M.Tech.

Metallurgical and Materials Engineering - Scheme and Syllabi

METALLURGICAL AND MATERIALS ENGINEERING

RULES AND REGULATIONS SCHEME OF INSTRUCTION AND SYLLABI of

M.Tech. Programs

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

NATIONAL INSTITUTE OF TECHNOLOGY

WARANGAL 506 004

SCHEME OF INSTRUCTION AND EVALUATION

M.Tech. (Materials Technology)

I Year I Semester
S. No. 1 2 3 4 5 6 7 MM5104 Course No. MM5101 MM5102 MM5103 Course Name Phase Transformations in Materials Concepts in Materials Processing and Microstructural Evolution Mechanical Behaviour of Materials Elective - I Elective - II Elective - III Materials Processing and Microstructural Evolution Laboratory Materials Testing and Evaluation Laboratory Seminar TOTAL L T P C

4 4 4 3 3 3

0 0 0 0 0 0

0 0 0 0 0 0

4 4 4 3 3 3

0 0 0

0 0 0

3 3 3 9

2 2 2 27

8 9

MM5105 MM5191

18 0

I Year II Semester
S. No. 1 2 3 4 5 6 7 MM5153 Course No. ME5988 MM5151 MM5152 Course Name Materials Joining and Non-Destructive Testing Materials Characterization Techniques Particulate Materials Elective - IV Elective - V Elective - VI Materials Characterization Techniques Laboratory Particulate Materials Laboratory TOTAL L T P C

4 4 4 3 3 3 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 3 3 6

4 4 4 3 3 3 2 2 25

MM5154

21 0

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

II Year I Semester
S. No. 1 2 Course No. MM6142 MM6149 Course Name Comprehensive Viva-voce Dissertation Part-A TOTAL L 0 0 0 T 0 0 0 P 0 0 0 C 4 8 12

II Year II Semester
S. No. 1 Course No. MM6199 Course Name L T P C

Dissertation Part-B TOTAL

0 0

0 0

0 0

18 18

Credits requirements
Category of Course Departmental Core Courses Electives Mandatory Courses Dissertation Total Credits required
24 15

Credits offered 32 18 6 26 82

= 26 76 - 84

ELECTIVE COURSES
MM5111 MM5112 MM5113 MM5114 MM5115 MM5116 MM5117 MM5118 MM5119 MM5161 MM5162 MM5163 MM5164 MM5165 MM5166 MM5167 MM5168 MM5169 Environmental Degradation Materials Strengthening Mechanisms Alloy Design and Development Ceramics, Polymers and Composite Technology Advanced Thermodynamics and Kinetics Advanced Non Ferrous Metal Extraction Aerospace Materials Biomaterials Smart Materials Nuclear Meterials Refractory and Reactive Metal Extraction High Temperature Materials Nano Science and Technology Advanced Experiemental Techniques Industrial Powder Metallurgy Electronics Materials Surface Engineering Failure Analysis

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

SYLLABUS

M.Tech. (Materials Technology)

MM5101 PHASE TRANSFORMATIONS IN MATERIALS (4-0-0) 4

Introduction to thermodynamics and kinetics, basic crystallography, phase equilibria, phase diagrams, thermodynamics of transformations, free- energy vs composition curves in relation to phase diagrams, theory of nucleation and growth kinetics, diffusion in metals and materials, Pearlitic, bainitic, martensitic and massive transformations, spinoidal decomposition, precipitation phenomena, phase transformations in thin films, ceramics and glasses, shape memory effect, stress induced phase transformations. Reading: 1. A K Jena and M C Chaturvedi: Phase Transformations in Materials, Prentice Hall, 1992. 2. D. A. Porter and K. E. Easterling: Phase Transformations in Metals and Alloys, Van Nostrand Reinhold (International), 1989. 3. P.G. Shewmon: Transformations in Metals and Alloys, McGraw Hill Book Company, 1980. 4. S. P. Gupta: Solid State Phase Transformations, Allied Publishers, New Delhi, 2004. MM5102 CONCEPTS IN MATERIALS PROCESSING AND MICROSTRUCTURAL EVOLUTION (4-0-0) 4 Materials and processes, macro, micro and nanostructures, Micro-structural evolution, solidification, nucleation and growth kinetics, VAM, ESR, Induction melting, Zone refining, Czechrolski method, metal, ceramic and composite powder processing, metal working and heat treatment, joining methods, functional materials, residual compressive stresses, laser, friction, shot peening, functionally gradient materials, cellular structures, metallic foams, thin films and coatings. Reading: 1. Chester T. Sims, Williams C. Hagel: The Super Alloys, John Wiley & Sons, 1992. 2. V. Raghavan: Materials Science and Engineering, PHI, New Delhi 2004. 3. A. Upadhyaya, G S Upadhyaya: Materials Science and Engineering, Viva Books Pvt. Ltd, New Delhi, 2010. 4. R. Balasubramaniam (Adapted): Callister's Materials Science and Engineering, 7th Edition, Wiley India (P) Ltd., 2007. MM5103 MECHANICAL BEHAVIOUR OF MATERIALS (4-0-0) 4

Crystal structures, elastic properties of materials, theoretical cohesive strength, plastic deformation of metals, Bauschinger effect, flow, yield and failure criteria, dislocations, stress field, energy, sources and motion, effect of temperature and strain rate, strengthening mechanisms, concepts of fracture mechanics, strain energy release rate, Griffith theory, KIC, CTOD, J integral, plastic zone, Fatigue, S-N Curve, fatigue mechanism, creep, creep mechanisms and super plasticity.

