1

METALLURGICAL ENGINEERING


S.Y. B. Tech.
Effective from A. Y. 2012-13

INDEX

Item Page No.

UG Rules and Regulations


Detailed Syllabus


Annexure-I: List of Professional Science courses offered
by ALL departments


Annexure-II: List of Liberal Learning courses offered at
Institute level




List of Abbreviations







Sr. No. Abbreviation Stands for:
1 BSC Basic Science Course
2 PSC Professional Science Course
3 PCC Program Core Course
4 LC Laboratory Course
5 HSSC Humanities and Social Science Course
6 MLC Mandatory Learning Course
8 LLC Liberal Learning Course
2

CURRICULUM STRUCTURE OF S. Y.-B.TECH (Metallurgical Engineering)
Effective from A. Y. 2012-2013
III-Semester:
Sr.
No
Course
Type/ code
Subject Title Contact hours
L T P
Credits
01 BSC/MA201 Engineering Mathematics-III 3 1 - 4
02 PCC/MT201 Structure & Properties of
Materials
3 - - 3
03 PCC/MT202 Principles of Physical
Metallurgy
3 - - 3
04 PCC/MT205 Geology and Ore Dressing 3 - - 3
05 PCC/MT207 Electrical & Instrumentation
Technology
3 - - 3
06 LC/MT209 SPM Lab - - 2 1
07 LC/MT211 PPM Lab - - 2 1
08 LC/MT213 GOD Lab - - 2 1
09 LC/MT215 EIT Lab - - 2 1
10 PSC/*IS201 Professional Science courses 3 - - 3
11 LLC Liberal learning course 1 - - 1
Total 19 1 8 24

IV-Semester:

Sr.
No
Course
Type/ code
Subject Title Contact hours
L T P
Credits
01 PCC/MT203 Heat Treatment Technology 3 - - 3
02 PCC/MT206 Metallurgical Thermodynamics 3 1 - 4
03 PCC/MT204 Principles of Metal working 3 - - 3
04 PCC/MT208 Modeling in Materials
Engineering
2 - 2 3
05 PCC/MT210 Mechanical Technology 3 - - 3
06 LC/MT212 HTT Lab - - 2 1
07 LC/MT214 PMW Lab - - 2 1
08 LC/MT216 Mechanical Technology Lab - - 2 1
09 HSSC/AS204 Professional Communication 2 0 0 2
10 MLC/ML202 Environmental Studies 2 0 0 2
Total 18 2 6 23

*: Professional Science Course/s offered by Department of Metallurgy and
Materials Science :
1. Device Materials

3

Second Year B.Tech.(Metallurgical Engineering)
Semester III


MA 201 Engineering Mathematics III

Teaching Scheme: Examination Scheme:
Lectures : 3 hrs/week
Tutorial: 1 hr/week
100 marks:Test I:20 marks
Test II:20 Marks,
End-Sem Exam- 60 Marks

Objectives:
The basic necessity for the foundation of Engineering & Technology being mathematics,
the main aim is, to teach mathematical methodologies & models, develop mathematical
skills & enhance thinking power of students.

Unit 1 (4 hrs)

Gradient, Divergence and Curl: Vector and Scalar functions and Fields, Derivatives,
Gradient of a Scalar field, Directional derivatives, Divergence and Curl of a Vector field.

Unit 2 (6 hrs)

Vector Integral Calculus: Line Integrals, Line integrals independent of path, Greens
theorem in plane, surface integral, Divergence theorem and Stokes theorem.

Unit 3 (6hrs)

Fourier Series: Periodic functions, trigonometric series, Fourier series, half range series.

Unit 4 (6 hrs)

Partial Differential Equations: Basic concepts, method of separation of variables. One and
Two dimensional wave equation, one dimensional heat equation.

Unit 5 (10 hrs)

Laplace Transforms: Laplace Transform, Inverse Laplace Transform, linearity, shifting,
transforms of derivatives and integrals, differential equations, differentiation and integration of
transforms, convolution

Unit 6 (8 hrs)

Statistics: Random Variables, Probability Distributions, Mean and Variance of a distribution,
binomial and normal distributions, testing of hypothesis.

Text Books:
4

Erwin Kreyszig ,Advanced Engineering Mathematics, Wiley Eastern Ltd. (8th Student
Edition)
Maurice D. Weir, Joel Hass, Frank R. Giordano, Thomas Calculus, Pearson Education,
Delhi(11
th
Edition),

Reference Books:
P.N. Wartikar, J. N. Wartikar, Engineering Mathematics Vol I, II, III Pune Vidyarthi Gruha
Prakashan.
C.R. Wylie , Advanced Engineering Mathematics, McGraw Hill Publications, New Delhi.
Peter V. O Neil ,Advanced Engineering Mathematics, Thomson. Brooks / Cole,
Singapore(5
th
edition ) .
B. V. Ramana , Higher Engineering Mathematics, Tata McGraw Hill Publications.



5


MT201 STRUCTURE AND PROPERTIES OF MATERIALS

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

OBJECTIVES:
1. Introduce students to the field of materials testing and materials science.
2. Build the foundation for the courses to be studied further in Materials Technology.

Unit 1 (06)
Classification of materials based on applications and structure, Structure of Materials:
Types of bonds, Crystallography: System of crystal lattices, space lattice, unit cell,
primitive cell, crystallographic directions and planes, Miller indices of directions and
planes, non crystalline materials.

Unit 2 (06)
Solidification, nucleation and growth, dendrites, surface energy & interfacial phenomena,
interfacial phenomena in liquid-solid interface. Diffusion in solids, Arrhenius equation.

