09YN01 PROBABILITY AND STATISTICS 3 0 0 3

PROBABILITY AND CONCEPT OF RANDOM VARIABLE: Concepts of Probability Conditional Probability Independent Events Bayes Theorem - Random Variables Jointly Distributed Random Variables - Discrete and Continuous Distributions Mathematical Expectations - MGF - Mean and Variance. (8) TESTING OF HYPOTHESIS: Large sample tests - tests for means, variances and proportions. Small sample tests Tests based on t, F, and chi-square distributions. (6) CORRELATION AND REGRESSION: Linear Correlation Multiple and Partial Correlations - Linear Regression Multiple Regression analysis (6) DESIGN OF EXPERIMENTS: Introduction to design of Experiments - One way and Two way classifications CRD - RBD Models - Multiple Comparisons Graphical Analysis Latin Squares. Factorial experiments: Two Factor experiments Multifactor experiments 2n Factorial experiments Graphic Presentation of 22 and 23 Experiments. (8) STATISTICAL QUALITY CONTROL: Statistical basis for control charts control limits specification limits tolerance limits revised control limits control charts for variables defects -

c, u charts

_ p, np charts charts for X ,R, charts, charts for defective (5)

SAMPLING CONCEPTS : Introduction - Single sampling plan Double sampling plan Multiple sampling plan OC curves - consumers risk, producers risk. ASN, ATI, AOQ curves - Lot-by-Lot acceptance sampling plans for attributes - skip-lot sampling plans. Acceptance sampling plans. Acceptance sampling for continuous productions CSP-1 plans, CSP-2 plans (9) Total 42 REFERENCES 1. Engene L Grant and Richard S Leavenworth, Statistical Quality Control,Tata McGraw Hill Publishing Company, 2000 2. Douglas Montgomery, Introduction to Statistical Quality Control, Wiley & Sons, 2001. 3. Jay L Devore, Probability and Statistics for Engineering and the Sciences, Thomson Asia, 2002 4. Johnson R A, Miller and Freunds, Probability and Statistics for Engineers, Pearson Education Asia, 2002 5. Walpole , H. Myers, L. Myers and K.Ye, Probability & Statistics for Engineers and Scientists Pearson Education Asia, 2002 6. Sheldon M. Ross, Introduction to Probabilistic Models, , Academic Press, 2003 7. Daleh H Besterfield, Quality Control, Prentice Hall, 2003

09YN02 PHYSICAL METALLURGY 3003

CRYSTALLOGRAPHY AND CRYSTAL DEFECTS: Crystal systems-Detailed discussion of common crystal structures in metals and alloys. Crystal defects: Classification - Point, line, area and volume defects - Voids - types and location in BCC, FCC and .HCP structures- influence of defects on properties. (6) ALLOYING THEORY: Types of solid solutions and compounds - Hume-Rothery rules for formation of substitutional solid solutions- properties of solid solutions. Essential principles of solidification. (6) PHASE DIAGRAMS: Determination and uses of phase diagrams. Types of phase reactions with examples. Phase rule and its application to phase diagrams- Lever rule. Concept of ternary phase diagrams - Exercise problems. (9) DIFFUSION IN SOLIDS: Diffusion - Concept of activation energy- Mechanisms of diffusion - Fick's I Law of diffusion Diffusion coefficient- factors affecting diffusion coefficient - Fick's II Law of diffusions - inter diffusion - Kirkendall effect Modes of diffusion (surface, volume and grain boundary) - Industrial applications - Numerical problems. (8) THEORY OF PHASE TRANSFORMATIONS: Nucleation and growth - homogeneous and heterogeneous nucleation. Martensitic transformation in ferrous and non-ferrous metals - Shape Memory Effect and its applications, Diffusion controlled transformations and diffusion less transformations. (8) COLD WORKING AND HOTWORKING: Structure and properties of cold worked metals Annealing- Recovery, recrystallisation and grain growth, comparison of cold working and hot working. STRENGTHENING MECHANISMS: Cold working, Grain size control, precipitation hardening, martensitic strengthening, dispersion hardening. (5) Total 42 REFERENCES: 1. Van Vlack, L H, Elements of Material Science and Engineering, Addison Wesley Publication, New York, 1975. 2. Avner S H., An Introduction to Physical Metallurgy, McGraw Hill Book Co., New York, 1982. 3. James F Shackal Ford, Introduction to Material Science for Engineers, third edition, Macmillan, 1992 4. Willaim F Smith, Foundations of Materials Science & Engineering second edition, , Mc Graw Hill, 1993. 5. Anderson J C, Leaver K D, Leaver P and Rawlings R D, Material Science for Engineers , fifth edition Chapman and Hall, London, 2003. 6. Donald R Askeland, The Science and Engineering of Materials, fourth edition, Thomson Brooks / Cole, 2003 7. William D Callister, Jr, Materials Science Engineering- An Introduction , sixth edition, John Wiley & Sons, 2003. 8. Ragavan A, Material Science & Engineering-A First Course, fifth edition Prentice Hall International, NY, 2004. 9. Vijendra singh Physical Metallurgy, Standard Publishers distributors, 2005

212

09YN03 HEAT TREATMENT AND SURFACE ENGINEERING 3003

GENERAL PRINCIPLES OF HEAT TREATMENT: Phase diagrams and phase transformations. (3)

HEAT TREATMENT EQUIPMENT: Furnaces, Quenching methods, fixtures, control of furnace atmosphere, temperature control. (6) HEAT TREATMENT OF STEEL: Fe-C diagram. Effect of alloying elements on Fe-c diagram, Annealing(different types), normalizing, hardening - Quenching media - Martensite formation - TTT diagram - Hardenability - Influence of alloying elements. Tempering - Temper brittleness, Sub zero treatment - Control of retained austenite. Austempering, Martempering and Thermo-mechanical treatments. (9) SURFACE ENGINEERING TECHNIQUES: Flame and induction hardening. Carburising, nitriding, carbonitriding, boriding, , electron beam and laser beam hardening .PVD and CVD processes, sputter coating, ion plating, ion implantation, spray coatings. (9) HEAT TREATMENT OF FERROUS ALLOYS: Stainless steels, Tool steels and Cast irons, maraging steels, HSLA steels and dual phase steels. (6) HEAT TREATMENT OF NON-FERROUS ALLOYS: Heat treating of Aluminium -precipitation hardening, Copper, Magnesium and Titanium alloys, Ni-base super alloys (6) INSPECTION AND QUALITY CONTROL: Causes and remedies for defects (like low hardness and strength, soft spots, oxidation and decarburization, over heating and burning, quench cracks, distortion and warping) in heat-treated parts. (3) Design for heat treatment. Total 42 REFERENCES : Prabhudev K H , Handbook of Heat Treatment of Steels, Tata-McGraw Hill Publications. Co. Ltd., 1988. American Society of Metals, Metals Handbook, Volume IV, A.S.M., Metals park, Ohio, USA, 1991. Sudharsan T S , Surface Engineering, Ohio State University, 1992 Rajan and Sharma, Industrial Heat Treatment, Oxford and IBH, New Delhi, 1995. 5. Karl Eric Thelning, Steel anf its heat treatment, Butterworth Publications, 2000. 6. Vijendra singh, Physical Metallurgy, Standard Publishers distributors, 2005

1. 2. 3. 4.