Reading: 1. R. W. Hertzberg: Deformation and Fracture Mechanics of Engineering Materials, 4th Edition, John Wiley & Sons Inc., 1995. 2. M.A. Meyers and K.K. Chawla: Mechanical Behavior of Materials, Prentice Hall Inc., New Delhi, 1999. 3. T. L. Anderson: Fracture Mechanics- Fundamentals and Applications, 3rd Edition, CRC Press, 2011. 4. G. E. Dieter: Mechanical Metallurgy, McGraw-Hill, 2002.
MM5111 ENVIRONMENTAL DEGRADATION OF MATERIALS (3-0-0) 3

Corrosion principles - Electro chemical aspects- Environmental aspects- Metallurgical aspects - Forms of corrosion - Corrosion testing - Methods of corrosion prevention - Modern theory and principles - Corrosion rate measurement - Linear polarization technique - Tafel extrapolation- Electrode kinetics - High temperature Metal gas reactions - High temperature materials - Decarburisation and hydrogen attack and corrosion of metals by sulphur compounds at high temperatures.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

Reading: 1. Zaki Ahamad: Principles of Corrosion Engineering and Corrosion Control, Elsevier Sci. & Tech, 2006. 2. Fontana: Corrosion Engineering, McGraw Hill, New York, 2005. 3. Einar Bardal: Corrosion and Protection, Springer, 2004. 4. P.R. Roberge: Corrosion Engineering- Principles and Practice, McGraw Hill, New York, 2008.
MM5112 STRENGTHENING MECHANISMS (3-0-0) 3

Theoretical strength of crystals, activation volume and energy, Stages and theories of strain hardening, Elastic modulus, electrical, chemical and configurational interactions, Order hardening, Yield point, strain ageing and Snoek effect, precipitation, solution and dispersion hardening, Mechanism and characteristic features of martensitic and bainitic transformations. Strengthening due to point defects, grain refinement. Reading: 1. Derek Hull and D.J. Bacon, Introduction to Dislocations, Pergamon Press, 1994. 2. ASM Hand Book, Vol. 8, Mechanical Testing and Evaluation, 2000. 3. G. E. Dieter, Mechanical Metallurgy, McGraw Hill, 1988. MM5113 ALLOY DESIGN AND DEVELOPMENT (3-0-0) 3

Criteria for selection of materials, application of statistics in materials selection, specification of steels, Composition, heat treatment, microstructure and properties of ferrous and non-ferrous alloys, ceramics and polymers for light and heavy structural, corrosion resistant, magnetic, electrical and electronic applications, medical implants and prostheses application. Reading: 1. M.F. Ashby: Engineering Materials, 4th Edition, Elsevier, 2005. 2. M.F. Ashby: Materials Selection in Mechanical Design, Butterworth Heinemann, 2005. 3. ASM Publication, Vol.20: Materials Selection and Design, ASM, 1997. 4. Pat L. Mangonon: The Principles of Materials Selection and Design, Prentice Hall International, Inc. 1999. MM5114 CERAMICS, POLYMERS AND COMPOSITE TECHNOLOGY (3-0-0) 3

Ceramics, Classifications, Properties, Chemical bonding, Toughening mechanism, Processing of ceramics, Applications, Polymers, molecular weight, degree of polymerization, polymer crystallinity, molecular forces in polymers, introduction to polymer processing, Concept of composite materials, rule of mixtures, reinforcement geometry, Strength and Failure concepts, Composite Behavior and applications. Reading: 1. B. Raymond, Seymour and Charles E. Carraher Jr: Polymer Chemistry - An Introduction, 2nd Edition, Marcel Dekkar, Inc. New York, 1987. 2. Alan King: Ceramic Technology and Processing, Standard Publishers Distributors, 2004. 3. James S. Reed: Introduction to the Principles of Ceramic Processing, John Wiley, 1995. 4. A.B. Strong: Fundamentals of Composites Manufacturing- Materials, Methods and Applications, SME 1989. MM5115 ADVANCED THERMODYNAMICS AND KINETICS (3-0-0) 3

Concepts of micro and macro-states, Planck-Boltzmann equation, Solution theory, Quasichemical approach to solutions, activities in multi-component systems, Solubility of one component in another phase, Thomson - Freundlich equation, solubility of a metastable phase, retrograde solubility, Free energy vs composition diagrams, phase diagrams, Rate kinetics, diffusion of metals in fluids. Reading: 1. D. R. Gaskell, Introduction to Thermodynamics of Materials, Taylor and Francis, 2006. 2. Richardson, F.D., Physical Chemistry of Melts in Metallurgy, Vol. 1 and 2, Academic Press, 1974. 3. Matts Hillert: Phase Equilibria, Phase Diagrams and Phase Transformations: Their Thermodynamic Basis, Cambridge University Press, 1998.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

MM5116

ADVANCED NON FERROUS METAL EXTRACTION

(3-0-0) 3

Brief review of traditional methods of metal production of common metals such as copper, zinc, lead, aluminum - advanced converters for copper extraction- Hydrometallurgical processes for the extraction of zinc- flow sheets for the extraction of thorium, niobium, cobalt, zirconium, tungsten, molybdenum and gold. Reading: 1. C.A. Hampel, Rare Metals Hand Book, Robert E. Krieger Publishing Company, 1971. 2. Fathi Habashi, Hand Book of Extractive Metallurgy, Vols. II and III, Wiley- VCH, 1997. MM5117 AEROSPACE MATERIALS (3-0-0) 3

Requirements of space and aerospace materials, land base and aerospace materials, Identification of components of aero planes, space vehicles and missiles, materials usage in each sections and criticality of the components and their materials selection, gas turbine and aero engines, Creep, fatigue and corrosion, Ni and Co based super alloys, Special steels, Titanium alloys, Intermetallics, ceramics and their composites, New High strength materials. Reading: 1. Michael F. Ashby: Materials Selection in Mechanical Design, Butterworth-Heinemann, 2005. 2. George F. Titterton: Aricraft Materials and Processes, Himalayan Books, New Delhi,1998. 3. F.C.Campbell: Manufacturing Technology for Aerospace Structural Materials, Elsevier, UK, 2006. 4. Balram Gupta : Aerospace Materials with Material Technology for Engineers, Vol 1-4, S. Chand & Co., New Delhi, 1996 and 2002. MM5118 BIOMATERIALS (3-0-0) 3

Properties of Materials, Materials in Medical Applications, Stainless steel alloys, Cobalt based alloys, titanium based alloys, polymers, Bioresorbable and Bioerodible materials, bioceramics, porous ceramics, bioactive glasses, calcium phosphates, collagen, thin films, grafts and coatings, biological functional materials Latex products. Reading: 1. Shi, D: Biomaterials and Tissue Engineering, Springer, 2004. 2. Buddy D. Ratner, Bio Material Science: An introduction to Materials in Medicine, Elsevier, 2004. 3. S. V. Bhatt, Biomaterials, Narosa, 2002. MM5119 SMART MATERIALS (3-0-0) 3