Unit 3 (06)
Imperfections in crystals: Point and line imperfections- vacancies, impurity atoms, Frenkel
and Schottky imperfections, Dislocations- screw, edge and mixed, Slip system-slip plane
and slip direction, Burgers vector. Slip in plastic deformation, Twin in crystals. Grain
boundaries, twin boundaries, stacking faults, Large angle and small angle boundary.

Unit 4 (06)
Stress and strain, Elasticity, Tension test for common materials, elastic, plastic and
elasto-plastic behavior of materials, Stress-strain curves- Engineering and True,
Important definitions of properties and their relationship, plasticity index, Instability in
tension, Effect of strain rate and temperature. Testing methods and machines.
Application of various standards of such as ASTM, IS, ISO in materials testing.

Unit 5 (06)
Compression test: Behavior of materials in compression, application of compression tests.
Hardness tests: Brinell, Poldi, Vickers, Rockwell, Rebound hardness, Microhardness test,
Hardness Conversion, Principles of Bend test Fiber stress and bending shear stress,
Torsion tests Stress & strain variation in body under pure torsion, Combined bending and
direct stress. Combined bending and torsion. Combined bending, torsion and direct
stress.


Unit 6 (06)
Fatigue and Impact tests, Charpy and Izod methods, DBTT, fracture toughness, creep
tests. Non-destructive testing methods: visual and leak testing, dye-penetrant tests,
6

magnetic crack detection, eddy current, x-ray radiography, ultrasonic and acoustic
emission methods.


TEXT BOOKS:
1. Davis Troxell Hauck, The Testing of Engg. materials, 4th Ed., McGraw Hill,1982
2. George E.Dieter, Mechanical Metallurgy, Mc-Graw Hill Book Co.Inc.
3. Askland & Phule, Material science & Engineering of materials
4. Foundation of Materials Science and Engineering, William Smith, 2nd Edition, McGraw
Hill, 1993
5. The nature and Properties of Engg. Materials, Jastrzebaski, John Wiley & Sons, New
York

REFERENCE BOOKS:
1. Hardness Testing, edited by H.E. Boyer, ASM International, Ohio, 1987.
2. Introduction to Materials Science for Engineers, James Shackelford, 5th edition,
Pentice Hall international incorporation.
3. Materials Principles & Practice, Materials in action series, edited by Newey &
Weaver, Butterworth Heinmann, Oxford, 1990.



7


MT202 PRINCIPLES OF PHYSICAL METALLURGY

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks


OBJECTIVES:
To introduce the basic concepts of physical metallurgy of ferrous and non ferrous alloys.

Unit 1 (05)
Metallography: Specimen preparation for microscopic examination for different metals
and alloys, electrolytic polishing, etching and mounting techniques, metallurgical
microscope, Quantitative Metallography, volume fraction of phases by area, linear analysis,
point counting methods for grain size and phase measurements, grain size significance and
measurement, macroscopic examination methods, types of non metallic inclusions rating.


Unit 2 (06)
Solid Solutions and Phase diagrams: Solid solution and intermediate phases, Gibbs
phase rule, phase equilibria, alloy phases and compounds, Introduction to spinodal
decomposition, athermal transformation, classification of strengthening mechanisms, Binary
equilibrium diagrams and related microstructures, Lever rule application, numericals for
phase analysis, Non equilibrium cooling of alloys, Ternary diagrams-simple systems.

Unit 3 (08)
Iron-Carbide system: Iron-Iron carbide equilibrium diagram, critical temperatures, plain
carbon steels, slow cooling of steels and cooling curves, effect of impurities, property
variation with microstructure, classification and specifications of steels.
Isothermal transformation diagrams, Plotting, Transformation to pearlite, bainite and
martensite, Continuous cooling transformation diagram, Effect of carbon, grain size and
alloying elements, importance of IT and CCT diagrams to heat treatment.

Unit 4 (05)
Cast Irons: Fe-Graphite diagram, Factors controlling microstructure, Types of cast irons
:gray ,White ,malleable cast, Nodular, Chilled and Mottled cast iron, Step bar test, Alloy cast
irons: Ni hard, Ni resist, Silal, Austempered ductile iron

Unit 5 (06)
Copper and Copper base Alloys: Phase diagrams of Cu based alloys brasses, bronzes,
Sn Bronzes, Si Bronzes, Al Bronzes, Be Bronzes, Microstructure, Properties and
applications, various types of brasses and bronzes, important cast and wrought brass-
bronze alloys, Cupronickel and nickel silvers
8


Unit 6 (06)
Light metal alloys: Classification and temper designations of Aluminium alloys, phase
diagrams of Al-Cu, Al-Si, Al-Mg, Al-Zn systems, wrought and cast Al-alloys and applications,
precipitation hardening, Titanium alloys (alpha, alpha-beta alloys and beta alloys (like Ti-Al,
Ti-V and Ti-Mn alloys) and their applications, Mg and its alloys (Mg-Al, Mg-Zn, Mg-rare earth
based alloys)

TEXT BOOKS:
1. S.H.Avner, Introduction to Physical Metallurgy, McGraw Hill book co.inc.
2. Askland & Phule, Material science & Engineering of materials
3. R.A.Higgins, Engineering Metallurgy, Part I, App. Physical Met, ELBS
4. George Vanwert, Metallographic Techniques, ASM Publ.

REFERENCE BOOKS:
1. Reed Hill, Physical Metallurgy,
2. Raghvan, Physical Metallurgy
3. W.F.Smith, Foundation of Material Science & Engineering, McGraw Hill





9


MT205 GEOLOGY AND ORE DRESSING

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week

Test I20 marks
Test II 20 marks
End Sem exam 60 marks
OBJECTIVES:
To understand the principles of Geology and ore dressing as applied for metal winning.
To know various deposits of minerals/ores on the earth

Unit 1: [06]
General Geology & Petrology : Introduction, General Geology, Surface features, External &
Internal Agents modifying the earth, weathering, decomposition, earth movements,
metamorphism, volcanism. Rock and minerals.

