PHYSICAL AND MECHANICAL
METALLURGY
UNIT I
1.Elements of Materials Science:
Atomic binding, elementry crystallography, single crystals
and polycrystals, grain boundaries, point defects and
line defects. Binery equilibrium diagram, Gibbs' phase
rule, solid solutions and intermediate phases, transformations
during cooling of pure metal and typical alloys.
2.Materials testing:
Tension test, stress - strain curve, elastic and plastic
deformation, strength, ductility and toughness, Hardness,
impact, fatigue and creep testing.
3.Mechanical behaviour:
Slip and twinning, critical resolved shear stress. Elementary
dislocation theory, edge and screw dislocations, stress
fields around dislocations, dislocation interactions,
application to plastic deformation, work hardening,
recovery, recrystallization and grain growth. Strengthening
mechanisms. Ductile and brittle fracture, elementary
fracture mechanics. Fatigue and creep behaviour, mechamisms
and methods of improvement.
4.Heat treatment
of ferrous alloys:
Iron - carbon diagram, steels and cast irons, hypo -
and hyper - eutectoid steels. Decomposition of austenite
of continious cooling, effect of cooling rate, eutectoid
and martensitic reastions. Isothermal transformation
of austenite, formation of bainite, ttt and oct diagrams,
concept of hardenability. Temporing of martensite. Common
heat treatments of steel - annealing, normalising, hardening,
trmpering, case - hardening. Types of cast iron and
their heat treatment.
5.Classification
of steels:
Effect of alloying elements in steel, low - alloy and
high - alloy steels.
6.Phase transformations:
Principles of solidification, elementary ideas and diffusion,
diffusion - based solid - state transformations, including
precipitation from solid solution, age - hardening.
7. Important non-ferrous
alloys:
Physical metallurgy of aluminium, copper, nickel, magnesium,
titanium and znic alloys, useful alloys based on these
for industrial application.
8. Metallurgical
characterisation techniques:
Microscopic examination, X-ray diffraction, introduction
to transmission electron microscopy, and scanning electron
microscopy.
PAPER -II
CHEMICAL AND INDUSTRIAL
METALLURGY
UNIT 2
1. PRINCIPLES OF EXTRACTIVE METALLURGY
Thermodynamic principles metal extraction ,physio-chemical
aspects of pyrometallurgy ,hydrometallurgy and electrometallurgy,
principles of metal refining
2. PRODUCTION OF
IRON:
Raw materials and their beneficiation, description of
the blast furnace and its accessories, blast furnace
reactions, direct and indirect reductions, recent trends
in blast furnance technology. Other methods of iron
- making - electric and low - shaft practices. Iron
- making under Indian conditions.
3. PRODUCTION OF
STEEL:
Bessemer, open - hearth and L _ D processes, steel -
making reactions, control of composition, dephosphorization,
desulphurization and deoxidation reactions, electric
furnace steel - making, production of alloy steels,
recent developments in refining steels.
4. NON - FERROUS
EXTRACTION:
Ores and their availability in India, raw material beneficiation,
principles of extraction of copper, zinc aluminium,
magnesium, nickel and titanium. Extraction of uranium,
thorium and zirconium.
5. METAL JOINING:
Common welding processes including manual metal arc,
submerged arc and gas - shielded welding. Weld thermal
cycle and metallurgical principles in the welding of
steels, stainless steels and aluminimum allyos. Brazing
and soldering. Welding defects and remedies.
6. METAL CASTING:
Structure of ingots and castings, moulding processes,
principles of gating and risering, segregation and other
defects, remedies.
7. METAL FORMING:
Fundemental aspect of plasticity cold, warm and hot
working basic aspects of rolling, forging, extrusion,
wire - drawing and sheet metal working, forming defects
and remedies.
8. POWDER METALLURGY:
Powder production processes, characteristics of powders,
pressing and sintering, advantages and applications
of powder metallurgy.
9. NON -DESTRUCTIVE
TESTING AND FAILURE ANALYSIS:
Principles of dye - penetrant, magnetic particle, ultra
sonic and radiographic inspection, failures in engineering
components and methods of analysis.
10. CORROSION:
Forms of corrosion, corrosion testing procedures, measures
for minimizing corrosion like inhibition, anodic and
cathodic protection and surface treatment.
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