Course No.

Course Name

L-T-P-Credits

Year of Introduction

ME210

METALLURGY AND

MATERIALS ENGINEERING

3-0-0-3

2016

Prerequisite: nil

Course Objectives:

1.     To provide fundamental science relevant to materials

2.     To provide physical concepts of atomic radius, atomic structure, chemical bonds, crystalline and  non-crystalline  materials  and  defects  of  crystal  structures,  grain  size, strengthening

      mechanisms, heat treatment of metals with mechanical properties and changes in structure

3.     To enable students to be more aware of the behavior of materials in engineering applications and select the materials for various engineering applications.

4.     To understand the causes behind metal failure and deformation

5.     To determine properties of unknown materials and develop an awareness to apply this knowledge in material design.

Syllabus:-Chemical bonds – crystallography- imperfections- crystallization- diffusion- phase diagrams-heat treatment – strengthening mechanisms- hot and cold working – alloying- ferrous  and non ferrous alloys- fatigue-creep- basics, need, properties and applications of modern engineering materials.

Expected outcome: At the end of the course students will be able to

1.     Identify the crystal structures of metallic materials.

2.     Analyze the binary phase diagrams of alloys Fe-Fe₃C, etc.

3.     Correlate the microstructure with properties, processing and performance of metals.

4.     Recognize the failure of metals with structural change.

5.     Select materials for design and construction.

6.     Apply core concepts in materials science to solve engineering problems.

Text Books

1.     Raghavan V, Material Science and Engineering, Prentice Hall,2004

2.     Jose S and Mathew E V, Metallurgy and Materials Science, Pentagon, 2011 Reference

1       Anderson J.C. et.al., Material Science for Engineers,Chapman and Hall,1990

2       Clark and Varney, Physical metallurgy for Engineers, Van Nostrand,1964

3.     Reed Hill E. Robert, Physical metallurgy principles, 4^th Edn. Cengage Learning,2009

4.     Avner H Sidney, Introduction to Physical Metallurgy, Tata McGraw Hill,2009

5.     Callister William. D., Material Science and Engineering, John Wiley,2014

6.     Dieter George E, Mechanical Metallurgy,Tata McGraw Hill,1976

7.     Higgins R.A. – Engineering Metallurgy part – I – ELBS,1998

8.     Myers Marc and Krishna Kumar Chawla, Mechanical behavior of materials, Cambridge University press,2008

9.     Van Vlack -Elements of Material Science – Addison Wesley,1989

10.  http://nptel.ac.in/courses/113106032/1

11.  http://www.myopencourses.com/subject/principles-of-physical-metallurgy-2

12.  http://ocw.mit.edu/courses/materials-science-and-engineering/3-091sc-introduction-to-

solid-state-chemistry-fall-2010/syllabus/

13. http://www.msm.cam.ac.uk/teaching/partIA.php

Course Plan

Module

Contents

Hours

Semester Exam. Marks

I

Earlier and present development of atomic structure; attributes     of     ionization     energy     and              conductivity, electronegativity and alloying; correlation of atomic  radius to strength; electron configurations; electronic repulsion Primary bonds: – characteristics of covalent, ionic and metallic bond: attributes of bond energy, cohesive force, density, directional and non-directional and ductility. properties based on atomic bonding:- attributes of deeper energy              well    and    shallow    energy    well    to              melting temperature, coefficient of thermal expansion – attributes of modulus of elasticity in metal cutting process -Secondary bonds:- classification- hydrogen bond and anomalous behavior  of  ice  float  on water, application- atomic mass unit and specific heat, application. (brief review only, no University questions and internal assessment from these

portions).

2

15%

Crystallography:- Crystal, space lattice, unit cell- BCC,  FCC, HCP structures – short and long range order – effects  of crystalline and amorphous structure on mechanical properties.

1

Coordination number and radius ratio; theoretical density; simple problems – Polymorphism and allotropy.

1

Miller Indices: – crystal plane and direction (brief review)

– Attributes of miller indices for slip system, brittleness of BCC, HCP and ductility of FCC – Modes of plastic deformation: – Slip and twinning.

1

Schmid’s law, equation, critical resolved shear stress, correlation of slip system with plastic deformation in metals

and applications.

1

II

Mechanism     of      crystallization:     Homogeneous     and

heterogeneous nuclei formation, under cooling, dendritic growth, grain boundary irregularity.

1

15%

Effects of grain size, grain size distribution, grain shape,

grain    orientation    on    dislocation/strength    and            creep resistance – Hall – Petch theory, simple problems

1

Classification of crystal imperfections: – types of dislocation

– effect of point defects on mechanical properties – forest of dislocation, role of surface defects on crack initiation.