Unit 2: [06]
Mineral composition of Igneous Rocks, Textures & textural variation, conditions of cooling of
plutonic, hypabyssal and volcanic rocks. Classification of igneous rocks. Secondary Rocks
processes and products of decomposition and disintegration. Transport and deposition,
Classification of Sedimentary Rocks. Agents of transportation. Welding and cementation.
Grain size classification. Agents and types of metamorphism.

Unit 3: [06]
Economic Geology. Ore, ore minerals and gangue, tenor of ore, classification of ore
deposits. Process of formation of minerals deposits. Geology of the important Indian
deposits of aluminium, copper, iron, lead zinc, manganese, titanium, uranium and thorium
and industrial minerals. Deposits of coal and petroleum in India. National Mineral Policy.
Conservation and utilization of mineral resources.

Unit 4 [06]
Introduction to Ore Dressing. Sampling of ores by different methods. Theory of liberation of
minerals. Crushers: -Jaw, Gyratory, Cone, Rolls and toothed roll crushers.
Types of grinding operations like batch and continuous dry and wet grinding, open circuit
and closed circuit grinding. Grinding Mills: Ball mills, theory of ball mill operation, rod and
tube mills. Comminution laws. Sizing: Study of laboratory sizing techniques and reporting of
sizing data. Industrial sizing units: Types of screen surfaces. Grizzlies, trammels, vibrating
and shaking screens. Movement of solids in fluids: stokes and Newtons laws. Terminal
velocity and its relation with size.

Unit 5 [06]
Classification of classifiers, study of settling cones, rake classifier, spiral classifier and
cyclones. Heavy media separation: Principles, flow chart, different media used. Washability
curves for easy, normal and difficult coal.
Jigging: Theory of jigging. jigging machines, Tabling:-study of stratification on a table.
10

shaking tables, wilfley table.

Unit 6 [6]
Floatation: Principles of floatation. Factors affecting floatation. Classification of collectors and
frothers. Regulators and factors affecting their efficiency. Floatation machines: -Pneumatic
and mechanical floatation cells. Application of floatation process for Cu, Pb and Zn ores.
Magnetic separation processes and electrostatic separation process.

TEXT BOOKS:
1. A.M.Gaudin Principle of Mineral Dressing
2. R.H.Richards and C.E.locks Text book of Ore dressing
3. Handbook of Mineral Dressing Ores and Industrial Minerals A. E.Taggart
REFERENCE BOOKS:
1. S.J. Trussscott, Text book of Ore dressing
2. S.K. Jain, Ore dressing
3. Berry A Willis Mineral Dressing Technology
4. J.S.S. Brame and J.C.King Edward Fuels Solid, Liquid and Gaseous
5. G.W.Himus Elements of Fuel Technology




11


MT207 ELECTRICAL AND INSTRUMENTATION
TECHNOLOGY

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

OBJECTIVES:
To understand concepts of electrical, instrumentation and control involved in
equipments used in materials processing and characterization.

Unit 1 (08)
DC Machines:
a) DC Generator: Construction, generating action, emf equations, types of
generators, and characteristics of generators
b) D.C motor Motoring action, significance of back emf, types of dc motors, voltage
& current relationships of different motors, torque equation, torque-speed
characteristics, Different methods of starting (need of starter) different method of
speed control, braking & applications.

Unit 2 (08)
Induction Motor:
Types, principle of operation, types, slip, power flow diagram, torque equation,
condition of max. torque, torque slip characteristics, various methods of speed
control, braking & applications.
Single Phase Motors:
a) Single phase induction motors
b) Special purpose motors- A.C. series motors, universal motors
Factor affecting choice of above motors for industrial applications like rolling mills,
cranes, shear press, Mechanical press

Unit 3 (10)
Electrical Heating:
Resistance Heating: Direct and Indirect methods, Stefans law of radiation of
heat, Material used and designing of heating element, efficiency and control
equipment. Induction Heating: Construction, Working principle of induction
furnace, High/ Low frequency generation, Core type furnace, Coreless type furnace,
High frequency eddy current heating, Electric Arc Furnace: Types, Construction,
Working principle, Power factor, Impedance, Heat Treatment Furnace Heating:
Heating elements, Dimmer state, Voltmeter, Current measurement. Eddy Current
and Dielectric Heating

Unit 4 (07)
12

Definitions: Transducer, Sensor, Classification: Active, passive, primary,
secondary, mechanical, electronic, analog and digital transducers, Characteristics:
Static and Dynamic characteristics.
Displacement Measurement: Overview, principle of operation &applications:
Resistive: strain gauges. Inductive: LVDT, Capacitive: Capacitance pickups,
Piezoelectric, Ultrasonic transducers and Hall effect transducers.
Force: Basic methods of force measurement, elastic force traducers, strain
gauge

Unit 5 (04)
Temperature Measurement: Overview, principle of operation &applications:
RTD, Thermistors, Thermocouples, Semiconductor temperature sensors: Diode and
IC temp sensors. Ultrasonic temp detector,
Radiation: Pyrometers (Total and Selective), Infrared sensors.
Flow Measurement: Overview, principle of operation &applications:
Flow sensors: Orifice, Venturi and Nozzle. Variable area meter, Rotameter.
Turbine type flow meter, Electromagnetic flow type, ultrasonic flow meter,

Unit 6 (05)
Pressure measurement: Overview, principle of operation &applications:
High-pressure sensors: Dead weight tester, Vacuum sensors McLeod gauge,
thermal conductivity (Pirani, Thermocouple gage) ionization type. Level
measurement: Float, displacers, bubbler, and DP- cell, Ultrasonic, data loggers
Fundamentals of control system, Control actions:
On-off, proportional, integral, derivative, electronic controllers, stability of system

