SY BTech Metallurgy July2013

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METALLURGICAL ENGINEERING

S.Y. B. Tech.

Effective from A. Y. 2012-13

INDEX

Item Page No.

UG Rules and Regulations

Detailed Syllabus

Annexure-I: List of Professional Science courses offered by ALL departments

Annexure-II: List of Liberal Learning courses offered at Institute level

List of Abbreviations

Sr. No. Abbreviation Stands for: 1 BSC Basic Science Course

2 PSC Professional Science Course

3 PCC Program Core Course

4 LC Laboratory Course

5 HSSC Humanities and Social Science Course

6 MLC Mandatory Learning Course

8 LLC Liberal Learning Course

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CURRICULUM STRUCTURE OF S. Y.-B.TECH (Metallurgical Engineering)

Effective from A. Y. 2012-2013

III-Semester:

Sr. No

Course Type/ code

Subject Title Contact hours L T P

Credits

01 BSC/MA201 Engineering Mathematics-III 3 1 - 4

02 PCC/MT201 Structure & Properties of Materials

3 - - 3

03 PCC/MT202 Principles of Physical Metallurgy

3 - - 3

04 PCC/MT205 Geology and Ore Dressing 3 - - 3

05 PCC/MT207 Electrical & Instrumentation Technology

3 - - 3

06 LC/MT209 SPM Lab - - 2 1

07 LC/MT211 PPM Lab - - 2 1

08 LC/MT213 GOD Lab - - 2 1

09 LC/MT215 EIT Lab - - 2 1

10 PSC/*IS201 Professional Science courses 3 - - 3

11 LLC Liberal learning course 1 - - 1

Total 19 1 8 24

IV-Semester:

Sr. No

Course Type/ code

Subject Title Contact hours L T P

Credits

01 PCC/MT203 Heat Treatment Technology 3 - - 3

02 PCC/MT206 Metallurgical Thermodynamics 3 1 - 4

03 PCC/MT204 Principles of Metal working 3 - - 3

04 PCC/MT208 Modeling in Materials Engineering

2 - 2 3

05 PCC/MT210 Mechanical Technology 3 - - 3

06 LC/MT212 HTT Lab - - 2 1

07 LC/MT214 PMW Lab - - 2 1

08 LC/MT216 Mechanical Technology Lab - - 2 1

09 HSSC/AS204 Professional Communication 2 0 0 2

10 MLC/ML202 Environmental Studies 2 0 0 2

Total 18 2 6 23

*: Professional Science Course/s offered by Department of Metallurgy and Materials Science : 1. Device Materials

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Second Year B.Tech.(Metallurgical Engineering) Semester III

MA 201 Engineering Mathematics III Teaching Scheme: Examination Scheme: Lectures : 3 hrs/week Tutorial: 1 hr/week

100 marks:Test I:20 marks

Test II:20 Marks,

End-Sem Exam- 60 Marks

Objectives:

The basic necessity for the foundation of Engineering & Technology being mathematics, the main aim is, to teach mathematical methodologies & models, develop mathematical skills & enhance thinking power of students.

Unit 1 (4 hrs) Gradient, Divergence and Curl: Vector and Scalar functions and Fields, Derivatives, Gradient of a Scalar field, Directional derivatives, Divergence and Curl of a Vector field. Unit 2 (6 hrs) Vector Integral Calculus: Line Integrals, Line integrals independent of path, Greens theorem in plane, surface integral, Divergence theorem and Stokes theorem. Unit 3 (6hrs) Fourier Series: Periodic functions, trigonometric series, Fourier series, half range series. Unit 4 (6 hrs) Partial Differential Equations: Basic concepts, method of separation of variables. One and Two dimensional wave equation, one dimensional heat equation. Unit 5 (10 hrs) Laplace Transforms: Laplace Transform, Inverse Laplace Transform, linearity, shifting, transforms of derivatives and integrals, differential equations, differentiation and integration of transforms, convolution Unit 6 (8 hrs) Statistics: Random Variables, Probability Distributions, Mean and Variance of a distribution, binomial and normal distributions, testing of hypothesis.