Composites, Smart materials and their properties, Piezoelectric, magneto structure, Shape memory materials, Electro Rhieological fluids, Optical fibers, actuation, sensing and control augmentation, distributed/discrete sensing and actuation, methods of analyses, finite elements, applications: Vibration suppression, shape control, sizing and optimization. Reading: 1. Gandhi M V and Thompson B S, Smart Materials and Structures, Chapman & Hall, Madras, 1992. 2. Meirovitch L., Dynamics and Control of Structures, John Wiley, 1992. MM5104 MATERIALS PROCESSING AND MICROSTRUCTURAL EVOLUTION LABORATORY (0-0-3) 2

Synthesis of alloys, Heat treatment of high carbon steels and Al- alloys, Ageing of Aluminum alloys, Electrodeposition, plating and refining, Anodizing, Material forming by extrusion and injection molding, Rolling and sheet metal forming / tape casting / wire drawing, joining of metals, Thin film preparation / coating, Surface modification using fluidized bed. MM5105 MATERIALS TESTING AND EVALUATION LABORATORY (0-0-3) 2

Hardness, Tensile, Compression, Impact, wear, and erosion testing, Microhardness and indentation fracture toughness, Creep and stress rupture tests, fatigue testing, Corrosion tests - Pitting corrosion, NDT techniquesUltrasonic, magnetic particle, die penetrant test, Polarization studies.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

MM5151

MATERIALS CHARACTERIZATION TECHNIQUES

(4-0-0) 4

Classification of materials characterization techniques, principles of different microscopes (optical, electron microscopes, SEM, TEM, FEM, AFM, STM etc.,) and the preparation of samples, different modes and their applications, Spectroscopy techniques UV-Visible, AAS, AES, IR, FTIR, Raman etc., Thermal methods (DTA, TGA, DMA, DSC Dilatometry) interpretation of data.

Reading: 1. ASM Handbook: Materials Characterization, ASM International, 2008. 2. Robert F. Speyer: Thermal Analysis of Materials, Marcel Dekker Inc., New York, 1994. 3. V. T. Cherapin and A. K. Mallik: Experimental Techniques in Physical Metallurgy, Asia Publishing House, 1967. 4. S.J.B. Reed: Electron Microprobe Analysis, Cambridge University Press, London, 1975.
MM5152 PARTICULATE MATERIALS (4-0-0) 4

Preparation of metallic, ceramic and composite powders, Powder characterization, Shape Forming, Compaction, extrusion, injection molding, tape forming, slip casting and sol-gel casting, Powder coating on substrates, Flame and plasma spraying, elctrophoresis, electro-deposition, sol-gel coating, Solid state sintering, liquid phase sintering, reaction sintering, hot pressing, hot isostatic pressing and self propagating combustion sintering.

Reading: 1. ASM Hand book, Vol. 7: Powder Metallurgy, ASM International, 2010. 2. W.D. Kingery, H.K. Bowen and D.R. Uhlmann: Introduction to Ceramics, John Wiley & Sons, New York, 2009. 3. G. S. Upadhyaya: Powder Metallurgy Technology, Cambridge International Science Publishing, 2002. 4. P. C. Angelo and R. Subramanian: Powder Metallurgy- Science, Technology and Applications, PHI, New Delhi, 2008.
ME5988 MATERIALS JOINING AND NON-DESTRUCTIVE TESTING (4-0-0) 4

Solid state welding- friction stir processing, and friction stir surfacing, process characteristics and applications, friction stir processing of particle reinforced composite materials, electron beam welding- weldability of aluminum and its alloys, Mg and its alloys and steels, flux cored arc welding, laser beam welding, cracks in welds, operations, advantages and limitations, applications, liquid penetration test, eddy current test, ultrasonic test, magnetic particle test, X-ray radiography test.

Reading: 1. R S Mishra: Friction Stir Welding and Processing, ASM International, 2007. 2. R.S. Parmer: Welding Processes and Technology, Khanna Publishers, 2005 3. Baldevraj : NDT Techniques, Indian Institute of Metals, Calcutta, 2004.
MM5161 NUCLEAR MATERIALS (3-0-0) 3

Nuclear energy fundamentals - General feature of nuclear reactors - classification of nuclear reactors based on applications - moderator configuration- materials for nuclear - Reactor minerals - Occurrence in India Properties and processing of reactor fuels and other materials - Radiation protection standards-Radiation effects in solids - Radiation hazards and shielding - Uses of radioactive isotopes - Disposal of radioactive wastes - Nuclear power reactors in India.

Reading: 1. Bodansky: Nuclear Energy- Principles, Practices and Projects, Springer, 2004. 2. S. Glasstone and A. Sesonke: Nuclear Reactor Engineering, CBS Publishers and Distributors, Delhi, 2003. 3. C.A. Hampel: Rare Metals Hand Book, Robert E. Krieger Publishing Company, 1971.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

MM5162

REFRACTORY AND REACTIVE METAL EXTRACTION

(3-0-0) 3

Refractory and reactive metals and their applications-Principles. Techniques and limitations of chemical / pyro-chemical methods of upgrading ores- Purification of concentrates / compounds and production of intermediate salts- Basic chemistry of rare / reactive metal reduction and refining- Flow sheets for the extraction of uranium, zirconium, titanium, Beryllium, Niobium, Tantalum, Tungsten, Molybdenum and Vanadium. Reading: 1. C.A. Hampel, Rare Metals Hand Book, Robert E. Krieger Publishing Company, 1971. 2. Fathi Habashi, Hand Book of Extractive Metallurgy, Vols. II and III, Wiley- VCH, 1997. MM5163 HIGH TEMPERATURE MATERIALS (3-0-0) 3