1

Burgers vector –dislocation source, significance of Frank Read source in metals deformation – Correlation of dislocation density with strength and nano concept,

applications.

1

Significance high and low angle grain boundaries on

dislocation – driving force for grain growth and applications during heat treatment.

1

Polishing and etching to determine the microstructure and

grain size.

1

Fundamentals and crystal structure determination by X –

ray diffraction, simple problems –SEM and TEM.

1

Diffusion in solids, Fick’s laws, mechanisms, applications

of diffusion in mechanical engineering, simple problems.

1

FIRST INTERNAL EXAMINATION

III

Phase diagrams: – Limitations of pure metals and need of alloying – classification of alloys, solid solutions, Hume Rothery`s rule – equilibrium diagram of common types of

binary systems: five types.

2

15%

Coring – lever rule and Gibb`s phase rule – Reactions: – monotectic, eutectic, eutectoid, peritectic, peritectoid.

1

Detailed discussion on Iron-Carbon equilibrium diagram with microstructure and properties changes in austenite,

ledeburite, ferrite, cementite, special features of martensite transformation, bainite, spheroidite etc.

1

Heat treatment: – Definition and necessity – TTT for a

eutectoid iron–carbon alloy, CCT diagram, applications – annealing, normalizing, hardening, spheroidizing.

1

Tempering:- austermpering, martempering and ausforming

– Comparative study on ductility and strength with structure of pearlite, bainite, spherodite, martensite, tempered martensite and ausforming.

1

Hardenability, Jominy end quench test, applications-  Surface hardening methods:- no change in surface composition methods :- Flame, induction, laser and electron beam hardening processes- change in surface composition

methods :carburizing and Nitriding; applications.

2

IV

Types of Strengthening mechanisms: – work hardening, equation – precipitation strengthening and over ageing-

dispersion hardening.

1

15%

Cold working: Detailed discussion on strain hardening; recovery; re-rystallization, effect of stored energy; re- crystallization temperature – hot working Bauschinger effect

and attributes in metal forming.

1

Alloy steels:- Effects of alloying elements on steel: dislocation movement, polymorphic transformation temperature, alpha and beta stabilizers, formation and stability of carbides, grain growth, displacement of the eutectoid point, retardation of the transformation rates, improvement in corrosion resistance, mechanical properties

1

Nickel steels, Chromium steels etc. – Enhancement of steel properties by adding alloying elements: – Molybdenum, Nickel, Chromium, Vanadium, Tungsten, Cobalt, Silicon,

Copper and Lead.

1

15%

High speed steels:- Mo and W types, effect of different

alloying elements in HSS

1

Cast irons: Classifications; grey, white, malleable and spheroidal graphite cast iron etc, composition, microstructure, properties and applications.

1

Principal Non ferrous Alloys: – Aluminum, Copper, Magnesium, Nickel, study of composition, properties, applications, reference shall be made to the phase diagrams whenever necessary.

1

SECOND INTERNAL EXAMINATION

V

Fatigue: – Stress cycles – Primary and secondary stress

raisers – Characteristics of fatigue failure, fatigue tests, S-N curve.

1

20%

Factors affecting fatigue strength: stress concentration, size effect, surface roughness, change in surface properties,

surface residual stress.

1

Ways to improve fatigue life – effect of temperature on fatigue, thermal fatigue and its applications in metal cutting

1

Fracture: – Brittle and ductile fracture – Griffith theory of

brittle fracture – Stress concentration, stress raiser – Effect  of plastic deformation on crack propagation.

1

transgranular, intergranular fracture – Effect of impact loading on ductile material and its application in forging, applications – Mechanism of fatigue failure.

1

Structural features of fatigue: – crack initiation, growth, propagation – Fracture toughness (definition only) – Ductile to brittle transition temperature (DBTT) in steels and

structural changes during DBTT, applications.

1

V1

Creep: – Creep curves – creep tests – Structural change:-

deformation by slip, sub-grain formation, grain boundary sliding

1

20%

Mechanism of creep deformation – threshold for creep, prevention against creep – Super plasticity: need and

applications

1

Composites:- Need of development of composites – geometrical and spatial Characteristics of particles – classification – fiber phase: – characteristics, classifications – matrix phase:- functions – only need and characteristics of PMC, MMC, and CMC – applications of composites:  aircraft applications, aerospace equipment and instrument structure, industrial applications of composites, marine applications, composites in the sporting goods industry,

composite biomaterials..

2

Modern engineering materials: – only fundamentals, need, properties and applications of, intermetallics,  maraging steel, super alloys, Titanium – introduction to nuclear

materials, smart materials and bio materials.

2

Ceramics:-coordination number and radius ratios- AX,

A_mX_p, A_mB_mX_p type structures – applications.

1