Course Name :

MECHANICAL WORKING OF METALS

Course Code: MT421
Credits: 04 Design Points: 02
L T P :4 0 0
Pre Req: __
Lecture wise break-up
No. of lectures
1.

FUNDAMENTALS OF METAL WORKING:

(10)
Classification of Forming processes, Mechanics of Metal working, Flow stress
determination, Temperature in metal working, Strain rate effects, Metallurgical Structure,
Friction and lubrication, Deformation Zone geometry, Workability, Residual Stresses,
experimental Techniques for metal working processes, Computer aided Manufacturing
2.
FORGING:
(04)
Classification of Forging, Forging equipments, Forging in plain strain, Open die
and close die forging, Calculation of forging loads in closed die forging, Forging die
materials, Forging defects, Powder metallurgy forging, residual stresses in forgings, The
economics of forging, Problems
3.
ROLLING OF METALS:
(06)
Classification of rolling processes, Rolling Mills and the materials used for rolls,
hot rolling, cold rolling, rolling of bars and shapes, Forces and geometrical relationships
in rolling, simplified relationships in rolling load, rolling variables, Problems and defects
in rolled products, Selection of rolling mills and the sequence of rolling operations for a
given rolled product, Problems
4.
EXTRUSION:
(04)
Classification of extrusion processes, Extrusion Equipment, die materials, Hot
extrusion, Deformation, Lubrication, and defects in the extruded products, Analysis, Cold
extrusion, Hydrostatic extrusion, Problems.
5.
DRAWING OF RODS, WIRES AND TUBES:
(03)
Rod and wire drawing, analysis of wire drawing, Tube drawing processes,
analysis of tube drawing, Drawing equipments, Defects and Residual stresses in rod, wire
and tubes
6.
SHEET METAL FORMING:
(05)
Forming methods, Shearing, Blanking, Bending, stretch forming, deep drawing,
Rubber forming, Spinning, super plastic forming, Forming limit criteria, Defects in
formed parts, Equipments used for sheet metal forming, Production of honey comb
structures- Expansion, corrugation process, Dent resistance of sheet metal parts.
7.
NON CONVENTIONAL FORMING OPERATION:
(05)
Explosive forming, Magnetic forming, Electric discharge forming, Super plastic
forming for super plastic materials like Zn-22Al and Ti-6Al-4V alloys, combination of
super plastic forming and diffusion bonding (SPF/DB), Die materials used for super
plastic forming, Peen forming of thin sheet metals, Laser forming

BOOKS:
1.
Dieter :

Mechanical metallurgy, Macgraw Hill

REFERENCES:
1.
Kalpakjian and Schmid:
Pearson education

Manufacturing

Engineering

Course Name :
MECHANICAL WORKING OF METALS
Course Code: MT421H
Credits: 04 Design Points: 02

and

Technology,

L T P :4 0 0

In addition to the contents of MT 421 additional work material in this course for the
students will include: Providing Extra reading materials, Review Assignments of relevant
research Papers, Project/ Case study
Course Name :

STEEL AND ALLOY MAKING

Course Code: MT422

Pre Req.
:
Lecture wise break-up
1.

