INDUSTRIAL MATERIALS & METALLURGY
1st Semester |
S. No. |
Course Code |
Subject |
L |
T |
P |
Credits |
|
1 |
MT 501 |
Advanced Physical Metallurgy |
4 |
0 |
0 |
4 |
|
2 |
MT 502 |
Industrial Materials |
4 |
0 |
0 |
4 |
|
3 |
MT 503 |
Material Characterization Techniques |
4 |
0 |
0 |
4 |
|
4 |
|
Elective I |
4 |
0 |
0 |
4 |
|
Elective I |
S. No. |
Course Code |
Subject |
|
|
|
|
|
1 |
MT 504 |
Advanced Welding Technology |
|
|
|
|
|
2 |
MT 505 |
Particulate Materials & Industrial Systems |
|
|
|
3 |
MT 506 |
Mini Steel Plant Technology |
|
|
|
|
|
4 |
MT 507 |
Industrial Heat Treatment Practice |
|
|
|
|
|
5 |
MT 508 |
Advanced Foundry Technology |
|
|
Course Name : ADVANCED PHYSICAL METALLURGY
Course Code : MT 501
Credits : 4
L T P : 4 0 0
Lecture wise breakup No of lectures
PHASES (5)
Physical Nature of phase mixtures, thermodynamics of Solutions, Equilibrium between two phases, Two component systems containing two phases, Graphical determination of partial model free Energies, Two components with three phases in equilibrium, phase rule, Ternary systems (Introduction only), Problems.
BINARY PHASE DIAGRAMS (8)
Phase diagrams, Isomorphous alloy systems, Free Energy changes, Maxima minima Super Iattices, Miscibility Gaps, Eutectic Systems, microstructures, Peritectic, Monotectic, other three phase reactions, intermediate phases.
DIFFUSION IN SUBSTITUTIONAL SOLID SOLUTIONS (8)
Kirkendall effect, Porosity, Darken’s equations, Fick’s second law, Determination of intrinsic diffusivities, Self diffusion in pure metals, Temperature dependence of diffusion coefficient, Diffusion along grain boundaries, Free surfaces, Problems
INTERSTITIAL DIFFUSION (2)
Measurement of interstitial diffusivities, The snoek effect.
SOLIDIFICATION (5)
Nucleation and growth , Nature of liquid Solid interface, Continuous growth, Lateral growth, Dendritic growth, Solidification in alloy the Schil Equation, grain size castings, segregation, Homogenization.
The Iron – Carbon ally systems and selected Non ferrous alloy systems Cu-Alloy, A1 alloy, Ti alloy, Problems
(10)
Dislocations and grain boundaries
(4)
Plastic deformation
(4)
Strengthening – Precipitation Harding
(2)
Deformation Twinning and Martenstic Reasons
(2)
BOOK:
1. R.E. Reed Hill Abbaschain, Reza Abbaschain: Physical Metallurgy Principles REFERENCES:1. R.C. Sharma: Heat treatment of steels
2. R.C. Sharma: Phase transformation in materials
3. K.E Easterling, D.A. Poater Phase transformation in metals and alloys
4. Brick, R.M. and Phillips: Structure and Properties of Alloys, McGraw-Hill
5. Hume Rothery: Structural Metallurgy
6. Avner: Physical Metallurgy
7. Vijendra Singh: Physical Metallurgy
8. Clark and Varney: Physical Metallurgy
Course Name : INDUSTRIAL MATERIALS
Course Code : MT 502
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale: The course is meant to impart knowledge relating to selection of material. The course is designed to give an overview of different types of industrial material used in industry now a days
SELECTION OF MATERIALS (4)
Service requirement, Structure-Property correlations and reappraisal of the role of crystal structure and structural defects on properties.
METALLIC MATERIALS (10)
Engineering Ferrous materials, Aluminium, Copper, Nickel, Magnesium, Titanium alloys. Phase diagrams, properties and typical alloys with reference to their applications.