Creep, thermal fatigue, oxidation, high temperature corrosion, erosion, Ageing, structural changes, material damage, Crack propagation, damage mechanics, life time analysis, Creep resistant steels, superalloys, ceramics and polymers for high temperature applications, intermetallics, Usage of high strength steels, Spring steels, Fatigue, Evaluation of property data, extrapolation. Reading: 1. Evans, R.W and Wilshire, B: Creep of Metals and Alloys, Institute of Metals, London, 1985. 2. J. R. Davis: ASM Specialty Hand Book: Heat - Resistant Materials, ASM, 1997. MM5164 NANO SCIENCE AND NANO TECHNOLOGY (3-0-0) 3

Significance, properties and applications nanomaterials, carbon nano structures, nano indentation, super plastic behavior of nanomaterials, Ceramic nanosystems, quantum confinement, effect of size reduction on optical, electrical, electronic, mechanical, magnetic and thermal properties of materials, nano electronics, Nano fluidics, NEMS, photonic crystals, biomimetic nano structures. Reading: 1. Sulabha K. Kulkarni: Nanotechnology Principles and Practices, Capital Publishing Company, 2007. 2. H. Hosono, Y. Mishima, H. Takezoe and K.J.D Mackenzie: Nanomaterials-From Research to Applications, Elsevier Ltd., Noida, 2008. 3. Massimilano Di Ventra, S. Evoy and James R. Heflin, Jr.: Introduction to Nanoscale Science and Technology, Springer, Noida, 2009. 4. Charles P. Poole Jr. and Frank J. Owens: Introduction to Nano-technology, Wiley India, New Delhi, 2010. MM5165 ADVANCED EXPERIMENTAL TECHNIQUES (3-0-0) 3

Design of electron microscope, Field emission and Field ion microscopes, SEM, principles of microprobe analysis, specimen preparation and image interpretation, Applications of DTA and TGA, Dilatometry and interferometry, Growth of single crystals by zone melting. Reading: 1. Robert F Speyer: Thermal Analysis of Materials, Marcel Dekker, 1994. 2. Kauffmann: Characterization of Materials, Vols I & II, John Wiley, 2005. 3. ASM Handbook, Vol 10: Materials Characterization, ASM Intl., 2004. MM5166 INDUSTRIAL POWDER METALLURGY (3-0-0) 3

Basic steps of powder metallurgy, SWOT analysis of powder metallurgy, advanced powder fabrication and sintering techniques, Production of filters, self-lubricating bearings, gears, friction parts, electrical materials, sintering of carbide tools, fabrication difficulty of tungsten filament, synthesis and sintering of hydroxyapatite (HAP) and other bioceramics, powder metallurgy of stainless steel, Application of powder metallurgy in Indian industries. Reading: 1. G. S. Upadhyaya, Powder Metallurgy Technology, Cambridge International Science Publishing, 1998. 2. ASM Handbook, Vol-7, Powder Metallurgy, ASM International, 2010.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

3. P. C. Angelo and R. Subramaniam, Powder Metallurgy - Science, Technology and Application, PHI, New Delhi, 2008. 4. R. M. German, Powder Metallurgy- Principles and Applications, MPIF, Priceton, 1994. MM5167 ELECTRONIC MATERIALS (3-0-0) 3

Semiconductor materials, Wafer Technology, Basic patterning and surface preparation to exposure, photomasking, photoresist and their performance factors, Etching, dry and wet etching, resistor stripping, Chemical vapor deposition, Plasma Enhanced CVD, Vapor phase epitaxy, molecular beam epitaxy, MOCVD, deposited films, Photolithography process, Antireflective coatings. Reading: 1. Peter Van Zant: Microchip Fabrication, 4th Edition, McGraw Hill 2000. 2. James R. Chelikowsky: Electronic Materials - A New Era in Materials Science, Springer Verlag, 2001. MM5168 SURFACE ENGINEERING (3-0-0) 3

Importance and need of surface engineering, Past, present and future status of surface engineering; Damage of the surfaces by corrosion and wear, wear mechanisms and categories of wear, Substrates and their pretreatments, Purpose and scope of surface coatings, Overlay and diffusion coatings, surface modifications by diffusion coatings, by overlaying coatings, by heat treatment, surface processing by laser, electrons and ions, Characterization and Evaluation of coatings, Economics and energy considerations, and designing of surface engineering processes. Reading: 1. Tadeusz Burakowski and Tadeusz Wierzchon, Surface Engineering of Metals: Principles, Equipment, Technologies, CRC Press, 1999. 2. K. G. Budinski, Surface Engineering for Wear Resistance, Prentice Hall, New Jersey, 1998. 3. Howard E. Boyer (Editor), Case Hardening of Steel, ASM International, Metals Park, OH 44073. 4. ASM Metal Hand Book, Vol 20, Surface Engineering, ASM Int, 2004. MM5169 FAILURE ANALYSIS (3-0-0) 3

Aims of failure analysis, Prime factors in the premature failure of metallic components and structures, Tools and techniques in failure analysis, Types of failures: ductile, brittle, fatigue, creep, corrosion, wear etc., fractography, mixed mode and fatigue failures, Failure mechanisms, Embrittlement phenomena, environmental effects, Failures due to faulty heat treatments, Failures in metal forming and welding, Case studies in failure analysis, Prevention of failures, case histories of component failures. Reading: 1. S.T.Rolfe and J.M.Barsom, Fracture and Fatigue Control in Structures, Prentice Hall, 1972. 2. David and Bruck, Elementary Egnineering Fracture Mechanics, Norelho, 1975. 3. S. Suresh, Fatigue of Materials, Second Edition, Cambridge University Press, 1998. 4. ASM Metals Hand Book, Failure Analysis and Prevention, Vol. 11, ASM, 2002. MM5153 MATERIALS CHARACTERIZATION TECHNIQUES LABORATORY (0-0-3) 2

DSC, TGA, XRD, Analysis of residual stresses and texture, Phase analysis and lattice parameter calculations, SEM, EDX, optical microscopy, Gas chromatograph, UV-Visible spectroscopy, Chemical analysis of materials including C-O-H-N-S, SEM of ceramic materials, Atomic Force microscopy and scanning Tunneling Microscopy. MM5154 PARTICULATE MATERIALS LABORATORY (0-0-3) 2

Ball milling of powders, Chemical synthesis of powders, Electrolytic synthesis of iron powder, Cementation of powders, Determination of size and size distribution of metal powders, Determination of apparent density, tap density, flow rate of metal powders, Determination of surface area, Compaction of metal powders and determination of green density, Sintering of metal powders and determination of sintered density.