Credits

:04

LTP

:4 0 0
No. of lectures

PRESENT SCENARIO
(03)
Production and quality aspects for different steels and their importance for
Industrial Applications.
Application of alloy steels which makes it irreplaceable.
2.
PHYSIO CHEMICAL PRINCIPLES FOR STEEL MAKING
(06)
Physico chemical aspects of steel making reactions controlling the removal of
carbon, sulphur, phosphorous, silicon & manganese.
Slags their constitution & properties and the theories predicting their behaviour
3.
PRODUCTION OF STEEL
(04)
Constructional details of the Steel making furnaces. Design and description of
various parts and their functions. Bessmer converter, Open hearth and Electric arc
furnace. their control, constructional & operational details
4.
NEW DEVELOPMENTS
(07)
Modern pneumatic process viz L.D., Kaldo and Rotor process etc
Secondary processes of steel refining viz. Laddle furnace, AOD, VOD, & ESR. Their
construction aspects, principle of refining, charge estimation and typical applications in
the production of alloy/special steels.
5.
ELECTRIC ARC FURNACE
(04)
Its design considerations and other important characteristics, Physico chemical
aspects of the reactions in the recovery of alloying elements vix. Chromium, Manganese,
Nickel, Molybdenum, Tungsten, Vanadium and Titanium and micro alloy additions.
6.
GAS METAL INTERACTION:
(05)
Mechanism of gas absorption via entertainment during teeming of molten metals.
Solubility of oxygen in liquid metals its estimation, form EMF measurements involving
solid electrolytes.
7.
DEGASSING PROCESS:
(02)
Vacuum, Argon, Stream and recycling methods employed for degasification of
steel.
8.
SPECIAL ALLOY STEEL :
(04)

Production of special steel viz. stainless, interstitial free steel, Tool steels, HSLA
steels and Electrical steels etc.
9.
SOLIDIFICATION OF STEEL
(05)
Solidification defects viz. Inclusion, blowholes, crakes & segregation-their causes, effects
& remedies. Degassing processes, Teeming practices, Gas Metal interaction during
teeming,
10.

CONTINUOUS CASTING OF STEELS:

(05)
Types of casters, technology involved, latest developments, Defects and remedial
measures.
BOOKS:
1.
The manufacture of iron and steel (Vol. II & IV) Bashforth, R.G
REFERENCES:
1.
Electrometallurgy of Steel And Ferro Alloys Vol. I. F.P. Erineral
2.
Physical Chemistry of Iron and Steel Manufacturer C. Bodsworth
3.
Production of Ferro Alloys
A. Riss & Y. Khodorvosky
4.
Making, Shaping & Treating of steel
ASM Publishing, USA. Ed. 1990.
5.
Electro Slag Technology
B.I. Medover & G.A. Boyko, 1990
Ed.
6.
Proceedings, Secondary Steel Technology Dr. S.R. Prabhakar, 1994 IIM, Pub.
Calcutta.
Course Name :

STEEL AND ALLOY MAKING

Course Code: MT422

Credits

:04

LTP

:4 0 0

Project work will be assigned for the cost analysis of the production of alloy steel making
by different processes. Assignments involving new technologies for production of alloy
steel.

Course Name :
EXTRACTIVE METALLURGY LAB
Course Code: MT471
Credits :02 Design Points: 02
Pre Req. :
__

LTP :004

Experiment 1 a) Performing various operations of mineral dressing produce to

concentrate of the given ore.
b) Remove the moisture content from the concentrate
c) Calculate the extent of roasting of above roasted cake at
T= 640C, T= 700C, Plot curve S removed vs. time of Roasting
Experiment 2 a) To perform Sintering of given Fe ore
b) To perform Palletizing and then compare the final products in terms of
i) Its porosity
ii) Reducibility

iii) Shatter Index etc.

Experiment 3 a) Study solidification defects in steels with the help wax casting.
b) Also study the effect of super heats (4, 7 & 10) on the piping in wax
casting.
c) How directional solidification can be achieved in the above castings.
Experiment 4 To determine the reducibility of an oxide ore.
Experiment 5 To calculate Partial moral volume of water alcohol system. Plot curve also.
Experiment 6 To find the constant temperature zone of a muffle furnace.
Experiment 7 To perform the shatter index and abrasion for sintered as well as on ore.
Experiment 8 To perform roasting of copper ore (i) Partial Roasting (ii) Dead roasting
Experiment 9 Secondary Extractive of Tin from Tinplated sheets.
Course Name :
CHARACTERIZATION OF MATERIALS LAB.
Course Code: MT472
Credits
:02
LTP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

:0 0 4

To analyse given samples using metascope for different elements and spark test
for Carbon content.
To find Fe content in Fe ore.
Nickel content in stainless steel by gravimetric analysis method.
To determine Sulphur content in a given sample.
To study Spectroscope analysis for Qualitative/ Quantitative
To study segregation of sulphur and phosphorus by sulphur printing and
phosphorus printing.
To study flow lines in a given forged sample.
To perform Izod test.
To perform hardness test using Rockwell Hardness Tester.
To study construction and operation of optical microscope.
To study the wear and friction monitor and to test the given materials.
Tensile test and compression test.
Fatigue test.