COMPOSITE MATERIALS (6)
Fibre reinforced, laminated and disperse materials with metallic matrix of aluminium, copper and Titanium alloys and with non metallic matrix of unsaturated polyesters and epoxv resins. Important properties of composting materials, their applications and development of these materials.
SYNTHETIC MATERIALS (6)
Classifications and structure of polymers, class transition temperature, mechanical properties of polymers. Artificial and synthetic materials.
NANO MATERIALS (6)
Classification, the structure, methods of their production, their properties and their sphere of applications.
SMART MATERIALS (6)
Shape Memory Alloys, Varistors and Intelligent materials for bio-medical uses including poly-acrylates, ABS plastics, polvmatha acrylates, nylon and teflon. Applications and development of these materials.
Case study of the failure of components due to wrong selection of materials.
(3)
Study and analysis of appropriate material for some specific application like aerospace, boiler tubes, turbine blades, automobiles and infrastructures (building and bridges).
(2) Course Name : MATERIAL CHARACTERIZATION TECHNIQUES
Course Code : MT 503
Credits : 4
L T P : 4 0 0
Lecture wise breakup No of lectures
Rationale: Characterizing a material involves the understanding of the ways the components of the material are arranged from atomic to a macro (visual with the eye) scale. These arrangements are correlated with the processing and coupled strongly with the material properties. Understanding these levels of the structure of materials is a basic part of the role of a materials person and this structural information serves as a means to understand and control the processing stages and to provide a similar basis for the physical properties of the material. This course provides with modern analytical techniques used by a metallurgist. It emphasizes the practical as well as the theoretical, describing the most common applications and limitations of each method.
Stereographic Projections, X-ray diffraction, crystal structure and phase identification,
residual stress measurement and other applications.
(10)
Outline of thermal analysis, technique, description of DTA/DSC/TGA techniques and instrumentation, applications, and case studies
(10)
Optical microscopy – light optics, microscope components, possibilities, and limitations. Scanning Electron Microscopy – Optics and performance of a SEM,
(04)
Image interpretation, crystallographic information in a SEM, analytical microscopy
(10)
Scanning Tunneling Microscopy
(04)
Transmission Electron Microscopy – Construction and operation of a TEM, Electron diffraction, Image interpretation
(10)
REFERENCES:
1. Introduction to Materials Characterization, ASM International, ASM Hand Book Vol 10
2. Developments in materials Characterization, edited by George Vander Voort and J. Friel, ASM International
Course Name : ADVANCED WELDING TECHNOLOGY
Course Code : MT 504
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale: The graduate student should be able to realize the importance of welding as a competitive component development/ reconditioning process. Since the attainment of properties being of vital significance, the appreciation of course will be aligned to the objective.
Welding as a Fabrication and repair process. Solidification structures in weld joints, alloying, diffusion and dilution. Metallurgical Changes in material during arc and gas Welding.
Pressure welding processes: solid phase bonding, friction welding, friction stir welding, Cold welding, ultrasonic welding, explosive welding, diffusion bonding and adhesive bonding. Resistance welding: spot, seam and projection welding. Flash and upset butt welding, percussion welding, HFRW & HFIW.
Electron beam and laser welding. Controls and applications of these processes.
Welding equipment, weld joint design, operations, techniques metal fusion and weld penetration, electrodes and their motion. Applications of GRAW for welding low steels, structures.
Welding of Stainless Steels and Aluminium in automotive, aeronautical and nuclear Industry :
Basic principle and welding variable and electrodes used joint design. Applications, Metal transfer, modes of metal transfer parameters effecting it and weld characteristics.
Metal surfacing and spraying – Introduction, selection of a surfacing process, materials of substate like, low alloy steels, plain ‘C’ steel with C O-45% classification & characteristics of surfacing materials – ironbase, Ni-base cobalt-base, Copper base alloys, carbides of Tungsten, Chromium surfacing techniques, Metal spraying & substate, caramic coatings, IS codes and specifications for welding materials & practices.