09YN04 METAL CASTING ENGINEERING 3014

INTRODUCTION: Comparison of Solidification route with other manufacturing routes. (2) (4)

PATTERNS: Types, design of patterns, Allowances material selection, manufacture of patterns

MOULDIING AND CASTING PROCESSES: Classification of moulding proesses, mould materials, basic requirement of mould sands, preparation of mould sands, bonds formed in moulding aggregates, Resin binder processes, Sand mouldings Bonded sand moulds and unbonded sand moulds. Core making processes, plaster moulding processes, ceramic moulding processes, investment casting processes, graphite moulding processes, permanent mould casting processes, die casting processes, types of centrifugal casting processes, continuous casting processes, new casting processes Squeeze casting, semi solid metal casting, directional solidification processes, CLA process, Thixocasting and Rheocasting processes. (7) MELTING: Construction and operation of electric arc furnace [Direct and Indirect Arc], resistance furnace - core and core less induction, cupola, rotary and crucible furnaces. (6) DEVELOPMENT OF LAYOUT AND FACILITIES: Layout, mechanisation and automation, fettling, inspection and pollution control. planning foundries of specified capacity for a particular alloy. (7) DESIGN CONSIDERATIONS: Casting design, methoding, Gating and Risering calculations, improvement of yield and efficiency, simple problems in gating and risering for steels and cast irons. (8) CASTING DEFECTS: Identification, analysis and Remedies COMPUTER APPLICATIONS: Solidification and simulation of metal casting-use of softwares (3) Total 42 REFERENCES: (5)

1. 2. 3.
4.

Srinivasan N K ,Foundry Engineering, Khanna Tech. Publication Co, New Delhi, 1992. Jain P L, Principles of Foundry Technology, Tata McGraw- Hill Publishing Co., Ltd, New Delhi 1995. Heine R W Loper and Rosenthal, Principles of Metal Casting, Tata McGraw Hill. Publication. Co, 1998. ASM Handbook, Vol. 15, Casting, ASM Publication, 1998.

213

5.

Peter Beelay, Foundry Technology, Butterworth, London, UK, 2001.

09YN05 MECHANICAL METALLURGY 3003

Plastic Deformation Dislocations - types, burgers vector, theoretical cohesive strength and practically measured strength, deformation by slip, critical resolved shear stress, deformation by twinning, stacking faults. Dislocation theory dislocation loop, dislocations in cubic and hexagonal lattices, stress fields and energies of dislocations, dislocation climb, intersection of dislocations, dislocation multiplication, dislocation pile-ups. Strain hardening of single crystals. (13) Fracture Types, Griffths theory of brittle fracture, fractography, effect of temperature, stress raisers and strain rate on fracture behaviour (5) TENSION TEST Engineering stress strain curve and true stress strain curve, instability in tension, measurement of tensile properties, factors affecting flow properties, notch tensile test. Hardness test Brinell hardness relationship between hardness and flow curve, Vickers hardness, Rockwell hardness, microhardness tests, hardness conversion relationships. Torsion Test Types, torsion test Vs tension test, hot torsion test. Overview of ASTM testing standards for tension, hardness and torsion tests, compression test. (9) Fracture mechanics stress intensity factor, fracture toughness, plane- strain toughness testing, crack opening displacement, probabilistic aspects of fracture mechanics. (6) FATIGUE S-N curve, fatigue testing, factors affecting fatigue properties, structural features of fatigue failures, low cycle fatigue. Creep creep curve, structural changes during creep, mechanisms of creep deformation, deformation mechanism maps, stress- rupture test, long term creep, Larson-miller parameter, creep analysis. Impact test Izod and Charpy tests, significance of transition temperature curve, DBTT, factors affecting transition temperature. Overview of ASTM testing standards for fatigue, creep and impact tests. Few case studies on the design of damage tolerant alloys. (9) Total 42 REFERENCES:

1.

Hayden W, Moffatt W G Wulff J, Structure and properties of Materials Volume: III: Mechanical Behavior, 5th reprint, Wiley eastern limited, New Delhi 1986.

2. 3. 4.

Dieter G E, Mechanical Metallurgy, McGraw hill book company, London 1988. Hull D and Bacon D J, Introduction to dislocations, fourth edition, Butterworth- Heinemann, Oxford, 2001. Courtney T H, Mechanical Behavior of Materials, second edition, Overseas Press (India) Private Limited, 2006.

09YN06 WELDING TECHNOLOGY 3014

INTRODUCTION: Welding processes and grouping, welding terms (2)

ARC CHARACTERISTICS: Plasma, electron emission and ionization potential, arc temperature, influence of magnetic fields on arcs, arc blow, metal transfer, effect of polarity, effect of gases. (2) POWER SOURCES: Power source characteristics, static and dynamic characteristics, CC and CV power source designs, current and voltage relationships, solid state power sources. (2) ARC WELDING PROCESSES: Detailed description about the process equipment, control of parameters, consumable, specifications for electrodes and filler metals and applications related to the following processes: Shielded metal arc welding, gas metal arc welding, flux cored arc welding, gas tungsten arc welding, plasma arc welding, submerged arc welding, stud arc welding. (18) OTHER WELDING PROCESSES: Oxy-fuel gas welding, Electro Slag Welding, Resistance welding, Electron Beam Welding, Laser beam Welding, thermit welding and solid state welding processes. Weld overlay, thermal cutting and thermal spraying. Brazing and Soldering (10) HEAT FLOW IN WELDING: Heat transfer in weldments, dissipation of welding heat, cooling rates, weld metal cooling curves, peak temperature, calculating width of heat affected zones, solidification rate and effects of heat input. (2) RESIDUAL STRESSES AND DISTORTION INTRODUCTION TO WELDING METALLURGY SAFETY IN WELDING (3) (2) (1) Total 42 1. 3. 4. REFERENCES: ASM Metals Hand Book, Vol 6, "Welding, Brazing and Soldering", ASM International, Metals Park, Ohio, 1993 2. Nadkarni S V Modern Arc Welding Technology, Oxford IBH Publishers, 1996. AWS Welding Handbook, Volume 1, Welding Science & Technology, American Welding Society, 2001 Howard B Cary "Modern Welding Technology", fifth edition, Prentice Hall, New Jersey, 2002

214

5. 6. 7.