TEXT BOOKS:
1. Stephen J., Fundamental of Electrical Machinery.
2. Nagrath & Kothari 2/e, Electrical Machines.
3. Instrumentation Measurements and Analysis B.C.Nakra and K.K.Choudhari
4. Electronic Instruments & Measurement - A. K. Sawhney, Dhanpatrai
publications, New Delhi
5. Process Control Instrumentation Technology - C.D. Johnson, PHI (5th Edition).
6. Analytical Instrumentation Handbook- R.S.Khandpur

REFERENCE BOOKS:
1. Dr. P. S. Bhimra, Electrical Machines
2. Little Richard, Welding Technology
3. Rajan & Sharma, Heat Treatment & Furnaces
4. Measurement Systems - E.O. Doebelin (4th Edition).
5. Principle of industrial Instrumentation Patranabis.
6. Process Measurement & analysis - B.G. Liptak (Vol-I)
7. Instrumentation Devices & system - Rangan Sarma
8. Instrumentation and Measurement Principles D.V.S. Murthi

13



MT209 STRUCTURE AND PROPERTIES OF MATERIALS
LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

TERMWORK:
List of Experiments: (Completing any 08 sets from the below mentioned sets of
experiment)
1.TENSILE TESTING (2 sets):
Study of universal testing machine, principle and construction, 1) Tension test: To
conduct tensile test on standard samples of M.S./ Aluminium/ C.I., Plotting of
stress-strain curves and comparison of test results. 2) Study the effect of Gauge
length on percent elongation.
2. 2. HARDNESS TESTING (5 Sets) :
Study of hardness testing machines such as:
1) Brinell
2) Vickers and
3) Poldi
4) Study of Rockwell/ Rockwell superficial hardness testing machines and
testing various materials with these machines using different loads and indenters
(i.e. Scales).
5) Study of Microhardness/ Schleroscope and testing various materials.
3. COMPRESSION TESTING (1 set):
Compression test on C.I./Aluminium (or Brass); study of the effect of L/D ratio on
the test results.
4. FATIGUE TESTING (1 set): Study of fatigue testing machine
5. IMPACT TESTING (1 set):
Study of Pendulum impact testing machine and conducting impact test on samples
of various materials/with different notches and interpretations of result.
6. TORSION TEST (1 set): On wire samples of mild steel / spring steel.
7. BEND TEST (1 set): On plate/torr steel rod samples.
8. NON-DESTRUCTIVE TESTING (5 sets): STUDY OF
1) Dye penetrant
2) Magnetic particle
3) Eddy current
4) Radiography
5) Ultrasonic methods.
9. Other test (2 sets):
Determination of porosity, density and cold crushing strength of ceramic materials,
Hardness testing of polymers and elastomers by Durometer.
10. Crystallography of lattices, Millers indices and crystal defects

14



MT211 PRINCIPLE OF PHYSICAL METALLURGY
LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

List of Experiments (ANY 08):
1. Preparation of specimens for microscopic examination steels, copper alloys
and aluminium alloys; hot mounting and cold mounting and mechanical fixtures.
2. Microstructural study by etching of specimens of steel, copper alloys and
aluminium alloys and cast iron.
3. Colour Metallography of selected steels to reveal specific phases.
4. Quantitative Metallography for grain size measurement by ASTM standard,
Mcquid and oxidation methods
5. Quantitative Metallography for phase volume fraction by point counting and
linear intercept method
6. Observation and drawing of different morphologies of grains equiaxed
dendrites, columnar dendrites, cellular structure, equiaxed grains, polygonal
grains, elongated grains.
7. Observation of microstructures using image analyzer, Quantitative
Metallography software, models and tools for grain size, shape, phases
distribution and porosity.
8. Estimation of phases and drawing of cooling curves for transformation of plain
carbon steels with varying carbon contents using Fe-C diagram. Observation
and description of microstructures of annealed plain carbon steels.
9. Observations and description of microstructures belonging to various cast irons,
brasses, bronzes, wrought and cast aluminium alloys; measurement of their
hardness.
10. Assessment of nonmetallic inclusions in steels as per ASTM E-45
11. Student will bring unknown metallic sample; prepare it for metallographic
observation; observe and describe the microstructure with identification of
phases present in it.

15



MT213 GEOLOGY AND ORE DRESSING
LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

TERMWORK:
List of Experiments:
1. Identification of the following minerals in handspecimens:
Quartz and its varieties, common varieties of cryptocrystalline and
amorphous silica, orthoclase, plagioclase, muscovite, biotite, zeolites, calcite,
icelandspar, gypsum, satinspar, fluorite, barites, tourmaline, beryl, graphite,
asbestos, talc, kyanite, garnet, galena, magnetite, haematite, limonite, iron
pyrites, chromite, bauxite, azurite, malachite, psilomelane.
2. Identification of the following rock type and the associated
economic minerals in handspecimens
Granites, syenites, diorites, gabbros, rhyolites, trachytes, andesites, basalts,
varieties of Deccan trap rocks, volcanic breccias, pegmatites, dolerites,
graphic granites.
Laterites, bauxites, conglomerates, breccias, sandstones, quartzites, grits,
arkose, shales, mudstone. Chemical and organic limestones.
Marbles, quartzites, varities of gneisses, slates, phyllites and varieties of
schists.

