This course enable the learners to understand the properties of metals, testing of materials, thermal equilibrium diagram, methods of producing iron and steel, non-ferrous metals and their alloys and corrosion and its prevention.
Engineering material - Introduction -Requirements of engineering materials. Classification of engineering materials - Classification of engineering materials - Applications of metals and non-metals. Engineering materials and applications - Engineering materials - Technological properties.
Mechanical properties of metals - Mechanical properties. Types of testing - Introduction - Classification of tests - Destructive tests - Non-destructive tests - Destructive tests vs. Non-destructive tests. Tensile test - Universal Testing Machine (UTM) - Tensile test - Results of tensile test - Example. Compression test - Compression test. Types of impact test - Types of impact test. Brinell hardness test - Hardness tests - Brinell hardness test. Vickers hardness test - Vickers hardness test. Rockwell hardness test - Rockwell hardness test - Hardness number - Comparison. Radiography test - Radiography. Gamma-ray radiography test - Gamma-ray radiography. Ultrasonic testing - Ultrasonic testing. Magnetic particle and penetrant testing - Magnetic particle testing - Penetrant testing.
Unit cell - Space lattice - Simple cubic structure. Bravais lattice and crystal systems - Bravais lattice - Crystal systems. FCC, BCC, HCP - Face-centered cubic (FCC) structure - Body Centered Cubic (BCC) structure - Hexagonal close pack system. Factors promoting grains size and crystallization - Factors promoting grain size - Crystallization. Grain - Formation of grains by dendritic growth - Effect of rate of cooling on grain formation - Effect of grain size on mechanical properties.
Solid solution and chemical compound - Alloys - Solid solution - Solid solution vs liquid solution - Types of solid solutions - Interstitial solid solution - Substitutional solid solutions - Phase rule - Phase. Allotropic forms of pure iron - Cooling curve for pure metals - Allotropic forms and cooling curve of pure iron - Critical points. Micro-Constituents of iron, carbon, and steel - Micro-constituents of iron and carbon alloy - Steel. Iron-carbon equilibrium diagram - Iron-carbon equilibrium diagram - Important points in iron-carbon equilibrium diagram. Calculating percentages of phases - Calculating percentages of phases - Transformation of a eutectoid steel.
Raw materials for production of iron - Introduction to raw materials - Raw materials used in production of iron and steel. Manufacturing of pig iron in blast furnace - Iron making - Manufacture of pig iron in blast furnace - Operation of blast furnace. Production of cast iron - Cupola furnace - Cupola operation. Production of steel - Introduction - Making of steel - Process of making of steel. Bessemer process - Bessemer process - Bessemer converter - Reactions on Bessemer process. L.D process - L.D process - Operation of Linz Donawitz(L.D) process. Arc furnace - Electric process - High frequency electric furnace. White cast iron - Types of cast iron - White cast iron - Applications of white cast iron. Grey cast iron - Grey cast iron - Applications of Grey cast iron. Malleable cast iron - Malleable cast iron - Applications of malleable cast iron. Spheroidal graphite cast iron - Spheroidal graphite cast iron - Applications of spheroidal graphite cast iron. Alloy cast iron - Alloy cast iron.
Plain carbon steel - Alloys of iron with carbon - Plain carbon steel - Classification of plain carbon steel. Alloying steel - Alloying steel - Effect of alloying elements. Alloy steel - Alloy steel - Classification of alloy steels - Plain carbon and alloy steels - Molybdenum steel - Nickel steel - Chromium steel - Silicon steel - Silicon manganese steel - Manganese steel - Cobalt steel. Engineering applications of steels - Stainless steels - Types of stainless steels - Invar steels - Chromium steels - Selection of proper alloy steel.
Non-ferrous metals - Ferrous alloys - Non-ferrous metals - Classification of non-ferrous alloys - Lead - Titanium - Titanium alloy - Zirconium. Aluminium - Aluminium- Properties of aluminium alloy - Application of Al and Al-alloys - Aluminium alloys - Duralumin - Magnalumin. Copper and copper alloys - Copper - Uses of copper - Properties of copper alloys - Copper and copper alloys. Brass and bronzes -Brass - Classification of brass - Bronzes - Gunmetal - Bearing materials. Tin and zinc - Tin - Zinc. Nickel alloys - Nickel - Nickel alloys - Inconel - Super alloy - Nichrome.
Glass and its types - Glass - Types of glass - Glass lining for process equipment. Carbon - Carbon -Carbon element. Graphite - Graphite - Classifications of graphite. Stoneware -Stoneware - Properties of stoneware - Types of stoneware - Uses of stoneware. Asbestos - Asbestos - Applications of asbestos. Rubber - Elastomers or rubber - Fundamental properties of elastomers or rubbers - Applications of rubbers. Polymers - Polymer - Polymerisation - Classification of polymers - Applications of polymers. Refractories - Introduction to refractories - Need and selection of refractories - Classification of refractory materials - Properties of refractory materials - Properties of refractories. Glass ceramics - Glass-ceramics - Ceramites - Glass wool.
Corrosion - Corrosion - Causes of corrosion - Types of corrosion. Electrochemical theory - Electrochemical or wet corrosion - Hydrogen evolution corrosion - Corrosion slightly alkaline environment. Electrode potential - Electrode potential - Passivity. Electrochemical series - Electrochemical series - Features of the electrochemical series - Polarization. Uniform and stress corrosion - Types of corrosion - Uniform corrosion - Example of uniform corrosion - Stress corrosion - Stress corrosion. Pitting and crevice corrosion - Pitting corrosion - Crevice corrosion. Hydrogen attack and bimetallic corrosion - Hydrogen attack - Example of hydrogen attack - Bimetallic corrosion. Grain boundary and fatigue corrosion - Grain boundary corrosion - Fatigue corrosion - Mechanism of corrosion fatigue. Methods of prevention of corrosion - Methods of prevention of corrosion - Proper design of material components. Anodic and cathodic protection - Anodic protection - Cathodic protection - Comparison of cathodic protection with anodic protection - Inhibitors - Anodic inhibitors - Cathodic inhibitors. Surface coatings - Introduction - Organic coatings - Inorganic coatings.