Text Books:

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Erwin Kreyszig ,Advanced Engineering Mathematics, Wiley Eastern Ltd. (8th Student Edition)

Maurice D. Weir, Joel Hass, Frank R. Giordano, Thomas Calculus, Pearson Education, Delhi(11th Edition),

Reference Books:

P.N. Wartikar, J. N. Wartikar, Engineering Mathematics Vol I, II, III Pune Vidyarthi Gruha Prakashan.

C.R. Wylie , Advanced Engineering Mathematics, McGraw Hill Publications, New Delhi. Peter V. O Neil ,Advanced Engineering Mathematics, Thomson. Brooks / Cole,

Singapore(5th edition ) . B. V. Ramana , Higher Engineering Mathematics, Tata McGraw Hill Publications.

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MT201 STRUCTURE AND PROPERTIES OF MATERIALS

Teaching Scheme Examination Scheme

Lectures: 3 hrs/week Test I20 marks Test II 20 marks End Sem exam 60 marks

OBJECTIVES: 1. Introduce students to the field of materials testing and materials science. 2. Build the foundation for the courses to be studied further in Materials Technology. Unit 1 (06)

Classification of materials based on applications and structure, Structure of Materials: Types of bonds, Crystallography: System of crystal lattices, space lattice, unit cell, primitive cell, crystallographic directions and planes, Miller indices of directions and planes, non crystalline materials. Unit 2 (06)

Solidification, nucleation and growth, dendrites, surface energy & interfacial phenomena, interfacial phenomena in liquid-solid interface. Diffusion in solids, Arrhenius equation. Unit 3 (06)

Imperfections in crystals: Point and line imperfections- vacancies, impurity atoms, Frenkel and Schottky imperfections, Dislocations- screw, edge and mixed, Slip system-slip plane and slip direction, Burgers vector. Slip in plastic deformation, Twin in crystals. Grain boundaries, twin boundaries, stacking faults, Large angle and small angle boundary. Unit 4 (06)

Stress and strain, Elasticity, Tension test for common materials, elastic, plastic and elasto-plastic behavior of materials, Stress-strain curves- Engineering and True, Important definitions of properties and their relationship, plasticity index, Instability in tension, Effect of strain rate and temperature. Testing methods and machines. Application of various standards of such as ASTM, IS, ISO in materials testing. Unit 5 (06)

Compression test: Behavior of materials in compression, application of compression tests. Hardness tests: Brinell, Poldi, Vickers, Rockwell, Rebound hardness, Microhardness test, Hardness Conversion, Principles of Bend test Fiber stress and bending shear stress, Torsion tests Stress & strain variation in body under pure torsion, Combined bending and direct stress. Combined bending and torsion. Combined bending, torsion and direct stress. Unit 6 (06)

Fatigue and Impact tests, Charpy and Izod methods, DBTT, fracture toughness, creep tests. Non-destructive testing methods: visual and leak testing, dye-penetrant tests,

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magnetic crack detection, eddy current, x-ray radiography, ultrasonic and acoustic emission methods.

TEXT BOOKS: 1. Davis Troxell Hauck, The Testing of Engg. materials, 4th Ed., McGraw Hill,1982 2. George E.Dieter, Mechanical Metallurgy, Mc-Graw Hill Book Co.Inc. 3. Askland & Phule, Material science & Engineering of materials 4. Foundation of Materials Science and Engineering, William Smith, 2nd Edition, McGraw

Hill, 1993 5. The nature and Properties of Engg. Materials, Jastrzebaski, John Wiley & Sons, New

York REFERENCE BOOKS: 1. Hardness Testing, edited by H.E. Boyer, ASM International, Ohio, 1987. 2. Introduction to Materials Science for Engineers, James Shackelford, 5th edition,

Pentice Hall international incorporation. 3. Materials Principles & Practice, Materials in action series, edited by Newey &

Weaver, Butterworth Heinmann, Oxford, 1990.

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MT202 PRINCIPLES OF PHYSICAL METALLURGY



OBJECTIVES: To introduce the basic concepts of physical metallurgy of ferrous and non ferrous alloys.