Course Name :

ADVANCED MATERIALS AND TECHNOLOGY

Course Code: MT425

Pre Req.
:
Lecture wise break-up

Credits

:04

LTP

:4 0 0

No. of lectures

INTRODUCTION TO FERROUS MATERIALS

(07)
Plain carbon steels, their properties and application: plain carbon steels, effects of
alloying elements in plain carbon steels. Alloy steels, tools steels, stainless steels, low
and high temperature resisting steels, high strength steels, selections, specifications, form
and availability of steel. Cast irons-white, grey, nodular malleable and alloy cast irons.
Recognised patterns of distribution of graphite flakes in grey cast iron.
2.
HEAT TREATMENT OF STEELS
(08)

TTT diagrams, annealing, normalizing, hardening and tempering of steel.

Austempering and martempering of steel. Surface hardening of steel-Carbonising
nitriding carbonitriding cyniding, and inducation hardenirng .
3.
NONFERROUS MATERIALS
(07)
Ultra light materials. Properties and application, brasses, bronzes, copper-nickel
alloys, aluminum, magnesium and titanium alloys, bearing materials. Heat treatment of
nonferrous materials solutionizing, Aging and precipitation hardening.
4.
COMPOSITES
(10)
Polymer polymer, metal-metal, ceramic ceramic, ceramic-polymer, metalceramic, metal-polymer composites. Properties and applications. Dispersion reinforced,
particle reinforced, laminated and fiber reinforced composites. Refractory materials and
coatings for high temperature applications. Smart Materials-introduction, types and
applications. Thin film shape memory alloys.
5.
BIOMATERIALS
(07)
Classes and application of materials in medicine and dentistry. Stress strain
behaviour of bone. The mechanical properties including elasticity, hardness,
viscoelasticity, surface and fatigue properties of skin; soft tissues; bone; metals; polymers
and ceramics. Biocompatible materials and its applications. The effects of degradation
and corrosion.
6.
NUCLEAR MATERIALS
(07)
Introduction to nuclear materials. Materials for nuclear fuel in fission and fusion
reactors, Fissile and fertile materials. Control & Construction Materials for Nuclear
reactors, Moderators, Heat Exchangers. Radiation proof materials. Brief discussion of
safety and radioactive waste disposal.
7.
ELECTRONIC MATERIALS
(02)
Introduction, types and applications. Aerospace Materials, Construction Materials
and Photonic Materials.
BOOKS:
1.
W.D. Callister, Jr, Material Science & Engineering Addition-Wesly Publishing
Co.
2.
Van Vlack Elements of Material Science & Engineering John Wiley & Sons
REFERENCES:
1.
Biomaterials Science- An Introduction to Materials in Medicine. Buddy
D.Rattner,
A.S. Hoffman, F.J. Sckoen, and J.E.L Emons, Academic Press,
second edition, 2004.
2.
Biomaterials: An Introduction (second edition) Joon B.Park & Roderic S.Lakes,
Plenum Press, 1992.
Course Name :

ADVANCED MATERIALS AND TECHNOLOGY

Course Code: MT425H

Credits

:04

LTP

In addition to the contents of MT 425 the additional topics:

Additional work material in this course for the students will include:

:4 0 0

Providing Extra reading materials, Review Assignments, Project/ Case study, Design
Assignments

Course Name :
CAST IRON TECHNOLOGY
Course Code: MT427
Credits
:04
Lecture wise break-up
1.