BOOKS:
1. R.S. PARMAR (1995) Welding processes and technology.
2. PATON, B.E. (Editor (1983) Electroslag welding and surfacing Vol. I to Z, MIR Pub. Moscow.
3. SMITH, DAVE; Welding I (1986). Skills and technology, McGraw Hill book Co. Sincapore, 1986.
4. TRENT, B.M. (1984) : Metal cutting, Buter worths, London 2nd Edn.
5. M.M. MANKO (1979) Solders and Soldering, McGraw Hill.
6. B. NIKALAEV (1979) Brasing and soldering of metals, Mir Pub. Moscow.
7. K.EASTERLING, Introduction to Physical Metallurgy of Welding, Butterworths Publication, 1983.
8. Sindo Kou Welding Metallurgy, John Wiley, 1987
9. S.A.David, Ed.; Advances in Welding Science and Technology, American Society for Metals, Ohio, 1986
Course Name : PARTICULATE MATERIALS AND INDUSTRIAL SYSTEMS
Course Code : MT 505
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale:The graduate student should be able to realize the importance of Particulate Materials & their Technology as a competitive component development process. The student should be able to identify, analyze and characterize component behavior when made by particulate technology
.
Particulate technology in process industry
(1)
Role of particulate size, its optimization
(2)
Introduction of fine and ultra fine powder by grinding, pulverization, liquid phase displacement and other techniques.
(4)
Measurement & characterization with special reference to morphological analysis.
(4)
Applications of laser micron sizes and other modern size analysers
(1)
Mixing and packing of powders. Uniaxial and isostatic processing, Shipping
(2)
Study of advanced shaping methods as applied to particulate systems, Metal Injection Molding (MIM)
(3)
Net shaping and consolidation techniques for particulate matters
(4)
Study of single and multiple practical attributes.
(2)
Advanced continuous compacting processes
(3)
Sintering of particulate matter
(3)
Theories of sintering
(3)
Industrial practice of sintering
(2)
Testing & quality control
(2)
Dispersion strengthened Particle systems
(3)
BOOKS:
1. German RM Particulate Material Science & Technology REFERENCES:
- UPADHYAYA G.S. (Editor) (1990). Sintering in multiphase Metal and Ceramic systems, Sci. Tech. publishers.
- ARUMACHLAN V.S. RAMAN O.V. (1989) Powder Metallurgy Recent advance, Oxford & IBM Publ.
- HOWARD. NULLIN & FERGUSON ELYNN (1994) Powder forging : Publ. European Powder Metals Assoc. London.
- THOMALER F ODERACKER R (1994), Powder Metallurgy Publ. European Powder Metals Assoc. London .
Course Name : MINI STEEL PLANT TECHNOLOGY
Course Code : MT 506
Credits : 4
L T P : 4 0 0
Lecture wise breakup No of lecturesINTRODUCTION Distinguishing Mini Steel Plant from Integrated Steel Plant w.r.t. raw materials used, furnaces and equipments, technology, rang of products, quality of products, economic and commercial aspects, employment opportunities.
MINI STEEL PLANTLayout of mini steel plants using different equipments/ furnaces and producing different products, case studies, scrap – sorting/sizing, importance and availability of local / imported scrap for MSP, Technical of commercial aspects energy optimization and pollution control.
ELECTRIC STEEL MAKINGArc furnace Vs Induction furnace, capital employed and productivity, design equipment and instrumentation, popularity and growth of induction furnace units. Refractories and other materials used viz sponge iron, Arc furnace and its operation, melting sponge iron Production of various types of steels viz mild steel, plain carbons steels, special alloy steels, stainless steel and tool steels, use of oxygen in refining operations. Induction furnace and melting practice. Coddle Metallurgy, Laddle furnace and other processes for secondary steels viz AOD, VOD, VAD, CLU, Argon stirring. Their process parameters and applications, ESR, ingot defects and remedies, Gases in steel. Degassing, and vacuum treatment of liquid steel, Non metallic inclusions in steel.