Parmar, R.S, Welding Engineering and Technology, Khanna Publishers, 2003 AWS Welding Handbook, Volume 2, Welding Processes, Part 1, American Welding Society, 2004 AWS Welding Handbook, Volume 3, Welding Processes, Part 2, American Welding Society, 2004

06YN07 FORMING PROCESSES 3014

THEORY OF PLASTICITY: State of stress, components of stress, symmetry of stress tensor, principal stresses, stress deviator, Von Mises, Tresca yield criteria, comparison of yield criteria, Forming load calculations. (6) FUNDMENTALS OF METAL FORMING: Flow stress determination, Temperature in metal forming, Hot, Cold and Warm working, Strain rate effects, Metallurgical structures, friction and lubrication, Deformation zone geometry, Hydrostatic pressure, Workability, Residual stresses, deformation processing maps. (6) FORGING AND ROLLING: Forging -types of presses and hammers. Open die forging and closed die forging, die design, forging in plane strain, forging defects- causes and remedies.Rolling: Classification of rolling processes, types of rolling mills, hot and cold rolling, rolling of bars and shapes, forces and geometrical relationship in rolling, rolling defects- causes and remedies, ring rolling and thread rolling. (10) EXTRUSION AND DRAWING: Direct and indirect extrusion, variables affecting extrusion, Port-hole extrusion die, hydrostatic extrusion, defects and remedies, simple analysis of extrusion, tube extrusion and production of seamless pipe and tube. ECAP, Drawing of rods, wires and tubes. (6) SHEET METAL FORMING: Forming methods - Shearing, blanking, bending, stretch forming, deep drawing. Types of dies used in press working, defects in formed part, sheet metal formability, formability limit diagram. (5) HIGH VELOCITY FORMING AND SUPERPLASTIC FORMING: Comparison with conventional forming. Explosive forming, Electro hydraulic, Electro Magnetic forming, Dynapak and Petro-forge forming. Superplasticity- definition, merits and demerits, superplastic forming methods. (5) FORMING SOFTWARE: CAD, CAM in forming, Introduction to forming softwares. (4)

Total 42 REFERENCES: 1. Knigery W D, Ceramic Fabrication Processes, John Urley, 1950. 2. Belzalel Avitzur, Metal Forming- Processes and Analysis, Tata McGraw Hill, 1977. 3. ASM Metals Handbook, Vol. 14, Forming & Forging, ASM, Metals Park, Ohio, USA, 1998. 4. Dieter G E, Mechanical Metallurgy, McGraw Hill, 2001. 5. William F Hasford, Robert M Caddell Metal Forming: Mechanics and Metallurgy Cambridge University Press P.ltd, 2007.

09YN08 NON DESTRUCTIVE EVALUATION 3003

INTRODUCTION: Significance of Non destructive evaluation, role of NDT in quality control, classification of Non destructive testing methods. (3) VISUAL INSPECTION, DYE PENETRANT TEST, INFRARED AND THERMAL METHODS: Principles of testing methods, equipment, testing procedures, applications. (5) (6) RADIOGRAPHY: Principle of testing, production of X-rays, characteristics of X-rays, differential absorption, factors influencing contrast, sensitivity and resolution. Geometrical factors: sharpness of image, inverse square law; Penetrameters; Filters; Image intensifiers; real time image analyzer, X-ray fluoroscopy, Gamma ray radiography - natural and artificial sources, characteristics, comparison with X-rays, neutron radiography, safety in radiography. (9) (4) ULTRASONICS : Definition and production of ultrasonic waves; Transducers; Different techniques; Transmission techniques; Pulse echo technique; Resonance technique; Calibration, reference blocks and standards; Applications; Thickness gauging. (9) (7) MAGNETIC PARTICLE INSPECTION: Principles and applications, methods of magnetization; Demagnetisation (3)

EDDY CURRENT TEST, ACOUSTIC EMISSION TEST, AND HOLOGRAPHIC TEST: Principles of testing methods, equipment, testing procedures, applications. (6) CASE STUDIES: Testing of Welded, formed and cast components. (3)

CODES AND STANDARDS RELATED TO NDT: ASME Boiler & Pressure Vessel Code Section 5, ASTM Standards on Nondestructive Testing (4) Total 42 1. REFERENCES: ASM Metals handbook, Vol.17, Nondestructive Evaluation and Quality Control, ASM, Metals Park, OH, USA, 1989. Halmshaw R, Nondestructive Testing second edition, Arnold, London, 1991.

2.

215

3. 4.

Cartz L, Nondestructive Testing, ASM, Metals Park, OH, 1995. Hull, Nondestructive Testing, ELBS, 1996. ASNT, Nondestructive Testing Handbook, second edition, Vol.10: NDT Overview, ASNT, 1996. ASME Boiler & Pressure Vessel Code Section V.

5. 6.

09YN09 FERROUS AND NON FERROUS ALLOYS 3003

INTRODUCTION TO SPECIAL STEELS (1)

STEELS: Effect of alloying elements in formation of Ferrite, Austenite, Martensite, Carbides and Bainite. Effect of alloying elements in Iron Carbon diagram. (3) MARAGING STEELS : Manufacture, structure, property, heat treatment and applications of maraging steels. (1) HSLA AND MICROALLOYED STEELS: Melting, heat treatment of HSLA steels; the effect of microalloy additions; thermomechanical processing; different strengthening mechanism; significance of grain refinement; applications. (4) STAINLESS STEELS: Types of stainless steels; ferritic, martensitic, austenitic, precipitation hardening, duplex, heat resisting, their properties, structure and applications; nickel free stainless steels high nitrogen stainless steels their manufacture, structure, properties and applications. Sensitisation and the remedial measures for austenitic stainless steel. (6) TOOL STEELS: Classifications of tools steels by AISI System, composition, properties, applications of tool steels, heat treatment of tool steels (3) SILICON STEELS: Structure, properties and applications. HIGH MANGANESE STEELS: Structure, properties and applications. (1) (1)

STEELS FOR SPECIAL APPLICATIONS: Armour steel, steels for high and low temperature applications High carbon steels, Ultra high strength steels, creep resistant steels. (3) NON FERROUS ALLOYS (with ASTM standards): COPPER AND COPPER ALLOYS: Properties and applications of metallic copper; influence of alloying elements Brasses Cu-Zn alloys. (1) BRONZES:: Tin bronze, phosphor bronze, Al bronze, Be bronze; compositions, properties and uses; copper-nickel alloys; properties and applications; strengthening of copper alloys by mechanical alloying, OFHC copper and its applications; heat treatment of alloys of copper. (2) ALUMINIUM: properties and uses of metallic aluminium; classification of aluminium alloys, wrought and cast alloys; heat treatable and non-heat treatable alloys; Physical metallurgy of Al alloys, strengthening mechanisms in non-heat treatable alloys and heat treatable alloys; effect of alloying elements and impurities; mechanical processing and properties; Al-Li alloys, superplastic forming of Al alloys; powder metallurgy and rapid solidification of Al alloys. Aerospace applications (6) MAGNESIUM: properties and applications of magnesium and magnesium alloys; casting processes; influence of alloying elements Al, Mn, Zn, Si, Ag, Th, Zr; classification cast alloys and wrought alloys (2) TITANIUM: Introduction; Ti and its alloying capability, Alloying elements Alpha stabilisers; beta stabilisers; alpha titanium alloys; beta titanium alloys; alpha-beta titanium alloys; structure-property correlations; melting, casting, welding of titanium alloys. (4) NICKEL: Metallurgy of nickel base alloys Alloying elements and their effects Nickel base superalloys composition; melting, forging; solid solution alloys, precipitation hardenable alloys, ODS alloys heat treatment, properties and applications; Nickel-iron base alloys, heat treatment, properties and applications; Ni base soft magnetic alloys, Ni base heating element alloys; Ni base controlled expansion alloys; nickel base, Ds alloys and single crystals. (4) Total 42 REFERENCES: 1. Edgar C Bain and Paxton H W , "Alloying elements in steel", American Society for Materials, 1966. 2. Wilson R N, Metallurgy and Heat Treatment of Tool Steels, McGraw Hill, New York, 1975. 3. Clark and Varney, "Physical Metallurgy for Engineers", Affiliated East West press, New York, 1987. 4. Lula R, Stainless Steels, ASM, Ohio, 1990. 5. Brick, Gordon and Pense, "Structure and Properties of Engineering Materials", McGraw Hill Book Co., New York, 1992. 6. Balram Gupta, "Aerospace Materials", Vol.1, 2 and 3, S Chand & Co., New Delhi, 1996. 7. ASM Hand Book, Vol. 15, Casting, ASM Hand Book Committee, 1998.