Unit 1 (05) Metallography: Specimen preparation for microscopic examination for different metals and alloys, electrolytic polishing, etching and mounting techniques, metallurgical microscope, Quantitative Metallography, volume fraction of phases by area, linear analysis, point counting methods for grain size and phase measurements, grain size significance and measurement, macroscopic examination methods, types of non metallic inclusions rating.

Unit 2 (06) Solid Solutions and Phase diagrams: Solid solution and intermediate phases, Gibbs phase rule, phase equilibria, alloy phases and compounds, Introduction to spinodal decomposition, athermal transformation, classification of strengthening mechanisms, Binary equilibrium diagrams and related microstructures, Lever rule application, numericals for phase analysis, Non equilibrium cooling of alloys, Ternary diagrams-simple systems.

Unit 3 (08) Iron-Carbide system: Iron-Iron carbide equilibrium diagram, critical temperatures, plain carbon steels, slow cooling of steels and cooling curves, effect of impurities, property variation with microstructure, classification and specifications of steels. Isothermal transformation diagrams, Plotting, Transformation to pearlite, bainite and martensite, Continuous cooling transformation diagram, Effect of carbon, grain size and alloying elements, importance of IT and CCT diagrams to heat treatment.

Unit 4 (05) Cast Irons: Fe-Graphite diagram, Factors controlling microstructure, Types of cast irons :gray ,White ,malleable cast, Nodular, Chilled and Mottled cast iron, Step bar test, Alloy cast irons: Ni hard, Ni resist, Silal, Austempered ductile iron Unit 5 (06) Copper and Copper base Alloys: Phase diagrams of Cu based alloys brasses, bronzes, Sn Bronzes, Si Bronzes, Al Bronzes, Be Bronzes, Microstructure, Properties and applications, various types of brasses and bronzes, important cast and wrought brass-bronze alloys, Cupronickel and nickel silvers

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Unit 6 (06) Light metal alloys: Classification and temper designations of Aluminium alloys, phase diagrams of Al-Cu, Al-Si, Al-Mg, Al-Zn systems, wrought and cast Al-alloys and applications, precipitation hardening, Titanium alloys (alpha, alpha-beta alloys and beta alloys (like Ti-Al, Ti-V and Ti-Mn alloys) and their applications, Mg and its alloys (Mg-Al, Mg-Zn, Mg-rare earth based alloys) TEXT BOOKS: 1. S.H.Avner, Introduction to Physical Metallurgy, McGraw Hill book co.inc. 2. Askland & Phule, Material science & Engineering of materials 3. R.A.Higgins, Engineering Metallurgy, Part I, App. Physical Met, ELBS 4. George Vanwert, Metallographic Techniques, ASM Publ. REFERENCE BOOKS:

1. Reed Hill, Physical Metallurgy, 2. Raghvan, Physical Metallurgy 3. W.F.Smith, Foundation of Material Science & Engineering, McGraw Hill

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MT205 GEOLOGY AND ORE DRESSING


Lectures: 3 hrs/week

Test I20 marks Test II 20 marks End Sem exam 60 marks

OBJECTIVES:

To understand the principles of Geology and ore dressing as applied for metal winning. To know various deposits of minerals/ores on the earth

Unit 1: [06]

General Geology & Petrology : Introduction, General Geology, Surface features, External & Internal Agents modifying the earth, weathering, decomposition, earth movements, metamorphism, volcanism. Rock and minerals. Unit 2: [06]

Mineral composition of Igneous Rocks, Textures & textural variation, conditions of cooling of plutonic, hypabyssal and volcanic rocks. Classification of igneous rocks. Secondary Rocks processes and products of decomposition and disintegration. Transport and deposition, Classification of Sedimentary Rocks. Agents of transportation. Welding and cementation. Grain size classification. Agents and types of metamorphism. Unit 3: [06]

Economic Geology. Ore, ore minerals and gangue, tenor of ore, classification of ore deposits. Process of formation of minerals deposits. Geology of the important Indian deposits of aluminium, copper, iron, lead zinc, manganese, titanium, uranium and thorium and industrial minerals. Deposits of coal and petroleum in India. National Mineral Policy. Conservation and utilization of mineral resources. Unit 4 [06]