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

M.Tech. (Industrial Metallurgy)

I Year I Semester

S. No. 1 2 3 4 5 6 7 8 9

Course No. MM5201 MM5202 MM5203

Course Name Concept in Materials Processing and Microstructural Evolution Advanced Ferrous Production Technology Advanced Metal Casting Elective - I Elective - II Elective - III

4 4 4 3 3 3 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 3 3 3 6

4 4 4 3 3 3 3 2 2 27

MM5204 MM5205 MM5291

Materials Processing and Microstructural Evolution Laboratory Materials Testing and Evalution Laboratory Seminar TOTAL

18 3

I Year II Semester
S. No. 1 2 3 4 5 6 7 8 MM5989 MM5253 Course No. ME5988 MM5251 MM5252 Course Name Materials Joining and Non-Destructive Testing Materials Characterization Techniques Powder Processing Technology Elective - IV Elective - V Elective - VI Metal Joining Laboratory Powder Processing Laboratory TOTAL L T P C

4 4 4 3 3 3 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 3 3 6

4 4 4 3 3 3 2 2 25

18 3

10

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

II Year I Semester
S. No. 1 2 Course No. MM6242 MM6249 Course Name Comprehensive Viva-voce Dissertation Part-A TOTAL L 0 0 0 T 0 0 0 P 0 0 0 C 4 8 12

II Year II Semester
S. No. 1 Course No. MM6299 Course Name L T P C

Dissertation Part-B TOTAL

0 0

0 0

0 0

18 18

Total Number of Credits = 82

Credit requirements
Category of Course Departmental Core Courses Electives Mandatory Courses Dissertation Total Credits required
24 15

Credits offered 32 18 6 26 82

= 26 76 - 84

ELECTIVE COURSES
MM5211 MM5212 MM5213 MM5214 MM5215 MM5216 MM5217 MM5218 MM5219 MM5261 MM5262 MM5263 MM5264 MM5265 MM5266 MM5267 MM5268 MM5269 Environmental Degradation Materials Energy Conservation and Pollution Control in Metallurgical Industries Materials Selection and Design Ceramics, Polymers and Composite Technology Advanced Thermodynamics and Kinetics Advanced Non Ferrous Metal Extraction Computer Applications in Materials Engineering Process Modeling and Simulation Special Steels Nuclear Metallurgy Rare and Reactive Metal Extraction High Temperature Materials Nano Technology Advanced Experiemental Techniques Industrial Powder Metallurgy Advances in Mechanical Working Fracture Mechanics Failure Analysis

11

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

M.Tech. (Industrial Metallurgy)

MM5201 CONCEPTS IN MATERIALS PROCESSING AND MICROSTRUCTURAL EVOLUTION (4-0-0) 4 Materials and processes, macro, micro and nanostructures, Microstructural evolution, solidification, nucleation and growth kinetics, VAM, ESR, Induction melting, Zone refining, Czechrolski method, metal, ceramic and composite powder processing, metal working and heat treatment, joining methods, functional materials, residual compressive stresses, laser, friction, shot peening, functionally gradient materials, cellular structures, metallic foams, thin films and coatings. Reading: 1. Chester T. Sims, Williams C. Hagel: The Super Alloys, John Wiley and Sons, 1992. 2. V. Raghavan: Materials Science and Engineering, PHI, New Delhi, 2004. 3. A Upadhyaya, G S Upadhyaya: Materials Science and Engineering, Viva Books Pvt. Ltd., New Delhi, 2010. 4. R Balasubramaniam (Adapted): Callister's Materials Science and Engineering, 7th Edition, Wiley India (P) Ltd., 2007. MM5202 ADVANCED FERROUS PRODUCTION TECHNOLOGY (4-0-0) 4

Blast Furnace Iron production and its limitations, Sponge Iron Processes- HYL, SL/RN, Midrex, HIB and Fluidised bed Processes, Smelt reduction Processes- COREX, INRED and ELRED and mini blast furnaces, modern steel making processes, Physical Chemistry of steel making, Deoxidation, Secondary Steel Making processes. Reading: 1. Amit Chatterjee: Beyond the Blast Furnace, CRC Press, 1992. 2. Ahindra Ghosh and Amit Chatterjee: Iron Making and Steel Making- Theory and Practice, Prentice Hall of India Pvt. Ltd., 2008. 3. Ahindra Ghosh: Secondary Steel Making- Principles and Applications, CRC Press, 2001. 4. B IIschner and N J Grant (Eds): Ladle Metallurgy, Springer Verlag, New York, 1989. MM5203 ADVANCED METAL CASTING (4-0-0) 4

Pattern design and construction, Solidification of metals and alloys, gating and risering of castings, metal filtration, special casting techniques, typical problems encountered during melting and casting, Fettling and heat-treatment of castings, casting defects, modernization and mechanization of foundries. Reading: 1. A.K. Chakrabarti: Casting Technology and Cast Alloys, PHI Learning Pvt. Ltd., New Delhi 2009. 2. P.L. Jain: Principles of Foundry Technology, Tata McGraw Hill, 1983. 3. Peter Beeley: Foundry Technology, Newnes Butterworths, London, 1972. 4. John Campbell: Castings - The New Metallurgy of Cast Metals, 2nd Edition, Elsevier, 2004. MM5211 ENVIRONMENTAL DEGRADATION OF MATERIALS (3-0-0) 3

Corrosion principles- Electro chemical aspects- Environmental aspects- Metallurgical aspects - Forms of corrosion - Corrosion testing - Methods of corrosion prevention - Modern theory and principles - Corrosion rate measurement- Linear polarization technique - Tafel extrapolation- Electrode kinetics - High temperature Metal - gas reactions- High temperature materials - Decarburisation and hydrogen attack and corrosion of metals by sulphur compounds at high temperatures. Reading: 1. Zaki Ahamad: Principles of Corrosion Engineering and Corrosion Control, Elsevier Sci. & Tech, 2006. 2. Fontana: Corrosion Engineering, McGraw Hill, New York, 2005. 3. Einar Bardal: Corrosion and Protection, Springer, 2004. 4. P.R. Roberge: Corrosion Engineering - Principles and Practice, McGraw Hill, New York, 2008.

