This course enable the learners to understand about structure of materials, alloys, phase diagrams and its applications, various heat treatment processes, ferrous and non-ferrous materials and mechanical testing of metals.
Atomic Structure- Ionic or electrovalent bond, Covalent bond, Metallic bond. Crystal Structure - Unit cell, Lattice parameters, Bravais Lattice and Basis, Crystal systems, Miller Indices, Space Lattice, Simple cubic, Body center cubic structure (BCC), Face center cubic structure (FCC), Hexagonal Closed Packed (HCP) Structure. Crystallization of pure metals - Crystallization, Nuclei formation, Crystal growth, Effect of rate of cooling on grain formation, Formation of dendrites, Coring, Nucleation, Homogeneous nucleation, Heterogeneous nucleation, Cast Structure. Crystal imperfections - Point defect, Line defect (qualitative), Screw and edge dislocation, Burgers vector, Surface or Planar defects, Volume defects. Concept of Slip and Twinning - Plastic deformation of metals, Plastic deformation of single crystal, Slip, Deformation by dislocation, Twins and twinning, Difference between slip and twinning deformation. Atomic Diffusion -Diffusion, Fick's law, Fick's second law of diffusion, Factors affecting Diffusion.
Constitution of alloys- Metal, Alloys, Difference between metals and alloys, Solid solutions, Solid solution vs liquid solution, Types of solid solutions, Substitutional solid solution, Interstitial solid solution, Factors Governing Solid Solubility, Possibilities of Solid Solutions. Phase diagrams - Why should phase diagrams be studied, Information from phase diagram, Terminology used in phase diagrams, Phase rule, Gibbs phase rule, Application of phase rule, Types of equilibrium diagrams, Binary equilibrium diagram, Ternary equilibrium diagram, Classification of binary diagram, Types of binary phase diagram, Isomorphous system, Construction of equilibrium diagram of isomorphous system, Construction of diagram, Lever rule, Example on phase diagrams, Cooling of an alloy in isomorphous system. Phase reactions- Eutectic system, Examples of eutectic system, Phase diagram of eutectic system, Phase diagrams - Binary eutectic systems, Property variations in eutectic system, Properties of an eutectic alloy, Peritectic system, Eutectoid system, Peritectoid systems, Monotectic system, Solidification of monotectic alloy, Types of monotectic alloys, Syntectic reaction, Equilibrium diagram of syntectic reaction. Allotrophy of iron - Allotrophic forms of Pure iron, Critical Points. Iron carbon Equilibrium diagram - Iron-carbon equilibrium diagram, Importance of Fe-C system, Characteristics of Fe-Fe3C diagram, Iron carbon system, Eutectoid transformation, Eutectic transformation, Critical temperature lines. Iron carbon alloys - Comparison of steel and cast iron, Steels and cast irons in Fe-Fe3C diagram, Steel, Cast iron, Variations in microstructure in steels, Transformation during slow carbon of steel, Classification of steels, Hypo-eutectoid steels, Hypereutectoid steels, Classification of plain carbon steels, Critical temperature. Cu-Ni and Al-Cu Phase diagrams- Cu-Ni alloys - Cupronickels, Phase diagram of Cu-Ni alloy.