09YN11 IRON AND STEEL TECHNOLOGY 3003

History of iron making, overview of steel making processes and their developments (1)

216

Fundamentals of iron and steel making: Basic thermodynamics and kinetics, properties of gases, molten steel, molten slags, iron making reactions, steel making reactions (5) Steel plant refractories: iron making refractory systems, steel making refractory systems, industrial gases for iron and steel making (3) Raw materials for iron making, manufacture of metallurgical coke and recovery of coal chemicals, iron ore Beneficiation and agglorneration pelletisation, sintering, fluxes (4) Blast furnace design and construction, accessories for blast surface charging equipment, gas cleaning, hot blast stoves (4) Blast furnace operation, operational irregularities (3)

Direction reduction and smelting Corex and Hismelt, Modern trends in blast furnace technology Oxygen enrichment, fuel injection, high top pressure (3) Heat and Mass transfer, transport phenomena, Pre-treatment of hot metal for steel making, oxygen steel making processes principle, design and operation of LD converter, Kaldo, Rotor (10) Electric steel making Secondary steel making and refining of stainless steels Alternative oxygen steel making processes Ingot production and continuous casting, tundish metallurgy Iron and steel making in India overview of Indian steel plants (3) (2) (1) (2) (1) Total 42 REFERENCES:

1.
2.

Bashforth G R , Manufacture of Iron & Steel, Vol. 1 & 2, Chapman & Hall, London,1964. "Making Shaping and Treating of Steel", US. Steel Corporation, 1994. Tupkary R J , "Introduction to Modern Iron Making", third Edition , Khanna Publishers, New Delhi, 1998.

3.

09YN12 CERAMICS, POLYMERS & COMPOSITES 3003

CERAMICS: Introduction - important properties - Typical example of conventional and advanced ceramics. Comparison with metals and polymers - Fine ceramics (3) PRODUCTION AND PROPERTIES: Boron Nitride, Silicon Carbide, SIALON - Technical applications CERMETS Types- examples - production, properties and applications CERAMICS for magnetic and super conducting functions. POLYMERS: Introduction - Types of polymers - examples. examples and applications. Processing techniques (brief idea). ELASTOMERS - types - properties and applications COMPOSITES: Introduction - Classification - Examples (3) (3) Thermoplastic and thermosetting Plastics - important (7) (3) (2) (4)

FIBER COMPOSITES: Constituents and functions of fiber composites - Rule of Mixtures - Types of fibers and matrices. (2) PRODUCTION TECHNIQUES (IN BRIEF) FOR FIBER COMPOSITES: Use of fiber composites in automobile, aerospace, sports and leisure applications. Particulate composites - True particulate and Dispersion Strengthened Composites. (6) DISPERSION STRENGTHENED COMPOSITES: Particles size and inter particle spacing properties examples. Production technique (brief) Applications in various fieldsLaminar Composites - Production (brief) properties prediction and applications- Miscellaneous types of composites (hybrid, filled composites). (9) Total 42 L : 45 Total : 45 1. 2. REFERENCES Van Vlack L K Physical Ceramics for Engineers, Addison Wesley, Massachusetts, 1964. Gabor Koves, Materials for structural and Mechanical Functions, Taraporevala & Sons, Bombay, 1980. Broutman L J and Krock R J, Modern Composite Materials, Addison Wesley Pub. Co., Massachusetts, 1986. Jacobs, J A and Kilduff T F, Engineering Materials Technology, Prentice Hall Inc., N.J., 1988. Mathews & Rawlings, Composites: Science and Engineering, ELBS, London, 1994.

3. 4.
5.

09YN13 ADVANCED MATERIALS AND PROCESSING

217

3003
INTRODUCTION: Introduction to advanced ceramics and metallic materials-advantages (6) NANOMATERIALS: Introduction-structure of nanomaterials- classification of production methods-Nanomaterials-Preparation techniques-Sol-gel method, combustion synthesis, evaporation and condensation method Examples. Nanoceramics for electrical, magnetic, mechanical and structural functions-applications. (9) METALLIC MATERIALS: Pure metals, alloys, intermetallics, immiscible alloy systems and composites; their preparation and applications (9) ADVANCED MATERIALS PROCESSING: Mechanical alloying-processing capabilities-process parameters - Examples of material synthesized - Rapid Solidification Processing - Melt spinning, atomization techniques -examples - Self Propagating High Temperature Synthesis - Process - Advantages -examples. (9) CONSOLIDATION TECHNIQUES: Consolidation techniques for ceramics and metallic powders-Die compaction -Hot pressing, Cold and Hot Isostatic Pressing, Powder extrusion, Equal Channel Angle Process (9) Total 42 1. REFERENCES: Metals Handbook Vol. 9 "Powder Metallurgy" ASM Metals Park, Ohio, 1991. Nobru H Ichinose, "Introduction to Fine Ceramics", Butterworth-Heinman Ltd, NY,1992

2.

09YN14 MATERIALS FOR NUCLEAR AND AERO SPACE APPLICATIONS 3003

NUCLEAR APPLICATIONS: Nuclear power plant uses: uranium fuel, structural elements- carbon steel and low alloy steels, zirconium alloys, stainless steels, nickel base alloys. (3) The effect of stress on the material, temperature, neutron flux -irradiation growth and irradiation creep, fatigue and fracture, susceptibility to low and high temperature embrittlement, swelling & formation of voids, change of chemistry . Materials for Thermal reactor, fast breeder reactor, pressure and heavy water reactor and fusion materials. (3) Use of low alloy steel, stainless steel, super alloys, Zirconium alloys and moderator materials. Use of quadruple melting to reduce lower levels of H2 (c5PPM) Use of austenitic stainless steel AISI 316 with about 20% cold work for standard cladding and wrapper material. (5) Use of Ti to AISI316 and its effect on properties with low nitrogen content. Use of 9 Cr. Mo. Steel for fusion reactors. Reactor materials for thermonuclear experimental reactor and copper alloys for the heat sink, dilute beryllium-titanium alloys. (10) AERO SPACE APPLICATIONS Data of aircraft materials Y-S Vs test temperature properties of low density materials such as Al-Li, Al- Mg. Al-Li, MG- Al-Cu alloys. Structural integrity of AL- Li alloys and the role of microstructure in affecting fracture toughness. Recent work on spray casting of AL-6 Mg-1.6 Li 0.3-0.4 Zr, 0.2Sc alloys and how the microstructure is refine and consequent effect on properties. (6) Forging of this alloys and the properties compared with the conventional Alloy AA 7010 -T4 and mechanically alloyed AA 5091. Turbine blade development and the material characterisation of nickel base super alloys in wrought, cast, directionally solidified and single crystal form. Creep strengthening in nickel alloys by solid solution strengthening, precipitation hardening. (4) Effect of alloying elements- Re, W, Ta, Mo and RU and their effect on creep properties. Super alloys for turbine disc applications. Processing by the powder route and open and closed die forging. Recent trends in composition, microstructure and properties of turbine disc alloys. Factors affecting fatigue resistance and impact strength of nickel based super alloys.Non destructive evaluation of turbine discs. (7) Thermal barrier coating and environmental degradation processes for the deposition of coatings on the super alloys. Factors controlling the thermal conductivity of ceramic coating. Diffusion coating and the failure mechanism in thermal barrier carbing systems. Future trends in super alloys and processes for turbine disc applications. (4) Total 42 REFERENCES: 1. Sims C T, Stology N S and Hagel W C, Super alloys II high temperature materials for Aerospace and industrial power, New york, John wiley and sons. 1987 2. Roger C Reed, The super alloys Fundamentals and applications, Cambridge university press, 2006 3. Suri A K Proceedings of International Symposium on Energy related materials, Indian Institute of Metals, 2007

