification reference

Print DATE: 06/20/97

Material: LEADED RED BRASS PER ASTM B584-87 ALLOY UNS NO. C83600

Print requires (19)87 Version of ASTM B584

The earliest edition of the standard that we could find was (19)98a

The sample was out-of-specification for 98a

This is the current (2008) version of the ASTM standard.

However, the question remains:

Was the al loy o ut-of-speci f icat ion in the 1987 vers ion o f the ASTM standard?



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SAE vs. ASTM test methods

Test Method SAE ASTM

Hardness J417 Dec 1983

E10-10

E18-08b

E140-07

Decarburization J419 Dec 1983 E1077-01(2005)

Inclusions J422 Dec 1983 E45-11

Case Depth J423 Feb 1998 None!

ASTM is updated much more frequently so procedures are different.

SAE test methods, except for case depth, are hardly used anymore.



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SAE vs. ASTM alloy specifications

ASTM usually requires more and different things.

SAE has more ambiguities.

AlloySpecification

SAE ASTM

Plain Carbon

Steels

J403

November 2001(wrought only)

A684(A684M)-10aforstrip with separate

standards for wroughtproducts of different form

(sheet, plate, tube, bar, etc.)

or castings

Ductile Iron J434 Feb 2004 A536-84 (2009)



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Differences in plain carbon steel specifications

SAE J403 November 2001

Requires C range

Mn range

P maximum

S maximum Report other elements

Special callouts for B and/or Si ranges

Copper minimum

Lead (Pb) range

No discussion of residuals Ni, Cr, Mo

Could lead to a tool, alloy orstainless steel being classifiedas a plain carbon steel

ASTM A684 (A684M)-10a

Requires C range

Mn range

P maximum

S maximum Si range (although exceptions)

Report other elements

Special callouts for B and/or Si ranges

Lead (Pb) range

Residuals are limited Ni, Cr, Mo, and Cu

Strip thickness is specified



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Example: A true, but sanitized and relevant story

Major OEM buys a safety-critical fastener system from fastener manufacturer inaccordance with a print specifying 1050 steel per SAE J403.

Fastener manufacturer buys a component for the system from heat treater

Heat Treater buys 1050 steel from Service Center #1.

Service Center #1 buys 1050 steel from another service center (call it #2).

Service Center #2 supplies 3150 steel, and doesnt report (to Heat Treater andService Center #1) that the steel contains 0.8%Cr and 1.25%Ni.

Dont worry if youve never heard of 3150; it was only obsoleted in 1952.

Service center #1 reports only C, Mn, P, S, and Si to Heat Treater

Heat treater hardens and tempers 3150, certifies it as 1050, and reports ServiceCenter #1s composition to fastener manufacturer.

Fasteners embrittle in the field and this caused a large recall.

Major OEM very upset OEM metallurgists say everyone should know that 1050 steel wasnt supplied

OEM quality engineers and Tartaglia say 3150 steel is no different than 1050 steelbased on SAE J403



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Ways That Failures Can Be Caused by

Incorrect, Ambiguous, or Insufficient

Specifications or Test Methods Due to cost, availability, volume, or dimensional

considerations

Prototypes often survive Production Part Approval Process(PPAP),* but production material fails because it is specified

differently before production launch*PPAP definition Per AIAG (Automotive Industry Action Group)

Prototype testing is only conducted on one end of the specificationlimit, but production parts may still fail even if they meet designspecification

Specification is incomplete and inaccurate

Conformance testing is not specified or ambiguouslyspecified



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How can you be sure?

Test, test, test, TEST

Ask Element about what kind of tests to

run

Supply Element with your specifications

and ask us about certification options



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Aspects of Mechanical Testing

Standards

Definitions in ASTM E6

Different ASTM tensile test

methods

Determining yield strength and

modulus from tensile tests

Differing elongation methods

(ASTM vs. ISO & JIS)

Charpy V-notch toughness (ASTM

vs. ISO & JIS)



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ASTM tensile test methods

E8 standard English method

Uses psi or ksi and 4:1 gauge length to diameter/width ratio

Mechanical/Uniaxial ASTM E28.04 subcommittee

E8M standard metric units method

Now combined standard, with E8

Uses 5:1 gauge length to diameter/width ratio

Same as ISO and JIS test methods, except for elongation calculations Uses MegaPascals=MPa = MN/m2 = N/mm2( kg/mm2)

B557/B557M

For nonferrous wrought and cast aluminum and magnesium only

Light Metals and Alloys (product) ASTM B07.05 subcommittee responsibility

A370

For steel products

Includes many tests besides tensile

Steel (product) ASTM A01.13 subcommittee responsibility

All have virtuallysame requirements (now) thankfully



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Methods and terminology for strength

testing in various standards

JIS Z2241, and DIN EN 10 002-1 results have thesame yield and tensile strength requirements as ASTM,although the JIS and DIN test methods use differentsymbols for the results versus ASTM.