Practical Work: Minerology 4 practicals
Igneous rocks 3 practicals
Secondary rocks 3 practicals
Metamorphic rocks 2 practicals
Ore Dressing:
4. Construction, Working Principle of Jaw Crushers and crushing of ores on Jaw
Crushers.
5. Construction, Working Principle of Ball mill and grinding of ores by wet and dry
grinding in a ball mill
6. Study of laboratory sizing techniques and reporting of sizing data
7. Study of settling cones, rake classifier, spiral classifier and cyclones
Conduct separation of minerals by
a. Froth floatation,
b. Magnetic separation
c. Electrostatic separation

16


MT215 ELECTRICAL AND INSTRUMENTATION
TECHNOLOGY LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

List of Experiments:
Instrumentation department will conduct following experiments.
1. Characterization of temperature measurement system.(RTD, Thermocouple)
2. Characterization of flow measurement system.(Orifice, Venturi)
3. Characterization of level measurement system.(Capacitive, Bubbler)
4. Characterization of pressure measurement system(Load cell)

Electrical department will conduct any 4 experiments from the following
5. External & internal characteristics of a D.C. shunt generator.
6. A) Speed control of D.C. shunt machine by
(i) Armature voltage control
(ii) Field current control method
B) Study of motor starters
(i) 3 point starter
(ii) 4 point starter
(iii) 2 point starter
7. Load test on D.C Shunt motor
8. Load test on 3ph and 1 ph Induction motor to determine its performance
9. Study of induction motor starters

17


IS201 PROFESSIONAL SCIENCE COURSES

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

Institution level course

LIBERAL LEARNING COURSE

Teaching Scheme Examination Scheme
Lectures: 1 hrs/week

Institution level course


18


Second Year B.Tech.(Metallurgical Engineering)
Semester IV

MT203 HEAT TREATMENT TECHNOLOGY

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

OBJECTIVES:
To understand the fundamentals of various Heat Treatments.
To understand physical metallurgy of Alloy Steels and their Heat Treatments.
To understand working principle of different Heat treatment Furnaces.

Unit 1 (06)
Heat treatment of plain carbon steels: Annealing, Isothermal and subcritical
Annealing types, Normalizing.
Hardening Heat Treatment: Quenching process, characteristics and kinetics of
martensitic transformation, Bain model, Retained austenite and its effect,
Tempering and subzero treatment.
Hardenability: Mass effect, Grossman method, Critical and ideal critical diameter,
Jominy End Quench method, Use and Significance of Hardenability data, Effect of
grain size and composition, Residual stresses, Quench cracking, case studies of
design changes for hardening.

Unit 2 (06)
Classification of alloying elements and their effects on IronIron carbide phase
diagram, TTT Diagram and CCT Diagram, General Heat treatments such as
Annealing, Normalizing, Hardening, Tempering, Austempering, Martempering.
Hardenability concept, Stages of Quenching and their effects, Types of quenching
media such as oils, polymers; Cooling characteristics of quenching media, Control of
quenching parameters, quenching fixtures, Dimensional changes during hardening
and tempering

Unit 3 (06)
Introduction to classification and Heat treatment of Low alloy steels: Micro- alloyed
(HSLA), Dual phase steels, Free cutting steels, Spring steels; bearing steel, Tool
Steel: Selection criteria and properties of Tool steels, Classification of Tool Steels:
Cold work, Hot Work Tool Steels, High Speed Steels and Stellites; Heat treatments
of Die and Tool steels, Secondary hardness and Red Hardness, Subzero treatment,
Super High Speed Steels, TRIP Steels.

Unit 4 (06)
Stainless Steels: Fe-Cr, Fe-Ni Phase Diagram, Schaeffler Diagram and its
modifications, Classification of Stainless Steels, sensitization, Heat treatment of
19

stainless steels, Precipitation Hardening Stainless Steels, Marageing Steels,
Superalloys and their heat treatment.

Unit 5 (06)
Surface hardening: Carburizing, Carburizing atmosphere and Heat treatment after
Case Hardening, Bainite control in case, Case depth measurement, ASTM E1077-01
Depth of carburization, Drip Feed Carburizing, dimensional changes during case
hardening; Nitriding, Carbonitriding, Tufftriding, Nitrocarburising, Plasma Nitriding;
Induction Hardening, Flame Hardening, Laser Hardening, Selection of steels for
these treatments and their applications.

Unit 6 (06)
Classification of atmospheres for heat treatments, Generation of atmospheres and
their applications. In situ atmosphere generation, Thermodynamics and Kinetics of
atmospheres, Control and monitoring of Furnace Atmospheres: Infrared controller,
Gas chromatography, Dew point analyzer and Oxygen probe analyzer

Unit 7 (04)
Heat treating furnaces: Salt bath furnace, Fluidized bed furnace, Sealed Quench
furnace, Vacuum furnace, Heat Treatment Defects such as Distortion, Residual
stresses, quench cracks and Design for Heat treatment

TEXT BOOKS:
1. Heat Treatment of Metals, Vijendra Singh, 2007, Standard Publishers
and Distributors, New Delhi
2. R.A. Higgins, Engineering Metallurgy, Part I, App. Physical Met, ELBS,
5th ed., 1983
REFERENCE BOOKS:
3. Steel and its Heat Treatment -K.E Thelning, Butterworth, London
4. Handbook of Heat Treatment of Steels Prabhudev-Tata Mc Graw Hill.
New Delhi, 1988
5. Heat Treatment of Ferrous Alloys, Brooks, Washington: Hemisphere
Pub., 1979
6. ASM Metals Handbook Heat treatment Vol. Metals Park Ohio
7. ASM Metals Handbook Steels Vol. Metals Park Ohio

20


MT206 METALLURGICAL THERMODYNAMICS

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week
Tutorial: 1hr/week
Test I20 marks
Test II 20 marks
End Sem exam 60 marks
OBJECTIVES:
To teach the students the importance of thermodynamic concepts with reference to
metallurgical systems.