09YN15 MATERIALS FOR POWER PLANTS AND PETROCHEMICAL INDUSTRIES 3003

POWER PLANTS: Development of steels for the power plants past present and future needs. Role of carbides and carbides and their stability at high temperature steels for power turbine. Main requirements for HP Rotor, IP Rotor LP Rotor and generator rotor. Role of alloying elements and the effect of heat treatment. Role of microstructure, materials for turbine castings, turbine generator and rings. (8)

218

Development of turbine bolts and turbine blades current scenario and the development of steel, for higher pressure and temperature. Ferritic steels. Austenitic steels and oxide dispersion strengthened materials for power plant application. Use of Nickel base alloys for gas turbines development. (8) Role of W and Nb in ferritic steels for high temperature application for super power plants and the physical Metallurgical principles involved in developing materials for 7000C applications for super heater tubes. (5) PETROCHEMICAL INDUSTRIES: Development of Pipe line steels for oil and gas sector. Current trend in the development of high strength steel. Concept of micro alloying and physical Metallurgical principles involved in the development of these steels. (6) Role of alloying elements and concept of controlled rolling and its effect on microstructure. Control of microstructure during controlled rolling. Effect of accelerated cooling and production of low carbon steels, Difference in properties, effect on rolling effect of alloying elements. (8) Effect of B and Mo and Nb on properties of line pipe steels,. Bimodal distribution of grain size and their effect on mechanical properties. Latest trend in the development of ultra high strength line pipe steel with improved toughness. Total 42 REFERENCES: 1. Gladman T, The Physical Metallurgy of Micro alloyed steel, The Institute of Materials, London, UK, 1997 2. Llewellyn D T, Roger Hudd Steels: Metallurgy and Applications, third edition, Butterworth-Heinemann, 1998

09YN16 MATERIALS FOR AUTOMOBILE INDUSTRY 3003

Current trend in the development of high strength steels for automotive application. concept of plastic strain ratio and work hardening exponent. Role of Biaxial stretching concept of FLD . Effect of alloying element on r and n and role of textures in deep drawing characteristics. (10) Effect of Nb and Ti addition. Development of multiphase steels such as Dual phase, Complex phase and TRIP (Transformation induced plasticity, steels. High strength intestinal free (IF HSS) bake hardening (BH) and rephosphorised of steel grades. (10) Processing of sheet such as forming assembling and painting recent innovations-concept of recent alloy design and processing route to control microstructure to enable to attain final material properties. Concept of tailored blank. roll forming, hot forming. Tube hydroforming, sheet hydro forming and laser welding. Current use of TWIP (Twinning induced plasticity) Fe Mn, Fe-Mn-Al and Fe Al Cr Steel and their mechanical properties. Advanced high strength steels (AHSS) and use of Phase transformation to control microstructure. (12) Role of Nb as the galvanized coating microstructure of IF steels. Effect of microstructure such as retained austenite polygonal ferrite and annealed martensite or bainitic ferrite and their influence on properties.. Use of modern technology such as thin lab casting and direct hot rolling to produce steel with required properties. (10) Total 42 REFERENCES: 1. Gladman T, The Physical Metallurgy of micro alloyed steels, The Institute of Materials, London, UK 1997. 2. Llewellyn D T, Roger Hudd Steels: Metallurgy and Applications, third edition, Butterworth-Heinemann, 1998 3. Mallok D K and De Cooman B.C International Conference on Advanced steels for Automotive applications Proceedings, AIST PA 2004 4. International Symposium on Niobium Micro alloyed sheet steel for Automotive applications Proceedings Brazil 2005 Edition Hashmoto, Jamsheto. H Maharastra.

09YN17 POWDER METALLURGY 3003

INTRODUCTION: Steps in Powder Metallurgy, scope, advantages, limitations and applications of P/M with specific examples. (2)

POWDER PRODUCTION TECHNIQUES: Classification and brief discussion of important physical, chemical and mechanical methods - characteristic features and examples of powders produced by different methods. Detailed discussion on atomization and Mechanical Alloying. (7) (6) POWDER CHARACTERISATION: Basic concepts of sampling and characterization. Techniques for detailed analysis of chemical, physical and mechanical characteristics of metal powders . Scope and limitation of various techniques. (6) POWDER CONSOLIDATION: Techniques of compaction, Die compaction- equipments- methods, problems, design considerations. High density processing,- Cold Isostatic Pressing, powder rolling and powder forging. High temperature consolidation-Hot pressing and Hot Isostatic Pressing (HIP) (9) SINTERING: Theory of solid state and liquid phase sintering. Stages in sintering, structure and property changes. Sintering mechanisms with examples. Other types of sintering. Sintering furnaces-types. Sintering atmospheres- types, production, properties and applications (9) FINISHING OPERATIONS AND SECONDARY OPERATIONS: Machining, plating, heat treatment and infiltration (1)

P/M PRODUCTS - Production of bearings, friction materials, carbide tools, P/M magnetic materials, tools and dispersion strengthened alloys by P/M. (4)

219

IMPORTANT P/M ALLOYS AND APPLICATIONS OF P/M PARTS: Nickel base alloys, titanium base alloys- processing Applications of commercial P/M Alloys in automobile, aerospace, nuclear and miscellaneous applications of P/M parts (4) Total 42 REFERENCES: 1. Metals Handbook volume 7: "Powder Metallurgy", ASM Metals Park, Ohio, 1989. 2. Sinha A K , Powder Metallurgy, Dhanpat Rai & Sons, New Delhi, Second Edition, 1992. 3. Randall M German, Powder Metallurgy of Iron & Steel, John Wiley & Sons Inc. New York, 1998. 4. Angelo P C and Subramanian R Powder metallurgy Science, Technology and applications, Prentice Hall of India, New Delhi, 2008.