Introduction to Ore Dressing. Sampling of ores by different methods. Theory of liberation of minerals. Crushers: -Jaw, Gyratory, Cone, Rolls and toothed roll crushers. Types of grinding operations like batch and continuous dry and wet grinding, open circuit and closed circuit grinding. Grinding Mills: Ball mills, theory of ball mill operation, rod and tube mills. Comminution laws. Sizing: Study of laboratory sizing techniques and reporting of sizing data. Industrial sizing units: Types of screen surfaces. Grizzlies, trammels, vibrating and shaking screens. Movement of solids in fluids: stokes and Newtons laws. Terminal velocity and its relation with size. Unit 5 [06]

Classification of classifiers, study of settling cones, rake classifier, spiral classifier and cyclones. Heavy media separation: Principles, flow chart, different media used. Washability curves for easy, normal and difficult coal. Jigging: Theory of jigging. jigging machines, Tabling:-study of stratification on a table.

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shaking tables, wilfley table. Unit 6 [6]

Floatation: Principles of floatation. Factors affecting floatation. Classification of collectors and frothers. Regulators and factors affecting their efficiency. Floatation machines: -Pneumatic and mechanical floatation cells. Application of floatation process for Cu, Pb and Zn ores. Magnetic separation processes and electrostatic separation process. TEXT BOOKS: 1. A.M.Gaudin Principle of Mineral Dressing 2. R.H.Richards and C.E.locks Text book of Ore dressing

3. Handbook of Mineral Dressing Ores and Industrial Minerals A. E.Taggart REFERENCE BOOKS:

1. S.J. Trussscott, Text book of Ore dressing 2. S.K. Jain, Ore dressing 3. Berry A Willis Mineral Dressing Technology 4. J.S.S. Brame and J.C.King Edward Fuels Solid, Liquid and Gaseous 5. G.W.Himus Elements of Fuel Technology

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MT207 ELECTRICAL AND INSTRUMENTATION TECHNOLOGY



OBJECTIVES: To understand concepts of electrical, instrumentation and control involved in

equipments used in materials processing and characterization.

Unit 1 (08) DC Machines: a) DC Generator: Construction, generating action, emf equations, types of generators, and characteristics of generators b) D.C motor Motoring action, significance of back emf, types of dc motors, voltage & current relationships of different motors, torque equation, torque-speed characteristics, Different methods of starting (need of starter) different method of speed control, braking & applications. Unit 2 (08) Induction Motor: Types, principle of operation, types, slip, power flow diagram, torque equation, condition of max. torque, torque slip characteristics, various methods of speed control, braking & applications. Single Phase Motors:

a) Single phase induction motors b) Special purpose motors- A.C. series motors, universal motors

Factor affecting choice of above motors for industrial applications like rolling mills, cranes, shear press, Mechanical press Unit 3 (10) Electrical Heating: Resistance Heating: Direct and Indirect methods, Stefans law of radiation of heat, Material used and designing of heating element, efficiency and control equipment. Induction Heating: Construction, Working principle of induction furnace, High/ Low frequency generation, Core type furnace, Coreless type furnace, High frequency eddy current heating, Electric Arc Furnace: Types, Construction, Working principle, Power factor, Impedance, Heat Treatment Furnace Heating: Heating elements, Dimmer state, Voltmeter, Current measurement. Eddy Current and Dielectric Heating Unit 4 (07)

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Definitions: Transducer, Sensor, Classification: Active, passive, primary, secondary, mechanical, electronic, analog and digital transducers, Characteristics: Static and Dynamic characteristics. Displacement Measurement: Overview, principle of operation &applications: Resistive: strain gauges. Inductive: LVDT, Capacitive: Capacitance pickups, Piezoelectric, Ultrasonic transducers and Hall effect transducers.