12

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

MM5212

ENERGY CONSERVATION AND POLLUTION CONTROL IN METALLURGICAL INDUSTRIES

(3-0-0) 3

Forms of energy, energy conversion, energy sources and resources, Review of commercial energies from solid, liquid and gaseous fuels, Nuclear energy systems, Improving energy efficiency in extractive metallurgical processes, Recycling of energy, Gas recovery in metal processing industries, gas cleaning and removal of particulate matter from gases. Reading: 1. Harker and Backhurst, Fuel and Energy, Academic Press, London, 1981. 2. C. B. Gill, Non-Ferrous Extractive Metallurgy, John Wiley, 1980. 3. S. P. Mahajan, Pollution Control in Process Industries, Tata McGraw Hill, 1985. MM5213 MATERIALS SELECTION AND DESIGN (3-0-0) 3

Criteria for selection of materials, application of statistics in materials selection, specification of steels, Composition, heat treatment, microstructure and properties of ferrous and non-ferrous alloys, ceramics and polymers for light and heavy structural, corrosion resistant, magnetic, electrical and electronic applications, medical implants and prostheses application. Reading: 1. M.F. Ashby: Engineering Materials, 4th Edition, Elsevier, 2005. 2. M.F. Ashby: Materials Selection in Mechanical Design, Butterworth Heinemann, 2005. 3. ASM Publication, Vol.20: Materials Selection and Design, ASM, 1997. 4. Pat L. Mangonon: The Principles of Materials Selection and Design, Prentice Hall International, Inc. 1999. MM5214 CERAMICS, POLYMERS, AND COMPOSITE TECHNOLOGY (3-0-0) 3

Ceramics, Classifications, Properties, Chemical bonding, Toughening mechanism, Processing of ceramics, Applications, Polymers, molecular weight, degree of polymerization, polymer crystallinity, molecular forces in polymers, introduction to polymer processing, Concept of composite materials, rule of mixtures, reinforcement geometry, Strength and Failure concepts, Composite Behavior and applications. Reading: 1. B. Raymond, Seymour and Charles E. Carraher Jr: Polymer Chemistry- An Introduction, 2nd Edition, Marcel Dekkar, Inc. New York, 1987. 2. Alan King: Ceramic Technology and Processing, Standard Publishers Distributors, 2004. 3. James S. Reed: Introduction to the Principles of Ceramic Processing, John Wiley, 1995. 4. A.B. Strong: Fundamentals of Composites Manufacturing- Materials, Methods and Applications, SME 1989. MM5215 ADVANCED THERMODYNAMICS AND KINETICS (3-0-0) 3

Concepts of micro and macro-states, Planck-Boltzmann equation, Solution theory, Quasichemical approach to solutions, activities in multi-component systems, Solubility of one component in another phase, Thomson - Freundlich equation, solubility of a metastable phase, retrograde solubility, Free energy vs composition diagrams, phase diagrams, Rate kinetics, diffusion of metals in fluids. Reading: 1. D. R. Gaskell, Introduction to Thermodynamics of Materials, Taylor and Francis, 2006. 2. Richardson, F.D., Physical Chemistry of Melts in Metallurgy, Vol. 1 and 2, Academic Press, 1974. 3. Matts Hillert: Phase Equilibria, Phase Diagrams and Phase Transformations: Their Thermodynamic Basis, Cambridge University Press, 1998. MM5216 ADVANCED NON FERROUS METAL EXTRACTION (3-0-0) 3

Brief review of traditional methods of metal production of common metals such as copper, zinc, lead, aluminum - advanced converters for copper extraction- Hydrometallurgical processes for the extraction of zinc- flow sheets for the extraction of thorium, niobium, cobalt, zirconium, tungsten, molybdenum and gold.

13

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

Reading: 1. C.A. Hampel, Rare Metals Hand Book, Robert E. Krieger Publishing Company, 1971. 2. Fathi Habashi, Hand Book of Extractive Metallurgy, Vols. II and III Wiley- VCH, 1997.
MM5217 COMPUTER APPLICATIONS IN MATERIALS ENGINEERING (3-0-0) 3

Computer Basics and programming, Techniques in Computer simulation, Finite Element Analysis, MonteCarlo Methods, Mathematical Modeling of Physical Concepts, Microstructure Modeling, Process Modeling, Integrated Selection of Materials and Processes, Calculation of materials properties starting from microscopic theories.

Reading:
1. R J Arsenault, J R Beeler Jr, D M Easterling (Eds): Computer Simulation in Materials Science, ASM International, 1986. 2. K. Ohno, K. Esfarjani, and Y. Kawazoe: Computational Materials Science - From Ab Initio to Monte Carlo Methods, Springer, 1999. 3. Wolfram Hergert, Arthur Ernst, Markus Dane: Computational Materials Science - From Basic Principles to Materials Properties, Springer, 2004. MM5218 PROCESS MODELING AND SIMULATION (3-0-0) 3

Principles of model development, simulation models, Mathematical Modeling of diffusional processes, Process modeling in Welding, Finite Element Model of one dimensional transient heat problem, Kinetic model for Nucleation and Grain Growth, Some case studies.

Reading:
1. Szekely, J., Evans, J.E. and Brimacambe, J.K., The Mathematical and Physical Modelling of Primary Metal Processing Operations, Wiley, 1988. 2. Hem Shankar Ray, Kinetics of Metallurgical Reactions, Oxford & IBH Publishing Co. Pvt. Ltd., 1993. 3. A. K. Mohanty, Rate Processes in Metallurgy, Prentice-Hall India Ltd., 2000. MM5219 SPECIAL STEELS (3-0-0) 3

High Strength Steels, Problems in developing high strength steels, HSLA steels, principles of micro alloying and thermo-mechanical processing, importance of fine grained steels, Dual phase steels, TRIP steels, Maraging steels, Stainless Steels, Tool Steels, special problems in heat treatment of tool steels, Ultra-fine grained steels.