LTP
:400
No. of lectures

INTRODUCTION
(06)
Cast irons various types/classification gray /vermicular gray (VG) or compacted
gray iron /white /mottled /chilled /malleable /nodular or ductile or SG iron /ADI,
composition , microstructures, properties, uses & applications, properties of cast irons vis
a vis steels, status of cast iron in ferrous metal scenario, cast iron foundry industry & roll
of gray cast iron metal in the development of metal casting industry
2. MELTING OF CAST IRONS
(12)
Various furnaces used viz crucible/rotary/ reverberatory/ cupola/induction, their
types /construction/operational details, Recent developments in cupola melting hot blast
cupola/water cooled cupola/divided blast cupola/use of oxygen in cupola/ cokeless or gas
fired cupola, selection of melting unit for a cast iron foundry, charging & charge balance,
Cupola - composition control, coke bed & stack gases; melting rate, combustion & melt
temp., chill control.
3. GRAY CAST IRON FOUNDRY PRACTICE
(14)
Molding, Gating & Risering, Fluidity of gray iron, shrinkage, gating design &
pouring rate, dirt prevention, Fe-C-Si phase diagrams & solidification of Fe-C-Si alloys,
carbon equivalent, graphitization & factors affecting graphitization during solidification
and in solid state, types of flakes & their effect on properties, Inoculation & inoculants
used, mechanism of inoculation graphite nuclei/degasification/silicate-slime/undercooling/carbide stability/surface tension & surface energy theories, Techniques of
inoculations ladle/stream/mold, Composition, microstructure, properties of gray irons,
Heat treatment of gray irons.
4. WHITE & MALLEABLE IRON FOUNDRY PRACTICE
(06)
Composition & solidification of white cast iron, microstructure & properties, types
& composition of malleable irons, malleablizing process malleable foundry practice.
5. S G IRON FOUNDRY PRACTICE
(08)
Microstructure, properties of SG iron, composition & melting of base iron,
desulpurization, magnesium treatment & post inoculation, solidification of SG iron &
mechanism of spheroidal graphite formation, uses & applications, Heat treatment of SG
iron castings,
6. VERMICULAR/COMPACTED GRAPHITE IRONS
(04)
Composition, microstructure, properties & production of VG/CG iron, melt
treatment & post inoculation, mechanism of VG formation.
7. AUSTEMPERED DUCTILE IRON
(04)
Composition, microstructure, properties & production, Heat treatment of AD irons,
uses & application
BOOKS:
1. Elliot

: Cast Iron Technology

2. S N Tiwari
REFERENCES:
1. Heine, Loper & Rosenthal
2. A. K Chakrabarti
3. P L Jain

: Cast iron Technology

: Principles of Metal Casting
: Casting Technology & Cast Alloys
: Principles of Foundry Technology

Course Name :
CAST IRON TECHNOLOGY
Course Code: MT427H
Credits
:04
LTP
:400
Students shall study in details austempered ductile iron, advances made recently in the
field of cast irons, development of tailor made cast irons, selection of different cast irons
for different applications and few home assignments.
Course Name:
ADVANCED FOUNDRY TECHNOLOGY
Course Code: MT428
Credits
:04
LTP
:4 0 0
Lecture wise break-up
No. of lectures
1.