Heat Treatment of steels - Heat treatment, typical heat treating cycle, Heat Treating Processes, Isothermal transformation, TTT diagrams, Critical cooling rate, Factors affecting the position of TTT curves, CCT diagram, Importance of CCT diagrams. Annealing- Various types of annealing processes, Full annealing, Isothermal annealing, Diffusion annealing, Recrystallisation annealing, Process annealing, Stress relieving annealing, Spheroidising annealing. Normalizing - Normalizing versus Annealing, Mechanical properties of normalized and annealed steels. Hardening. Tempering- Stages of tempering, Effect of tempering, Theory of tempering. Austempering and martempering - Austempering, Advantages and limitations, Effect of austempering on mechanical properties, Martempering. Hardenability - Difference between Hardness and Hardenability, Jominy End Quench Test, Test Procedure, Quenching, Measurement of Hardenability, Factors affecting Hardenability, Uses of Jominy End QuenchTest. Surface Hardening/Case Hardening Methods - Various Case Hardening Techniques. Carburizing- Pack Carburizing, Liquid Carburizing, Gas Carburizing, Advantages and Disadvantages of Carburizing, Applications of Case Carburized Steels. Nitriding - Nitriding Process, Effect of Nitriding on Mechanical Properties, Applications of Nitriding process, Advantages and Disadvantages. Cyaniding- Cyaniding Process, Advantages and Disadvantages. Flame hardening- Methods of Flame Hardening, Advantages and Disadvantages. Induction hardening- Advantages and Disadvantages. Heat Treatment of Non-Ferrous Metals- Heat treatment process, Annealing, Solution treatment, Introduction to Precipitation process, Precipitation Hardening, Theory of Ageing, Steps in Ageing Process, Precipitation hardening of Al-4.5% Cu alloy.
Ferrous materials- Classification of Ferrous Materials. Steels- Plan carbon steel, Effect of carbon on steel, Classification of Plain Carbon Steel, Alloying Steel, Effect of Alloying Elements Alloy Steels, Classification of Alloy Steels, Molybdenum steel, Nickel Steel, Chromium Steel, Manganese Steel, Hadfield Manganese Steel, Stainless Steel, Tool steel, Water hardening Tool steel. Cast iron- Classification of cast irons, White cast iron, Grey cast iron, malleable cast iron, Nodular cast iron, Alloy Cast Irons. Non-ferrous materials - Classification of Non-Ferrous Alloys. Copper and Copper alloys- Copper, Uses of Copper, Brass, Classification of brass, Alpha brasses, Microstructure of α+β brasses, Bronze, Classification of bronzes, Cu-Ni alloys - cupronickels, Phase diagram of Cu-Ni alloy, Cu-Ni alloys - Monel metal, Cu-Ni alloys – Nickel silvers. Aluminium and Aluminium alloys- Aluminium, Properties of Aluminium Alloy, Application of Al and Al-Alloys, Aluminium Alloys, Duralumin, Magnalumin, Al-Cu Phase diagram, Heat treatment of Aluminium alloys, Heat treatable aluminium alloys, Heat treatment of Al-Cu alloy, Non- heat treatable aluminium alloys. Other alloys - Bearing Alloy, Magnesium Alloys, Ni-base Super Alloys, Titanium Alloys.
Polymers - Types of polymerization reactions, Copolymerization. Plastics- Constitutes of Plastics, Classification of Plastics, Difference between Thermoplastic and Thermosetting Materials, Thermoplastic Materials, Polyethylene or Polythene (C2H4)n, Polyvinylchloride (PVC), Polypropylene(PP), Teflon(PTFE), Polystyrene, Acrylics (Polymethyl methacrylate), PMMA, ABS (Acrylontiric butadiene styrene), Silicones Polyvinylidene chloride, Polyamides, Thermosetting Materials, Phenol Formaldehyde (PF) – “Bakelite”, Amine formaldehyde (Urea and melamine formaldehyde), Polysters (unsaturated), Epoxy resins (Epoxies), Properties of Plastics, Shortcomings of Plastics, Mechanical behaviour of Plastics. Processing of Plastics- Moulding of thermoplastics. Ceramics- Ceramic materials, Classification of Ceramics, Advantages of ceramic materials, Structure of crystalline ceramics, Silicate structures, Silicon-oxygen tetrahedron structure, Applications of ceramics, Properties of ceramic materials, Electrical properties, Thermal properties, Chemical, optical and nuclear properties, Mechanical Behaviour of Ceramics, Processing of Ceramics. Composites- Composite materials/Composites, Classification of composite, Particle reinforced composites, Concrete, Reinforced cement concrete (R.C.C), Dispersion-strengthened composites, Fibre-Reinforced composites, Polymer matrix composites, Metal matrix composites, Ceramic matrix composites. Production of Composites- Fundamentals of Production of Composites, Basic Steps in a Composites Manufacturing Process, Processes for Production of Composites. Properties and Applications of Composites- Characterization of Composites, Constitutive Relations of Composites, Stress-Strain behaviour of Fibre. Applications of Composites.