0.2%YS, UTS, El, and RA are yield strength, (ultimate)tensile strength, Elongation, and reduction of arearespectively, in ASTM standards

Rp is proof strength, Rm is tensile strength, Z is reductionof area, and A is elongation for EN and JIS standards

Proof vs. Yield

Offset method is used for 0.2% offset YS in US & 0.1%proof stress in UK

Upperand loweryield strength is terminology reserved fordiscontinuous yielding in all the standards

In JIS and DIN, offset method is used for proof and theword yield is reserved for discontinuous yielding

All standards define 5% EUL (extension under load);mostly for Cu alloys



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Elongation measurements1. Elongation atfracture

Total elongation per current versions of ASTM test methods E8, B557 andA370

Measured by extensometer

2. Elongation afterfracture (manual and plastic)

Measured physically by pushing fractured samples together (under 2 ksipressure, if desired)

Measure final gauge length with digital calipers

Will overestimate elongation in brittle materials because you cannot push sampleends together perfectly

Will be similar to #1 for ductile materials

3. ASTM elongation calculation is all the same for JIS Z2242.

4. ASTM elongation calculation is mostly the same for DIN EN 10 002 Part 1 DIN EN has somewhat different gauge length requirements for some

specimens, and thus elongation is calculated somewhat differently thanASTM and JIS.



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Whats the results section of the

standard test method require?

Assumption:

In this age of computers, you can get sophisticated data

Potential problem:

But shouldyou trust it (GIGO=garbage in-garbage out)?

Example:

ASTM E8, JIS Z2242, and DIN EN 10 045 Results

Reports onlyultimate tensile strength (UTS), yield strength (YS),

elongation (%El), and reduction of area (%RA) and a few otheritems under some conditions in all three types of standards

What about modulus (E) and digital stress-strain curves?


El ti d l d di it l t t i


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Elastic modulus and digital stress-strain

determination: ASTM E111

0

50

100

150

200

250

300

0.000 0.200 0.400 0.600 0.800 1.000 1.200 1.400 1.600

Engineering Strain %

Stress(ksi)

Extensometer Strain %

Strain Gauge Strain %

Although this full

curve looks OK,

Only small difference

between

extensometer and

strain gauge here

significant inaccuracy hasoccurred at low strains

here, so strain gauge must

be used!


Ch i t t h


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Charpy impact toughness

ASTM E23 and the other worldwide standards

Fast and inexpensive

Constant overall standard geometry (10 mm by 10 mm by 55mm) and apparatus

V-notch is the same throughout the world

All standards report energy in Joules or ft-lbs

Multiply ft-lbs by 1.355 to obtain Joules (J)

U-notch can have different depth in US versus Europe

ASTM E23 and JIS Z2242 = 5 mm depth (although JIS allows2 mm in special instances)

EN 10 045 = 5 mm

DIN 50 115 = 3 mm for DVM (special for some ductile castirons)

Notch depths will give much different energy results

No testing standard allows or discusses reporting of energydensity (Joules per mm2), but many users scale energiesfor subsize samples

Although some product testing standards allow thiscalculation, this energy density calculation is fraught with peril!



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Inclusion Definitions & Analyses

Indigenous (endogenous): A nonmetallic material thatprecipitates from the melt. An indigenous inclusion isnative.

Exogenous: A nonmetallic constituent produced byentrapment of foreign material in the melt.

Inclusion cleanliness severity ratings are usually appliedto indigenous inclusions only, and mostly in steels. I willdiscuss ASTM, German DIN, and Japanese JIS methodsfor these.

Inclusion content determinations and elemental analysescan be applied to all inclusion types and metal alloys. Iwont discuss these, but they are covered in ASTM testmethods and practices E1245, E2283, and E2142.



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Inclusion Cleanliness Severity

Standards

American ASTM E45

German DIN 50602

Japanese G0555

All three rate by color and morphology only

No composition determination

Severity is defined as thickness/width and length,except for JIS which is in %



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Sample requirements (ASTM+DIN+JIS)

Careful mount polishing is required toavoid

Corrosion of inclusions

Pullout of inclusions

JIS requires hardened samples

Required sample orientation

in the radial longitudinal orientation (G) forround stock

in the long transverse orientation (E) for flatstock

Required sample state

in the semi-finished state only (e.g., not

after being forged or formed into a product)

JIS suggests hardening some samples

Required minimum sample size of

minimum 160 mm2 (0.25 in2) rated area


I t ti l C i


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International Comparison:

(Same types, but different abbreviations)

Type Morphology and Color Hardness

ASTM DIN JIS

Sulfide

Elongated, gray, and continuous

(stringers) elongation (orientation)

in working direction

Soft &

plasticA SS A1

SilicateElongated, dark, and continuouselongation (orientation) in working

direction

Soft &plastic

C OS A2

Alumina

Elongated and fragmented

(granular) with discontinuous

elongation (orientation) in working

direction

Hard B OA B

Globular

Rounded and individual with no

preferred orientation with respect

to the working direction

Hard D OG C



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To take away

Standards are part of our lives and societies Accept them

Use them

Contribute to their improvement

Standards have precision and provide

Requirements

Test methods

Rules for commerce There are fine points that are similar and

different between various worldwide standards



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Contact for questions

John M. Tartaglia, Ph.D., FASMSenior Metallurgical Engineer &

Engineering Manager

Element Materials Technology

51229 Century Court

Wixom, MI 48393-2074

Tel: 248-960-4900 Ext. 329Fax: 248-960-5973

E-mail: [email protected]

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