CASTING AS A COMPETITIVE MANUFACTURING

(05)
Casting as a competitive manufacturing process. Comparative evaluation of
potential and prospects. Intra Cast product and process types for comparative evaluation.
Properties and characterization of cast products.
2.
SOUND CASTING DEVELOPMENT
(10)
Product design development and process design of castings, Melting, Metal
Treatment, Inoculation (Types), Techniques & Converters) Solidification, Inclusion,
Structure Control, Grain / Dendrite Morphology. Role of Computers in Casting Biz
Process, Design and Development.
Founding of Cast Iron, Steels and Alloy Steels. Application of design to alloy casting
development.
3.
PROCESS DESIGN OF CASTING & MODLING
(12)
4.
AUTOMATION IN CASTING
(08)
Automation and options in Molding, Core making, Metal handling, Melt flow,
fore casting and simulation.
5.
NET SHAPE CASTING AND HIGH PERFORMANCE PROCESS (10)
Founding advances, goal of net shaping, net shaping process viz, liquid forging,
Watt technician process, DC casting, Thixoforming, Rheo Casting etc.
Net Shape and High Performance Process as mentioned.
6.
ENVIORNMENTAL CONCERNS
(03)
Founding Pollution Control and Energy efficiency.
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.
Course Name:
ADVANCED FOUNDRY TECHNOLOGY
Course Code: MT428H
Credits
:04
LTP

:4 0 0

1. Advances
Near Net Casting processes
Simulation of Riser design, Gating system, Metal Flows, etc for sound casting Design.
Structure sensitive properties and microstructure control. Control of solidification &
advances in dendritic structure development, DAS measurement
2. Handling and management of Molding
sizes.
Environmental and safety
considerations in handlingFounding. Energy conservation
3.Chill Design and Control, Modulus calculation of a complex system, Design of
materials for a CI casting/ alloy cast iron castings, Specific requirements may be asked
for please
Course Name:
NUCLEAR METALLURGY
Course Code: MT429
Credits
:04
Lecture wise break-up

LTP

:4 0 0
No. of lectures

1.

ELEMENTARY NUCLEAR PHYSICS AND CHEMISTRY:

(14)
Structure of nucleus, radioactivity, binding energy: nuclear interaction; fission
and fusion: nuclear reaction; energy release and chain reactions; neutron cross-section;
multiplication and criticality concepts and factors.
2.
MECHANISMS OF MODERATION:
(10)
Radiation detection, radiation effects on fissile and non fissile materials; radiation
damage and radiation growth; thermal cycling; protection against radiations.
3.
REACTOR COMPONENTS:
(02)
Types of reactors and classification.
4.

MATERIALS FOR NUCLEAR REACTORS:

(08)
Considerations in selection and properties of common materials used as fuels,
their physical and chemical properties; canning materials; coolants; control rods;
reflectors and shielding materials.
5.

PRODUCTION OF REACTOR MATERIALS:

(06)
Occurrence and general characteristics of nuclear minerals and their production.
Indian resources: Flow sheets of processing of nuclear minerals for the production of
nuclear grade uranium, thorium, beryllium and zirconium with emphasis on basic
scientific principles involved; production and enriched uranium and fabrication of fuel
elements.
6.
PROCESSING
(04)
Processing of irradiated fuel for recovery of Plutonium
7.
PRESENT SCENARIO
(02)

Nuclear power production in India and its economics.

BOOKS:
1. Wright JC -Metallurgy in Nuclear Power Technology: Iliffe Book Ltd., 1962
REFERENCES:
Nuclear Metallurgy : Donald E. Thomas
Nuclear Metallurgy : R C Dalzell
Wilkinson WD and Mrphy WF Nuclear Reactor Metallurgy Van Nostrand 1958
Symposium on Rare matierals: Indian Institute of Metals.
Glasstone S and Snesonske A; Prncipales of Nuclear Reactor Engineering:
Macmillan, London.
6. Grainger L Uranium and Thorium: George Newnes Ltd., London.
1.
2.
3.
4.
5.

Course Name:
NUCLEAR METALLURGY
Course Code: MT429H
Credits
:04

LTP

:4 0 0

Two review assignments from International journals, a case study, one project work and
atleast 30 conceptual problems
Course Name :
CAPSTONE PROJECT I
Course Code : MT430
Credits :04 Design Points: 02
Pre Req.: -

L T P :0 0 8

Selection and preparation of a project in any area of Metallurgical engineering. The

students will be required to submit the report and will work on the same topic to complete
the Capstone project-II