Reading:
1. W.C. Leslie, Physical Metallurgy of Steels, Tech Books, 1991. 2. F. B. Pickering, Physical Metallurgy and Design of Steels, Applied Science Publishers, 1978. MM5204 MATERIALS PROCESSING AND MICROSTRUCTURAL EVOLUTION LABORATORY (0-0-3) 2

Synthesis of alloys, Casting of low temperature alloys and their microstructure, Heat treatment of high carbon steels and Al- alloys, Ageing of Aluminum alloys, Electrodeposition, plating and refining, Anodizing, Material forming by extrusion and injection molding, Rolling and sheet metal forming / tape casting / wire drawing, joining of metals, Thin film preparation / coating, Surface modification using fluidized bed, Concentration techniques, reduction techniques, Work hardening. MM5205 MATERIALS TESTING AND EVALUATION LABORATORY (0-0-3) 2

Hardness, Tensile, Compression, Impact, wear, and erosion testing, Microhardness and indentation fracture toughness, Creep and stress rupture tests, fatigue testing, Corrosion tests - Pitting corrosion, NDT techniquesUltrasonic, magnetic particle, die penetrant test, Polarization studies.

14

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

ME5988

MATERIALS JOINING AND NON-DESTRUCTIVE TESTING

(4-0-0) 4

Solid state welding- friction stir processing, and friction stir surfacing, process characteristics and applications, friction stir processing of particle reinforced composite materials, electron beam welding- weldability of aluminum and its alloys, Mg and its alloys and steels, flux cored arc welding, laser beam welding, cracks in welds, operations, advantages and limitations, applications, liquid penetration test, eddy current test, ultrasonic test, magnetic particle test, X-ray radiography test. Reading: 1. R S Mishra: Friction Stir Welding and Processing, ASM International, 2007. 2. R.S. Parmer: Welding Processes and Technology, Khanna Publishers, 2005. 3. Baldevraj : NDT Techniques, Indian Institute of Metals, Calcutta, 2004. MM5251 MATERIALS CHARACTERIZATION TECHNIQUES (4-0-0) 4

Classification of materials characterization techniques, principles of different microscopes (optical, electron microscopes, SEM, TEM, FEM, AFM, STM etc.,) and the preparation of samples, different modes and their applications, Spectroscopy techniques UV-Visible, AAS, AES, IR, FTIR, Raman etc., Thermal methods (DTA, TGA, DMA, DSC Dilatometry) interpretation of data. Reading: 1. Robert F. Speyer: Thermal Analysis of Materials, Marcel Dekker Inc., New York, 1994. 2. V. T. Cherapin and A. K. Mallik: Experimental Techniques in Physical Metallurgy, Asia Pub. House, 1967. 3. D.G. Brandon: Modern Techniques in Metallography, Butterworths, London, 1966. 4. S. J. B. Reed: Electron Microprobe Analysis, Cambridge University Press, London, 1975. MM5252 POWDER PROCESSING TECHNOLOGY (4-0-0) 4

Production and characterization of powders, Compaction of metal powders - die compaction, Isostatic pressing, powder forging, powder rolling and extrusion, Pressureless compaction techniques, Hot pressing and Hot isostatic pressing, Sintering of powder compacts, Liquid phase sintering, Sintering furnaces, Post sintering operations, Applications of P/M parts. Reading: 1. J. S. Hirschhorn: Introduction to Powder Metallurgy, American Powder Metallurgy Institute, Princeton, NJ, 1976. 2. Fritz. V. Lenel: Powder Metallurgy Principles and Applications, Metal Powder Industries Federation, Princeton, N.J., 1980. 3. G. S. Upadhyaya: Powder Metallurgy Technology, Cambridge International Science Publishing, 2002. 4. Randall German: A-Z of Powder Metallurgy, Powder Metallurgy, Elsevier, 2005. MM5261 NUCLEAR METALLURGY (3-0-0) 3

Nuclear energy fundamentals, classification of nuclear reactors, materials for nuclear reactors, fabrication of fuel and cladding materials, Properties of uranium, uranium dioxide, uranium carbide, uranium nitride fuels, dispersion type fuels, plutonium and thorium type fuels, Processing of reactor fuels and other materials, radiation protection standards; radiation effects in solids; radiation hazards and shielding; uses of radioactive isotopes; disposal of radioactive wastes, Nuclear power reactors in India. Reading: 1. Bodansky: Nuclear Energy - Principles, Practices and Projects, Springer, 2004. 2. S. Glasstone and A. Sesonke: Nuclear Reactor Engineering, CBS Publishers & Distributors, Delhi, 2003. 3. C.A. Hampel: Rare Metals Hand book, Robert E. Krieger Publishing Company, 1971. MM5262 REFRACTORY AND REACTIVE METAL EXTRACTION (3-0-0) 3

Refractory and reactive metals and their applications-Principles. Techniques and limitations of chemical / pyro-chemical methods of upgrading ores- Purification of concentrates / compounds and production of intermediate salts- Basic chemistry of rare / reactive metal reduction and refining- Flow sheets for the extraction of uranium, zirconium, titanium, Beryllium, Niobium, Tantalum, Tungsten, Molybdenum and Vanadium.