Unit 1: [07]
Thermodynamics systems, Classification, thermodynamic variables, State functions, Process
variables, Extensive and intensive properties, Energy and first law of thermodynamics, Heat
capacity, Enthalpy, Heat of reactions, Hesss law, Kirchoffs equation, Thermochemistry.

Unit 2: [08]
Second law of thermodynamics, Entropy, Effect of temperature on entropy, Statistical nature
of entropy, Combined statements of first and second law of thermodynamics, Gibbs free
energy, Helmholtzs free energy, Maxwells equations, Gibbs-Helmholtz equation, Clausius-
Ciapeyrons equation and its application to phase changes, Free energy as criterion for
equilibrium and its applications to metallurgical reactions, Third law of thermodynamics.

Unit 3: [07 ]
Activity, Equilibrium constant, Le-Chateliers principle, Chemical potential, Law of mass
action, Effect of temperature and pressure on equilibrium constant, Vant Hoffs isotherm,
Free energy-temperature diagrams, oxygen potential and oxygen dissociation pressure,
Gibbs phase rule and its applications, Free energy composition diagram.
Unit 4 [07 hrs]
Solutions, Partial molar quantities, Ideal solutions, Raoults law, Non ideal solutions, Gibbs-
Duhem equation, Free energy of formation of solution, Regular solutions, application to
phase equiibria, excess thermodynamic quantities.

Unit 5 [06 hrs]
Electrochemical cell, Determination of thermodynamic quantities using reversible
electrochemical cell, EMF cell, electrode potential, Electrode potential-pH diagrams and their
applications

Unit 6 [04 hrs]
Reaction kinetics: Arrhenius equation, order of reactions

TEXT BOOKS:
1. D.R.Gaskell, Introduction to Thermodynamics of Materials, III Edition, MCGraw Hill Book
Co.Inc.
2. Ahindra Ghosh, Text book of Materials & Metallurgical Thermodynamics, Prentice Hall
India.
REFERENCE BOOKS:
1. L.S.Darken and R.W.Gurry, Physical Chemistry of Metals, McGraw- Hill, 1958.
21

2. R.H.Parker, An Introduction to Chemical Metallurgy: Pergamon Press, Inc.
3. G.S.Upadhya and R.K.Dubey, Problems in Metallurgical Thermodynamics and Kinetics,
Pergamon Press, Inc.
4. Thermodynamics of Materials Volume I and II, David V.Ragone, John Wiley & Sons,
Inc.1995

22


MT204 PRINCIPLES OF METALWORKING

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks
OBJECTIVES:
To make the students aware of strength of materials and their processing by mechanical
working. To introduce the students about the improvement in metallurgical quality
obtained by mechanical working.

Unit 1: [06]
Types of loading in materials used in engineering. Basic ideas about stress, direct stress,
and shear stress. Hookes law for three dimensions. Stresses and strains in bodies under
variety of loads and with varying dimensions. Thin cylinders under pressure. Hoop stress
and longitudinal stress, Concept and determination of two dimensional principal planes and
principal stresses, maximum shear stress.

Unit 2: [06]
Mohrs circle of stress- two dimensions, numerical problems based on analytical and Mohrs
circle method. System of a body under three dimensional stresses. Matrix representation of
the state of stress under three dimensions, determination of principal stresses, principal
planes and maximum shear stress for three dimensional state of stress, hydrostatic and
deviator component of stress relationship, strain energy, stress concentration.

Unit 3: [06]
Plastic deformation, flow curve, yielding criteria- Von Mises & Tresca, plastic stress-strain
relations, plastic deformation of single crystal, CRSS, strain hardening, cold, hot and warm
working processes, strain rate effect, metallurgical structure, friction and lubrication,
hydrostatic pressure and workability.

Unit 4 [06]
Classification of forming processes. Forces and geometrical relations in rolling. Projected
length of contact. Neutral point. Forward slip and backward slip. Rolling force and rolling
load. Angle of contact and angle of friction. Material spread in rolling. Torque and
horsepower in rolling. Problems and defects in rolled products.

Unit 5 [06]
Forging. Classification of forging processes. Forging equipment. Forging in plane strain.
Open and closed die forging. Calculations of forging loads in closed die forging. Significance
of flow lines, Residual forces in forging. Forging defects. Drawing of rods wires and tubes.
Analysis of tube drawing, Temperature increase in wire drawing. Die wear. Water-cooling of
dies. Residual stresses in drawn products.

Unit 6 [6]
23

Extrusion. Classification of extrusion processes. Extrusion equipment. Hot and Cold
extrusion. Deformation and lubrication in extrusion. Analysis of extrusion process.
Hydrostatic extrusion. Extrusion of tubing. Extrusion defects.
Sheet metal forming and forming methods. Rubber forming. Shearing and blanking,
Bending, Stretch forming, Deep drawing. Forming limit criteria. Defects in formed parts.
Concept of machinability.


TEXT BOOKS:
1. Mechanical Metallurgy, George E. Dieter, SI Metric Edition,1988, McGraw-Hill Book
Company.
2. Manufacturing Science Ghosh A., Mallik A.K., 1985, Affiliated East-West Press (P) Ltd.,
New Delhi.
3. Manufacturing Engineering and Technology, Serope kalpakjian, Steven R. Schmid,
International Edition, Fourth Edition, 2001, Prentice Hall International.
4. Metal Forming Process, Nagpal G.R., First Edition, 2000, Khanna Publishers, New Delhi.
REFERENCE BOOKS:
1. Mechanical Working of Metals, Harris J. N., 1983 Jan 01, Pergamon Press, Elmsford, NY.
2. Principles of Industrial Metalworking Processes, Rowe G. W, 1977, Edward Arnold
Publishers, London.
3. ASM Metals Handbook Vol. IV (Forming), Metals Park, Ohio



24


MT 208 Modeling of Engineering Materials

Teaching Scheme Examination Scheme
Lectures: 2 hrs/week
Practical : 2 hr

100 marks:
Assignment/Quiz -20,
MSE 30(Theory),
T/W 20,
ESE 30(Practical)

OBJECTIVES:
To understand the basics of modeling and computational simulation in
materials science and engineering
To study different tools such as matlab/scilab/spreadsheet for solving
mathematical problems in materials and their processing
To find approximate solutions to the problems, to interpret and visualize the
solutions.