CONTINUOUS CASTING (CONCAST)
Introduction, technical commercial justification vis a vis energy conservation, plants equipment, product range, product quality, product cost.
Basic principles, process details, types of machines, metallurgical aspects, economical aspects, worldwide situation, current and future developments, continuous billet casting for high tonnage, modern trends in design of billet casting, thermal aspects, surface and internal quality of cast billet Problems in continuous casting of stainless steel, alloy steels, special steels, tool steels etc., continuous casting of blooms, slab, larger and thin sections viz thin sable thin strip. Near net shape casting.
Quality Assurance in MSP
Quality aspects of steel produced by MSP, methods of quality assessments, quality control in steels.
BOOKS:
1. Principles of secondary processing and casting of liquid steel – A Ghosh, Oxford and TBH publishing Co. Ltd.
2. Laddle Metallurgy principles and practices – R.J. Prueean, Allied Publishers, Madras.
3. Laddle Metallurgy – J. Szerlly, Co Carlsson, International Book House, Delhi.
4. Principles of secondary steel – Geol, Kapoor
Course Name : INDUSTRIAL HEAT TREATMENT PRACTICE
Course Code : MT 507
Credits : 4
L T P : 4 0 0
Lecture wise breakup No of lectures
Rationale: Most of the useful properties are related to the micro structural state of the material, which can be altered in a controlled way by the heat treating processing. In many products the control of the processing is closely coupled with some property test and/or a structural characterization. Analysis of failed products is used to obtain feedback into the processing and its control as well as the initial selection of both the material and the stages of processing. The course on Heat treatment will help the student to understand the heat treatment processing in materials and train them in tailoring of processing stages to control the structure and properties of materials.
Austenitization of steels
(02)
TTT and CCT Curves
(03)
Hardenability -- Concepts, measurement and calculations
(05)
Annealing, Normalizing, Hardening, Tempering
(08)
Case hardening processes
(08)
Selection and specification of steels
(05)
New technology such as thermo-chemical, thermo-mechanical & thermocycling treatments
(06)
Quantitative approach to heat-treatment
(03)
Failure analysis of heat treated products
(05)
Applications tailoring and computer harmonizing techniques
(05)
REFERENCES:
1. ASM Hand book on Heat treating, ASM International
Course Name : ADVANCED FOUNDRY TECHNOLOGY
Course Code : MT 508
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale: The graduate student should be able to realize the importance of Founding Technology as a competitive component development/ reconditioning process. Since the attainment of properties being of vital significance, the appreciation of course will be aligned to the objective of producing a sound casting with low energy and environmental burden
Casting as a competitive manufacturing process
Casting with ferrous, non-ferrous and super alloys: Technology in molding materials/ Dies, Influence of mechanical properties w.r.t pattern of solidification/ molding materials.
Casting design: melt treatment and casting techniques, modeling of casting
Solidification :automation and quality control, solidification structures, influence and control of grain size and second phase
Net-shape casting: advances, goal of net shaping, net shaping processes viz. liquid forging, Watts Technicon processes, DC casting, Thixoforming etc.
Foundry pollution and control, energy conservation in foundries
BOOKS:
1. R.W. Heine, C.R. Loper and P.C. Rosenthal, Principles of metal casting, Heine, Loper
REFERENCES:
1. G.J. Davies, Solidification and Casting by G.J.Davies, Applied Science Publishers Ltd. 1973.
2. I. Minkoff, Solidification and Cast Structure, I.Minkoff, John Wiley, 1986.
3. P.R.R. Beeley, Foundry Technology, P.R.R.Beeley, Butterworths, 1972.
4. ASM Metals handbook, Vol.15, 9th edition, 1988.
5. P.D. Webster, Fundamentals of Foundry Technology, P.D.Webster, Portculillis Press, 1980.
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