15

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

Reading: 1. C.A. Hampel, Rare Metals Hand Book, Robert E. Krieger Publishing Company, 1971. 2. Fathi Habashi, Hand Book of Extractive Metallurgy, Vols. II and III, Wiley- VCH, 1997.
MM5263 HIGH TEMPERATURE MATERIALS (3-0-0) 3

Creep, thermal fatigue, oxidation, high temperature corrosion, erosion, Ageing, structural changes, material damage, Crack propagation, damage mechanics, life time analysis, Creep resistant steels, superalloys, ceramics and polymers for high temperature applications, intermetallics, Usage of high strength steels, Spring steels, Fatigue, Evaluation of property data, extrapolation. Reading: 1. Evans, R.W and Wilshire, B: Creep of Metals and Alloys, Institute of Metals, London, 1985. 2. J. R. Davis: ASM Specialty Hand Book: Heat - Resistant Materials, ASM, 1997. MM5264 NANO TECHNOLOGY (3-0-0) 3

Significance, properties and applications nanomaterials, carbon nano structures, nano indentation, super plastic behavior of nanomaterials, Ceramic nanosystems, quantum confinement, effect of size reduction on optical, electrical, electronic, mechanical, magnetic and thermal properties of materials, nano electronics, Nano fluidics, NEMS, photonic crystals, biomimetic nano structures. Reading: 1. Sulabha K. Kulkarni: Nanotechnology Principles and Practices, Capital Publishing Company, 2007. 2. H. Hosono, Y. Mishima, H. Takezoe and K.J.D Mackenzie: Nanomaterials- From Research to Applications, Elsevier Ltd., Noida, 2008. 3. Massimilano Di Ventra, S. Evoy and James R. Heflin, Jr.: Introduction to Nanoscale Science and Technology, Springer, Noida, 2009. 4. Charles P. Poole Jr. and Frank J. Owens: Introduction to Nanotechnology, Wiley India, New Delhi, 2010. MM5265 ADVANCED EXPERIMENTAL TECHNIQUES (3-0-0) 3

Design of electron microscope, Field emission and Field ion microscopes, SEM, principles of microprobe analysis, specimen preparation and image interpretation, Applications of DTA and TGA, Dilatometry and interferometry, Growth of single crystals by zone melting. Reading: 1. Robert F Speyer: Thermal Analysis of Materials, Marcel Dekker, 1994. 2. Kauffmann: Characterization of Materials, Vols I & II, John Wiley, 2005. 3. ASM Handbook, Vol 10: Materials Characterization, ASM Intl., 2004. MM5266 INDUSTRIAL POWDER METALLURGY (3-0-0) 3

Basic steps of powder metallurgy, SWOT analysis of powder metallurgy, advanced powder fabrication and sintering techniques, Production of filters, self-lubricating bearings, gears, friction parts, electrical materials, sintering of carbide tools, fabrication difficulty of tungsten filament, synthesis and sintering of hydroxyapatite (HAP) and other bioceramics, powder metallurgy of stainless steel, Application of powder metallurgy in Indian industries. Reading: 1. G. S. Upadhyaya, Powder Metallurgy Technology, Cambridge International Science Publishing, 1998. 2. ASM Handbook, Vol-7, Powder Metallurgy, ASM International, 2010. 3. P. C. Angelo and R. Subramaniam, Powder Metallurgy - Science, Technology and Application, PHI, New Delhi, 2008. 4. R. M. German, Powder Metallurgy- Principles and Applications, MPIF, Priceton, 1994. MM5267 ADVANCES IN MECHNICAL WORKING (4-0-0) 4

Forming processes, Forging processes, open and closed - die forging, Rolling processes, forces and geometrical relation ships in rolling, rolling variables, theories of cold and hot rolling, Extrusion processes, extrusion variables; production of seamless pipes, Rod and wire drawing, Bending, deep drawing, forming

16

M.Tech. Metallurgical and Materials Engineering - Scheme and Syllabi

limit criteria, High-energy rate forming operations, explosive forming, electro-hydraulic, electro-magnetic pulse forming, Effect of strain rate, temperature and metallurgical variables on super plasticity, applications. Reading: 1. G. E. Dieter: Mechanical Metallurgy, McGraw Hill Book Company, 1988. 2. C. J. Richardson: Worked Examples in Metal Working, Institute of Metals, London, 1985. 3. ASM Hand Book, Vol. 14: Forming and Forging, ASM, 1988. 4. Surender Kumar: Principles of Metal Working, Oxford & IBH Publishing Company, New Delhi 1991. MM5268 FRACTURE MECHANICS (4-0-0) 4

LEFM, Griffiths analysis, concept of energy release rate and fracture energy, critical stress intensity factor, plasticity at the crack tip, plastic zone shape and size, effect of constraint, plane stress, plane strain, thickness, EPFM, CTOD, J integral. Reading: 1. G. E. Dieter: Mechanical Metallurgy, McGraw Hill, 1988. 2. T. L. Anderson: Fracture Mechanics- Fundamentals and Applications, 3rd Edition, CRC Press, 2011. 3. R. W. Hertzberg: Deformation and Fracture Mechanics of Engineering Materials, 4th Edition, John Wiley & Sons Inc., 1995. MM5269 FAILURE ANALYSIS (4-0-0) 4

Aims of failure analysis, Prime factors in the premature failure of metallic components and structures, Tools and techniques in failure analysis, Types of failures: ductile, brittle, fatigue, creep, corrosion, wear etc., fractography, mixed mode and fatigue failures, Failure mechanisms, Embrittlement phenomena, environmental effects, Failures due to faulty heat treatments, Failures in metal forming and welding, Case studies in failure analysis, Prevention of failures, case histories of component failures. Reading: 1. S.T. Rolfe and J.M.Barsom, Fracture and Fatigue Control in Structures, Prentice Hall, 1972. 2. David and Bruck, Elementary Egnineering Fracture Mechanics, Norelho, 1975. 3. S. Suresh, Fatigue of Materials, 2nd Edition, Cambridge University Press, 1998. 4. ASM Metals Hand Book, Failure Analysis and Prevention, Vol. 11, ASM, 2002. ME5989 METAL JOINING LABORATORY (0-0-3) 2

Gas welding/ Torch brazing / Arc cutting, heat input calculation in arc welding, Submerged arc welding, resistance welding, Preparation of ALL-WELD - METAL test specimen and characterization of weldments, Flux cored arc welding, friction stir welding of Al alloys and testing, NDT - Liquid penetrant test, ultrasonic test of weldments, Study of microstructure of weld zone, heat affected zone and base metal of the welded specimen, to determine the tensile strength and ductility of a weld. MM5253 POWDER PROCESSING LABORATORY (0-0-3) 2

Powder Metallurgy- Ball milling of powders, Chemical synthesis of powders, Electrolytic synthesis of iron powder, Cementation of powders, Determination of size and size distribution of metal powders, Determination of apparent density, tap density, flow rate of metal powders, Determination of surface area, Compaction of metal powders and determination of green density, Sintering of metal powders and determination of sintered density.

17