09YN18 FOUNDRY METALLURGY 3003

SOLIDIFICATION OF METALS AND ALLOYS: Solidification of castings, Effect of moulding material, Composition on freezing pattern. Rate of solidification. Shrinkage of castings and directional solidification. (3) METALLURGY OF STEELS: Effect of normal elements and alloying elements in steels. Compositional aspects and properties of alloy steels. (3) METALLURGY OF CAST IRONS: Types of cast iron, Effect of normal elements and alloying elements in cast irons. Composition, properties, and production aspects of the gray cast iron, S.G.iron, Malleable cast iron, C.G.iron, Austempered ductile iron, High chrome iron, High silicon iron, Nihard cast iron and Ni-resist cast iron. (8) SPECIFICATIONS: Casting specifications and wrought specifications. Brief introduction to Indian and ASTM standard for Gray cast iron, S.G. iron, Plain carbon steels and Stainless steels, Al alloys and Cu alloys. (2) FLUIDITY: Definition, factors affecting fluidity and measurement of fluidity. RESIDUAL STRESSES: Causes harmful effects, Measurement of residual stresses. (2) (2)

METALLURGY OF NON FERROUS CASTING ALLOYS: Composition, specifications, properties and phase diagrams of Copper, Nickel, Aluminium, Magnesium, Zinc and Titanium base alloys. (7) Metallurgical aspects of gating and risering. (3)

MELTING TECHNOLOGY : Melting and Composition control of Cast Irons, Plain carbon steels, Low alloy steels, Stainless steels, Al alloys, Mg alloys, Zinc alloys and Copper alloys. Slag metal reactions Types of slag practices Desulphurisation - Dephosphorisation - deoxidisation - Modification and grain refinement of Al alloys Inoculation and inoculating techniques Gases in metals and degassing techniques . Change calculation for cast iron and steels. (12) Total 42 REFERENCES: 1. Ruddle R W, Solidification of Casting, 1968. 2. Flinn R A, Fundamentals of Metals Casting, Addison Wesley, 1983. 3. Murphy, Non-ferrous Foundry Metallurgy, 1984. 4. Heine, R.W., Loper, C.R., Rosenthal, P.C., Principles of Metal Casting, Tata - McGraw Hill Publishing Co., 1995. 5. A F S Cast Metals Hand Book, 1992. 6. Foseco Foundryman's Handbook, Pergamon Press, 1995. 7. Beeley P R, Foundry Technology, Butterworths, London, UK, 2001

09YN19 SPECIAL CASTING TECHNIQUES 3003

INTRODUCTION: Introduction to special casting techniques. (2)

SHELL MOULDING: Shell moulding machines - pattern equipments - sands, resins and other materials used in shell moulding - closing of shells - dimensional tolerances -applications of shell moulding - comparison of shell moulding with other competitive methods. (8) CENTRIFUGAL CASTING: Types of centrifugal casting processes - calculation of mould rotary speeds - techniques and equipments used in production processes - advantages and limitations of centrifugal casting methods. (8) INVESTMENT CASTING: Introduction - Pattern and mould materials used in investment casting - technique and production of investment moulds and castings - dimensional tolerances - applications of investment casting process - Shaw process comparison with other processes - full mould process. (8) DIE CASTING: Die casting machines - operation details - die materials - materials cast by die casting method. Die design comparison with other processes. low pressure die casting. Metal Injection Moulding. (6) OTHER PROCESSES: Fluid sand process - V Process - Rheo,thixo and compo casting processes - squeeze casting, Magnetic moulding, Hot box process, cold box process. No-bake processes, Graphite moulding process,Plaster moulding process. (8)

220

High Pressure moulding and continuous casting

(2) Total 42

REFERENCES :

1. 2. 3. 4. 5. 6.
7.

Beeley P R., Foundry Technology, second edition, Butterworths, Heinmann,oxford,2001. Clegg A J "Precision Casting Processes" Pergamon Press,London,U.K,1991 Barton H K, Die Casting Processes, Odhams Press Ltd,1985. Dumond T C "Shell Moulding and Shell Moulded Castings" ,Reinhold publishing corporation Inc.,1984. Doehler E H "Die casting", Mcgraw Hill Book Co, Newyork,1991. Heine Loper and Rosenthal, Principles of Metal Casting, Tata McGraw Hill Publishing Co,1995. ASM Handbook, Vol. 15, Casting, ASM Publication, 1998.

09YN20 WELDING METALLURGY 3003

WELD SOLIDIFICATION AND TRANSFORMATION IN WELDMENTS: Weld solidification, Absorption of gases, liquid metal reactions, solid state transformations in weldments, strengthening mechanisms in weld metals, heat affected zones WELDING DEFECTS: Causes and remedial methods (5) (2)

WELDING OF CARBON STEELS AND LOW ALLOY STEELS: Phase transformation, Hydrogen induced cracking, carbon equivalent, preheating and post heating, solidification cracking, lamellar cracking, reheat cracking. (6) WELDING OF STAINLESS STEELS: Welding of austenitic, ferritic, martensitic, duplex and precipitation hardenable stainless steels. General Welding characteristics, Weld microstructures, Weld cracking and other metallurgical difficulties, Use of Constitution diagrams (Schaeffler, Delong, WRC-1992), Filler metal selection, Dissimilar welds with stainless steels. (6) WELDING OF CAST IRONS: Weld metal and HAZ microstructures, Defects and remedies, Filler metal selection. (2)

WELDING OF ALUMINIUM ALLOYS: Oxide formation, Hydrogen solubility, Difficulties due to electrical and thermal characteristics, sensitivity to weld cracking. Filler metal selection. Weldability of heat treatable and non-heat-treatable aluminium alloys. (4) WELDING OF NICKEL ALLOYS, TITANIUM ALLOYS AND COPPER ALLOYS: Weld metal and HAZ microstructures, Defects and Remedies, Filler metal selection. (6) WELDING OF SPECIAL ALLOYS: Welding of magnesium alloys, tool steels and clad metals (3)

WELDABILITY AND WELDABILITY TESTING:Factors affecting weldability, cold cracking tests, hot cracking tests, Gleeble test, Mechanical tests (emphasis on tension and bend tests) (5) WELDING QUALIFICATIONS: Welding Procedure Specification, Procedure qualification and welder qualification. (3)

Total 42 REFERENCES: 1. Lancaster J F, "Metallurgy of Welding", George Allen Co, Boston, 1980. 2. ASM Metals Hand Book, Vol. 6, "Welding, Brazing and Soldering", ASM International, Metals Park, Ohio, USA, 1993. 3. Linnert G E, "Welding Metallurgy", Vol-1 and Vol-2, AWS, New York, 1995. 4. AWS Welding Handbook, eight edition, Vol.3: Materials and Applications - Part 1, AWS, New York, 1996. 5. AWS Welding Handbook, eight edition, Vol.4: Materials and Applications - Part 2, AWS, New York, 1998. 6. Sindo Kou, Welding Metallurgy, John Wiley & Sons, 2003.