Unit 1 (06)
Introduction of modeling:
Setting up of mathematical model, Simple linear model:; Non-linear model and
breakdown of analytical solutions; Integrated Computational Materials Engineering
(ICME), structural scale, macroscale, mesoscale, microscale, nanoscale and
electronic scale, solid mechanics and transport phenomena problems and their
solutions by finite element, finite volume and finite difference partial differential
equation

Unit 2 (05)
Interpolation: Lagrange Interpolation, Newtons forward, backward and Stirlings
central difference method, Newtons divided difference method, Inverse
Interpolation. Applications.
Numerical Differentiation: Forward, Backward and Central Difference Methods.
Applications.

Unit 3 (05)
Numerical Integration: Trapezoidal Rule, Simpson 1/3 and 3/8th Rule, Weddles
Rule, Gauss Quadrature - Two and Three Point Formula. Applications.
Curve Fitting: Least square criteria- 1st and 2nd Degree. Applications.

Unit 4 (05)
Partial Differential Equations:
Types of equations, Elliptic equations: Laplaces equation, Hyperbolic equations:
Wave equations, Parabolic Equations: Diffusion, The Equation of continuity, The
Diffusion equations: Applications in diffusion and mass transport in materials.

Unit 5 (05)
Monte Carlo Methods:
Monte Carlo Random Number Generators, Monte-Carlo Integration, , Monte Carlo
Method for simulating nucleation and growth of grains in materials
25


TERMWORK:
List of Experiments (ANY 08):

1. Curve fitting and interpolation using spreadsheet program for
finding relation between dependant variable and independent
variable.
2. Linear models: Hooks Law, Hall-Petch Equation, Lever Rule,
Arrhenius Equation for activation energy
3. Finding activation energy by Arrhenius equation, vacancy
concentration, rate of reaction, Effect of temperature on diffusion
coefficient
4. Application of Ficks law for carburizing and doping of
semiconductors, use of interpolation of error function data.
5. 2 D model of conductive heat transfer
6. Data structure: Hume-Rothery rules for substitutional solid
solution
7. Curve plotting: Engineering stress-strain curve; determination of
different properties from it; plotting true stress-strain curve and
determination of work hardening exponent. Effect of variation of
work hardening exponent.
8. Application of lever rule on binary equilibrium diagram; Estimating
microsegragation due to fast cooling rate.
9. Sieverts law for solubility of gases in liquid metal.
10. Pilling Bedworth model for oxide film growth
11. Application of Stokes law for slag removal in molten metal,
12. Bournaullis theorem: Application in gating system design for
casting
13. Finding surface area, volume and modulus of different shapes,
application of Chvorinovs rule for riser design, (casting software)
14. Image analysis tools for quantitative metallography (Source: ASM
Handbook)
15. Degree of polymerization
16. Design of energy efficient furnace
17. Estimation of M
S
, M
f
, A
3
, temperature from composition of alloy
steels
18. Application of Monte Carlo methods for simulating nucleation and
growth of grains in materials
19. Determination of crystal structure (cubic) using Braggs law of X
ray diffraction
20. Phase field models of phase transitions and microstructure
formation,
21. molecular dynamics (MD), molecular statics (MS),
22. Monte Carlo (MC), and kinetic Monte Carlo (KMC) formulations,
23. Schrdinger equations, density functional theory,
24. Computational thermodynamics for prediction of equilibrium phase
diagrams
26


Text Book:
Chapra, S.C. & Canale, R. P., Numerical Methods for Engineers, Tata McGraw Hill
Publication ( 5
th
Edition )
Computational Materials Engineering, 1st Edition An Introduction to Microstructure Evolution,
Authors: Janssens, Raabe, Kozeschnik, Miodownik, Nestler, Published: 03 Aug 2007, Academic
Press ISBN: 9780123694683
Integrative Computational Materials Engineering Concepts and Applications of a Modular
Simulation Platform, Edited by G.J. Schmitz and U. Prahl, Wiley, ISBN: 978-3-52733-081-2
Reference Books:
Balagurusamy, E., Numerical Methods, Tata McGraw Hill Publication.
Rajaraman, V., Computer Oriented Numerical Methods, Prentice Hall of India Ltd.
Sastry, S. S., Introductory Methods of Numerical Analysis, Prentice Hall of India Ltd.

27


MT210 MECHANICAL TECHNOLOGY

Teaching Scheme Examination Scheme
Lectures: 3 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

OBJECTIVES:
To apply fundamentals of Thermodynamics to various power producing and
power absorbing devices.
To understand basic principle of fluid mechanics & application to pumps.
To understand basic modes of heat transfer & to evaluate performance of heat
exchangers.

Unit 1 (07)
IC Engines:
Air standard Otto, Diesel cycles, systems classifications of I.C. engines such as fuel
supply system for SI & CI engines, ignition system, cooling system, lubrication
system, Performance of IC Engine Indicated power, Brake power, Thermal
efficiency, Specific fuel consumption.