Introduction to Dielectric Material - Fundamental definition, Effect of temperature on dielectric constant, Elementary ideas of Piezoelecrics, Ferro-electricity and Applications, Dielectric Polarization and Mechanism, Dielectric loss. Magnetic material - Classification of magnetic materials, Origin of magnetic moment, Bohr magneton, Types of magnetism, Domain theory, Hysteresis curve, Heisenberg's Uncertainty principle, Application of Heisenberg's Uncertainty principle, Structure of Ferrites, Preparation of Ferrites, Soft magnetic materials, Hard magnetic materials, Applications of ferrites. Semiconductor- Introduction to semiconductors, Classification of semiconductors, Introduction to Fermi level and carrier concentration, Variation of Fermi level with temperature, Carrier concentration in intrinsic semiconductor, Electrical conductivity in Intrinsic semiconductor, Band gap determination, Direct and indirect band gap-derivation, Basic Ideas of Compound Semiconductors(II-VI and III-V, Derivation of carrier concentration in n-type and p-type semiconductor, Variation of Fermi level with temperature and impurity concentration, Determination of Hall coefficient, Experiment of Hall effect, Application. Superconductor- Introduction to Superconductivity, Basic Concepts, Meissner effect, Properties of superconductivity, Type I superconductors, Type II superconductors, BCS theory of superconductors, High Tc superconductors, Application of superconductors. Glasses- Structure of glass, Properties of glass, Classification of glasses, Special types of glasses, Applications. Metallic glasses - Preparation, Properties, Applications. Cermet- Properties of cermets, Applications. Shape memory alloys- Phases of shape memory alloys, Characteristics of shape memory alloys, Pseudo elasticity, Nitinol, Mechanical properties of nitinol, Disadvantages of SMA. Optical Materials- BK 7, MgF2, Crystal Quartz, Zerodur, ZnSe, Properties of Optical Materials. Nanomaterials - Nanoscience, Pulsed laser deposition, Sol-gel process, Carbon nanotube, Arc Method, Application of CNTs. NLO materials - Introduction to NLO materials, Optical Kerr effect, Applications.
Tensile test- Universal testing machine, Tensile test, Results of tensile test. Compression test, Shear test and Torsion test- Shear strength, Torsion test. Hardness test- Hardness impression, Importance of hardness, Ball indenter, Indentation hardness test. Brinell Hardness test- Test procedure, Brinell hardness number BHN, Derivation of an expression to calculate BHN, Test with non standard load, Advantages and disadvantages, Industrial importance, Formulas in hardness test, Problems based on hardness test. Rockwell Hardness test- Range of loads and intenders, Different application combination of intenders and loads, Various combination of intenders and loads, Advantages and disadvantages, Rockwell superficial hardness test. Vickers Hardness test- Range of loads and intenders, Vickers hardness test iamond pyramid hardness test, Procedure of vickers hardness test, Industrial importance, Hardness conversion relationships, The hardness conversion. Impact test- Introduction of impact test, Impact load, Basic of test, Types of impact test. Charpy test- Principle of impact test, Impact testing machine. Izod test- Differences between Izod and charpy impact tests, Effect of variables on the impact test values, Energy losses, Striking velocity, Size and shape of the specimen, Temperature, Grain size, Composition, Temper embrittlement. Fatigue test- Fatigue failure, Factors causing fatigue failure, Structural features of fatigue, Model for fatigue crack initiation, Plastic blunting model of fatigue striation. Creep test- Introduction, What is creep, Importance of creep, Application area, Creep test, The stages of creep-test, Creep rate, Homologous temperature, Presentations of Creep data.