09YN21 MATERIALS CHARACTERISATION 3003

TECHNIQUES OF OPTICAL METALLOGRAPHY: Macro examination, micro examination specimen preparation, principle and description of metallurgical microscope, aberrations in optical microscopes and their remedial measures; definition of magnification, numerical aperture, resolving power, depth of focus, depth of field, light sources; microscopic techniques bright field and dark field microscopy, phase-contrast microscopy, polarized light microscopy, interference microscopy, high temperature microscopy; quantitative metallography. (5) OPTICAL AND X-RAY SPECTROSCOPY: Crystal, grating optical spectrometer, automation, X-ray fluorescence spectroscopy principle, equipment and applications (4)

X-RAY DIFFRACTION: Bragg's Law, Laue method of X-ray diffraction and applications, rotating crystal method and applications, X-ray powder diffractometer principle, equipment and applications. (5) TECHNIQUES OF ELECTRON MICROSCOPY: Electron optical instruments, electron specimen interactions, signals used in the different electron optical instruments; scanning electron microscopy principle, equipment, operating modes and applications; electron probe microanalyser - principle, instrumentation, qualitative and quantitative analysis, metallurgical

221

applications; transmission electron microscopy principle, instrumentation, bright and dark field imaging, selected area diffraction, analytical electron microscopy, specimen preparation for TEM; applications. (16) SURFACE ANALYSIS TECHNIQUES: Auger Electron Spectroscopy principle, instrumentation and applications in metallurgy; X-ray photoelectron spectroscopy - principle, instrumentation and applications; secondary ion mass spectroscopy/ion microprobe - principle, instrumentation and applications. (4) ADVANCED CHARACTERIZATION TECHNIQUES: Field ion microscopy including atom probe - principles, instrumentation and applications, scanning probe microscopy - principle, instrumentation and applications, atomic force microscopy principle, instrumentation and applications. (4) VACUUM TECHNIQUES:Primary, high and ultra high vacuum definition, pumps, gauges and systems. REFERENCES Smallman, R.E and Bishop,R.J.,"Metals and Materials", McGraw Hill Book Co., 1926. Kehl G L, "The Principles of Metallographic Laboratory Practice", McGraw Hill Book Company, 1949. Cherepin V T and Mallic A K, "Experimental Techniques in Physical Metallurgy", Asia Publishing Co, Bombay, 1967. Vandervort G F, Applied Metallography, Van Nostrand Reinhold Company, 1986. Culity B D, "Elements of X-ray Diffraction", Addison Wisley Publishing Co., USA, 1986. Brandon D G, "Modern Techniques in Metallography", Von Nostrand Inc, NJ, USA,1986. Lorelto M H, "Electron Beam Analysis of Materials", Chapman & Hall, 1994. (4) Total 42 1.

2. 3. 4. 5. 6. 7.

8.

Cahn R W, Haasen P. and Kramor E.J., "Materials Science and Technology Vol. 2B", VCH Publishers, London, 1994.

09YN22 METALLURGICAL FAILURE ANALYSIS 3003

FAILURE SOURCES: Classification and identification of various types of fractures. Deficiencies in design, material, processing, service and maintenance, Stages of failure analysis. Overview of fracture mechanics concepts; Ductile and brittle fracture - Fracture origin, initiators, characteristics of ductile and brittle fracture. (7) FATIGUE FAILURE: General concepts, Fracture characteristics; Factors affecting fatigue life. Case studies. CORROSION FAILURES: Factors influencing corrosion failures, analysis of corrosion failures. Types of corrosion. WEAR FAILURES: Type of wear, role of friction in wear, lubricated and non-lubricated wear. Analysing wear failure. (5) (5) (5)

ELEVATED TEMPERATURE FAILURES: Creep, stress rupture, Elevated temperature fatigue, Metallurgical instabilities, and Environmental induced failure. Case studies (4) FAILURE OF FORMED COMPONENTS AND FAILURE DUE TO HEAT TREATMENT. FAILURE OF WELDMENTS AND FAILURE DUE TO METAL WORKING. FAILURE OF CASTINGS: (4) (4) (4)

RELIABILITY: Reliability concept and hazard function, Life prediction, Condition monitoring, application of Poisson, exponential and Weibull distribution for reliability - bath tub curve - Parallel and series system - mean time between failures and life testing. (4) Total 42 REFERENCES: 1. Colangelo,V.J., and Heiser,F.A., "Analysis of Metallurgical Failures", John Wiley & Sons, Inc., New York, 1974. 2. Charlie.R.Brooks and Ashok Choudhury, "Metallurgical Failure Analysis", McGraw Hill Publishing Co., USA, 1993. 3. ASM Handbook- Vol.10, "Failure Analysis and Prevention", 10th edition, Metals Park, Ohio, USA,1995. 4. Das,A.K.,"Metallurgy of Failure Analysis", Tata McGraw Hill Publishing Co., New Delhi, 1996.

09YN23 COMPUTING APPLICATIONS IN MATERIALS ENGINEERING 3003

INTRODUCTION TO COMPUTATIONAL METHODS: Solving sets of equations Gauss elimination method, Choleski method, Iterative methods, Relaxation method, System of non-linear equations- Newton Raphson method, Computer programs. Numerical Integration - Newton-Cotes integration formulae, Trapezoidal rule, Simpson's rule, Gaussian quadrature. (6) NUMERICAL SOLUTION OF PARTIAL DIFFERENTIAL EQUATIONS: Laplace's equations - Representations as a difference equation, Iterative methods for Laplace's equations, Poisson equation - Derivative boundary conditions, Irregular and non-rectangular grids, Matrix patterns, Sparseness, ADI method, Applications to heat, mass and momentum transfer problems, Computer programs. (6) FINITE ELEMENT METHOD: Weighted residue technique, variational approach, element types, plane triangular, quadrilateral curved isoparametric elements, three dimensional elements. (12)

222

ANALYSIS OF PRODUCTION PROCESSES: Finite element analysis of metal casting - Special considerations, latent heat incorporation, gap element, Time stepping procedures Crank Nicholson algorithm, Prediction of grain structure. Basic concepts of plasticity solid and flow formulation small incremental deformation formulation (6) CURVE FITTING AND APPROXIMATION OF FUNCTIONS: Least square approximation, fitting of non-linear curves by least squares, Regression analysis, Computer programs. (4) Introduction to Artificial neural networks, various algorithms and case studies. Introduction to Genetic algorithms, GA for materials design and process optimization, case studies. Thermodynamics basis for phase transformations. Calculations of new phase diagrams using Thermocalc. REFERENCES: (3) (3) (2) Total 42

1. 2. 3.
4. 5. 6.

Shiro Kobayashi, Soo lkoh and Taylan Atlan, Metal Forming and the Finite Element Method, Shiro Kobayashi, Oxford and IBH Publishing, New Delhi, 1989. Rao S S, The Finite Element Method in Engineering, Pergammon Press, New York, 1989. Lewis R W, Morgan K, Thomas H R and Seetharaman K N, The Finite Element Method in Heat Transfer Analysis, John Wiley, 1994 Malanie Mitchell, An introduction to genetic algorithms, MIT Press, 1998 Rajasekaran S, Finite Element Analysis in Engineering Design, Wheeler Publishing, Allahabad, 2000 Curtis F Gerald, Patrick O Wheatley, "Applied Numerical Analysis", Pearson Education, 2002. Chandrupatla T R and Belegundu A D, Introduction to Finite Elements in Engineering, Pearson Education, New Delhi, 2002. Zoe Barber, Introduction to materials modeling, Maney Publishing, statute of Materials, London, 2005 Koenraad Janssens,Computational Materials Engineering, An introduction to microstructural evolution, Elsevier, 2007.