Unit 2 (07)
Fuels: Boilers & steam Turbines:
Boilers: Classification, Essential of a good boiler, Mounting and accessories,
Efficiency calculations.
Steam turbines: Types, construction, Working, Compounding, Velocity diagram,
Calculation of diagram efficiency

Unit 3 (07)
Compressor & Gas turbine:
Compressor: Uses of compressed air. Reciprocating compressors- effect of
clearance, FAD calculation, efficiency calculation, multistaging, Rotary compressors-
elementary treatment.
Gas Turbine: Classification, Brayton cycle, thermal efficiency

Unit 4 (06)
Pumps & Water turbine:
Pumps: Rotary & reciprocating pumps,-construction & operation, pumps
performance, their selection.
Water Turbine: Types, constructional details

Unit 5 (07)
Machining of Materials:
Machining basics, tool geometry, depth of cut, feed, speed, chip formation, machine
tools like lathe, turning, knurling, screw cutting, drilling, milling, planning, grinding
machines, factors affecting machinability, coolants, non-conventional machining
processes like EDM, ECM, water jet and ultrasonic cutting.

28

Unit 6 (06)
Metrology:
Interchangeability, limits, fits and tolerance, linear measurement, comparators, slip
gauges, angular measurements, screw thread measurements, Surface roughness
measurements, interferometer, profile projector.


TEXT BOOKS:
1. R.K .Rajput, Thermal Engineering, Laxmi Publications.
2. Modi, Seth , Hydraulics And Hydraulics Machinary.
3. R. K. Jain, Engineering Metrology, Khanna Publisher, Delhi.
4. Nakra Choudhary, Instrumental Measurement and analysis, Tata McGraw Hill.
5. D. S. Kumar, Mechanical measurement and control ,Metropolitan N Delhi.
6. Chapman, Workshop technology vol. I,II & III, Edward Arnold Publication Ltd.
London
7. Hajara Chaudhari S.K., Workshop Technology, Vol. I & II, Media Prom &
Publication, Mumbai..
8. R. K. Jain, Production technology, Khanna Publications.

REFERENCE BOOKS:
1. Y.A. Cengel, Thermodynamics an Engineering approach, Tata McGraw Hill.
2. Eastop, Mcconkey, Applied Thermodynamics, Addison Wesley Longman
Publishers.
3. IS codes for vernier caliper, micrometers, slip gauges, angle gauges, limits, fits,
tolerances, gauges, geometrical tests etc.
4. Collette & Hope,Engineering Measurement, ELBS publisher
5. HMT Hand book- Production Technology
6. P. C. Sharma, Production Engineering, Khanna Publications.



29



MT212 HEAT TREATMENT TECHNOLOGY LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Oral: 50 Marks

Objective:
Correlation of equilibrium diagram, heat treatment, microstructure and
properties,
student will be able to draw heat treatment cycles and predict resultant
microstructure and properties

Instructions:
Student are not expected to draw microstructures, instead they will take digital
microphotographs on image analyzer and describe them along with the
properties achieved.
Wherever required, heat treatment thermal cycle must be drawn.

List of Experiments: (Completing any 08 from given below)
1. Observation and description of microstructure of various stainless steels.
2. Observation and description of microstructure of typical alloy steels such as
micro-alloyed steel, dual phase steel, free cutting steel, bearing steel and
maraging steel.
3. Performing annealing, normalizing and hardening heat treatment of steel
samples; observation of microstructures and hardness.
4. Hardenability determination by Jominy End Quench test as per ASTM standard;
estimation of hardenability using composition of steel.
5. Designing of Spheroidizing annealing cycle for eutectoid steel.
6. Performing Hardening and multiple tempering of High speed steel.
7. Design of isothermal heat treatment cycle using TTT/CCT diagram using
fluidized bed and salt bath furnace.
8. Performing surface heat treatments like carburizing, nitriding on steels;
estimating resultant case depth.
9. Design of precipitation hardening treatment of age hardenable aluminium alloys.
10. Case Study of defects due to heat treatment and remedial design changes.


30



MT 214 PRINCIPLES OF METALWORKING
LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

List of Experiments:
1. Effect of cold working and process annealing on microstructure and properties.
(Set of 3 experiments by using 3 processes like cold rolling, swaging, wire
drawing, and raw materials from copper, alpha brass, plain carbon steel and
stainless steel.)
2. Effect of hot working on microstructure and properties (by using rolling process
and 3 materials like alpha-beta brass, plain c steel and stainless steel.)
3. Study of open- and closed die forging processes. To perform open die forging of
steel samples; observation of flow lines pattern of forged parts.
4. To determine formability of sheet metal using cupping test; to study and
perform sheet metal working operations like deep drawing, stretch forming,
shearing, blanking and bending.
5. Study of rolling mill, effect of rolling parameters on final product; defects in
rolled products and their remedial measures.
6. Study of extrusion of aluminium and its alloys
7. Numerical problems based on strength of materials, plastic deformation, and
metal working processes.


31



MT 216 MECHANICAL TECHNOLOGY
LABORATORY

Teaching Scheme Examination Scheme
Laboratory: 2 hrs/week Term work: 50 Marks
Practical: 50 Marks

List of Experiments:
1. Study of Solex carburettor & Bosch type fuel injector pump.
2. Test on Diesel/Petrol engine to determine BP, bsfc, Brake thermal efficiency
3. Study of boiler mountings & accessories
4. Trial on reciprocating air compressor
5. Trial on centrifugal pump
6. Machining on Lathe , milling machine and drilling machine
7. Surface roughness, Angular, screw thread measurement (Any Two)
8. Interferometer, profile projector measurements (Any Two)

AS 204 PROFESSIONAL COMMUNICATION

Teaching Scheme Examination Scheme
Lectures: 2 hrs/week Test I20 marks
Test II 20 marks
End Sem exam 60 marks

Institution level course

ML 202 ENVIRONMENTAL STUDIES

Teaching Scheme Examination Scheme
Lectures: 2 hrs/week

Institution level course