7. 8. 9.

09YN24 METALLIC CORROSION AND ITS CONTROL 3003

THERMODYNAMICS OF AQUEOUS CORROSION: Electrode processes electrode potential, free energy, emf series, potential measurements with reference electrodes, three electrode systems. Computation and construction of Pour baix diagrams of Fe, Al, Ni and Zn practical use of E-pH diagrams. Chemical Vs electrochemical mechanisms of corrosion reactions corrosion rate expressions. (6) KINETICS OF AQUEOUS CORROSION: Corrosion current density and corrosion rate. Exchange current density polarization activation control Tafel equation, mass transport control, mixed potential theory and behaviour of galvanic couples in acidic environments, effect of oxidizer, combined polarization, factors affecting polarizations and rate of corrosion. Passivity potentiostatic polarization curves, factors affecting passivity, mechanism of action of passivators. (9) FACTORS AFFECTING AQUEOUS CORROSION: Effect of environmental variable pH, oxidation potential, temperature, velocity/fluid flow rate, concentration, biological effects. Effect of metallurgical variables metals and their surfaces, alloys and their surfaces, effect of alloying on corrosion resistance, effect of heat treatment. (4) FORMS OF CORROSION: General corrosion atmospheric corrosion, galvanic corrosion, general biological corrosion. Localised corrosion filiform corrosion, crevice corrosion, pitting corrosion, localized biological corrosion. Metallurgically influenced corrosion inter granular corrosion, de-alloying. Mechanically assisted corrosion erosion corrosion, fretting corrosion, corrosion fatigue. Environmentally induced cracking mechanisms of stress corrosion cracking and hydrogen embitterment. (9) PREVENTION AND CONTROL OF CORROSION: Corrosion control design, selection of corrosion resistant materials alloying stainless steel and brass. Oxidation resistant materials control of high temperature oxidation. Cathodic and anodic protection methods. Corrosion inhibitors types, applications. Corrosion in cold water pipes Langalier saturation index. Galvanising and painting. (4) CORROSION MONITORING: On-stream monitoring electrical resistance, linear polarization, hydrogen test probe, ultrasonic testing, radiography and corrosion coupons. Off-stream monitoring acoustic emission testing, eddy current inspection, liquid penetration inspection. (5) CORROSION TESTING: Purpose and classification. Dimensional change Ultrasonic thickness measurements, eddy current, microscopic examination. Weight change specimen prepration, test conditions and evaluation of results for overall corrosion, SCC, IGC. Electrochemical techniques polarization curves, Tafel extrapolation, linear polarization, AC impedence methods electrochemical impedence spectroscopy. (5) Total 42 REFERENCES: 1. Philip A Schweitzer, "Corrosion and Corrosion Protection Handbook", USA, 1983.

2.
3. 4. 5.

Herbert H Uhlig and Winston Revie , "Corrosion and Corrosion Control An Introduction to Corrosion Science and Engineering", Third Edition, John Wiley & Sons, 1985. Mars G.Fontana, "Corrosion Engineering", Third Edition, McGraw Hill Inc., 1987. Rajnarayan, "Metallic Corrosion and Prevention", Oxford Publications, 1988. Kenneth R Trethewey and John Chamberlain, "Corrosion for Science and Engineering", Second Edition, Longman Inc., 1996. Denny A. Jones, "Principles and Prevention of Corrosion", second edition, Prentice Hall Inc., 1996.

6.

223

7.

ASM Hand book Vol 13: Corrosion, ASM International, 2001.

09YN41 INDUSTRIAL VISIT AND TECHNICAL SEMINAR 1022

The student will make atleast two technical presentations on current topics related to the specialization. The same will be assessed by a committee appointed by the department. The students are expected to submit a report at the end of the semester covering the various aspects of his/her presentation together with the observation in industry visits. A quiz covering the above will be held at the end of the semester.

09YN51 METALLOGRAPHY LABORATORY 0032

1.

Study of metallurgical microscope & specimen preparation 2. Study of cast irons in the unetched and etched conditions 3. Study of plain carbon steels 4. Study of heat treated steels 5. Study of stainless steels and tool steels 6. Study of Aluminium, Nickel and copper base alloys. 7. Structural analysis of materials using XRD 8. Structural analysis of materials using SEM 9. Hardness measurement of heat treated steels 10. Colour Metallography of grey cast iron

09YN52 MATERIALS CHARACTERISATION AND TESTING LABORATORY 0032

1. SEM study of metal powders and fractographic analysis 2. XRD for crystal structure and phase analysis 3. Study of relative amounts phases using image analyzer 4. Adhesive & Abrasive wear testing of metallic materials 5. Corrosion testing of stainless steels (ASTM A262) 6. Micro hardness testing of phases 7. Tensile and Impact testing of steels. 8. Surface NDT testing using PT and MT 9. Volume NDT testing using RT and UT

09YN53 CASTING AND JOINING LABORATORY 0032

CASTING 1. a) Moisture Content of Foundry Sand b) AFS Grain Fineness Number 2. a) Sand Strength Tests b) Mould/Core Hardness Test and Compactability Test 3. a) Permeability Test b) Shatter Index Test 4. a) Mouldability b) Flowability 5. Study on Casting Defects JOINING 1. Welding Metallurgy of low C steels (microstructure and transverse hardness characterisation) 2. Welding Metallurgy of stainless steels (microstructure and transverse hardness characterisation) 3. Practice for preparation of WPS and PQR. (welding procedure specification and procedure qualification record) 4. Implant Test 5. Diffusible Hydrogen Determination

09YN54 COMPUTATIONAL MATERIALS LABORATORY 0032

Physical metallurgy of steels, strengthening mechanisms, phase diagrams, transformation temperatures and factors that affect transformation temperatures. (4) Basics of welding, effect of heat input and heat-treatment on welds. Power plant steels. nomenclature, precipitation, strengthening mechanisms, creep, welding power plant steels. Ferritic steels, welding ferritic steels, effect of process parameters on properties of weldments. Austenitic stainless steels, effect of various alloying elements on its mechanical properties. (3) (7) (7) (7)

224

Total 28 Instructions to students: Use the established models to predict the various properties. Infer about the observed behaviour from physical metallurgy point of view for the different processes. Exercises: 1. Artificial material simulation- effect of alloying elements on Ac1 2. Artificial material simulation -effect of various alloying elements on creep rupture strength in Ferritic steel welds 3. Artificial material simulation-effect of alloying elements and weld process parameters on toughness in ferritic steel welds 4. Artificial material simulation-effect of alloying elements and weld process parameters on YS in Ferritic steel welds 5. Artificial material simulation-effect of alloying elements and weld process parameters on UTS in Ferritic steel welds 6. Artificial material simulation-effect of alloying elements & weld process parameters on elongation in Ferritic steel welds 7. Artificial material simulation -effect of alloying elements on Yield strength, toughness and elongation in austenitic steels

225