Force: Basic methods of force measurement, elastic force traducers, strain gauge

Unit 5 (04) Temperature Measurement: Overview, principle of operation &applications: RTD, Thermistors, Thermocouples, Semiconductor temperature sensors: Diode and IC temp sensors. Ultrasonic temp detector, Radiation: Pyrometers (Total and Selective), Infrared sensors. Flow Measurement: Overview, principle of operation &applications: Flow sensors: Orifice, Venturi and Nozzle. Variable area meter, Rotameter. Turbine type flow meter, Electromagnetic flow type, ultrasonic flow meter, Unit 6 (05) Pressure measurement: Overview, principle of operation &applications: High-pressure sensors: Dead weight tester, Vacuum sensors McLeod gauge, thermal conductivity (Pirani, Thermocouple gage) ionization type. Level measurement: Float, displacers, bubbler, and DP- cell, Ultrasonic, data loggers Fundamentals of control system, Control actions: On-off, proportional, integral, derivative, electronic controllers, stability of system TEXT BOOKS: 1. Stephen J., Fundamental of Electrical Machinery. 2. Nagrath & Kothari 2/e, Electrical Machines. 3. Instrumentation Measurements and Analysis B.C.Nakra and K.K.Choudhari 4. Electronic Instruments & Measurement - A. K. Sawhney, Dhanpatrai

publications, New Delhi 5. Process Control Instrumentation Technology - C.D. Johnson, PHI (5th Edition). 6. Analytical Instrumentation Handbook- R.S.Khandpur REFERENCE BOOKS: 1. Dr. P. S. Bhimra, Electrical Machines 2. Little Richard, Welding Technology 3. Rajan & Sharma, Heat Treatment & Furnaces 4. Measurement Systems - E.O. Doebelin (4th Edition). 5. Principle of industrial Instrumentation Patranabis. 6. Process Measurement & analysis - B.G. Liptak (Vol-I) 7. Instrumentation Devices & system - Rangan Sarma 8. Instrumentation and Measurement Principles D.V.S. Murthi

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MT209 STRUCTURE AND PROPERTIES OF MATERIALS

LABORATORY


Laboratory: 2 hrs/week Term work: 50 Marks Practical: 50 Marks

TERMWORK: List of Experiments: (Completing any 08 sets from the below mentioned sets of experiment)

1.TENSILE TESTING (2 sets): Study of universal testing machine, principle and construction, 1) Tension test: To conduct tensile test on standard samples of M.S./ Aluminium/ C.I., Plotting of stress-strain curves and comparison of test results. 2) Study the effect of Gauge length on percent elongation.

2. 2. HARDNESS TESTING (5 Sets) : Study of hardness testing machines such as:

1) Brinell 2) Vickers and 3) Poldi 4) Study of Rockwell/ Rockwell superficial hardness testing machines and

testing various materials with these machines using different loads and indenters (i.e. Scales).

5) Study of Microhardness/ Schleroscope and testing various materials. 3. COMPRESSION TESTING (1 set): Compression test on C.I./Aluminium (or Brass); study of the effect of L/D ratio on the test results. 4. FATIGUE TESTING (1 set): Study of fatigue testing machine 5. IMPACT TESTING (1 set): Study of Pendulum impact testing machine and conducting impact test on samples of various materials/with different notches and interpretations of result. 6. TORSION TEST (1 set): On wire samples of mild steel / spring steel. 7. BEND TEST (1 set): On plate/torr steel rod samples. 8. NON-DESTRUCTIVE TESTING (5 sets): STUDY OF

1) Dye penetrant 2) Magnetic particle 3) Eddy current 4) Radiography 5) Ultrasonic methods.

9. Other test (2 sets): Determination of porosity, density and cold crushing strength of ceramic materials, Hardness testing of polymers and elastomers by Durometer. 10. Crystallography of lattices, Millers indices and crystal defects

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MT211 PRINCIPLE OF PHYSICAL METALLURGY

LABORATORY



List of Experiments (ANY 08):

1. Preparation of specimens for microscopic examination steels, copper alloys and aluminium alloys; hot mounting and cold mounting and mechanical fixtures.

2. Microstructural study by etching of specimens of steel, copper alloys and aluminium alloys and cast iron.

3. Colour Metallography of selected steels to reveal specific phases. 4. Quantitative Metallography for grain size measurement by ASTM standard,

Mcquid and oxidation methods 5. Quantitative Metallography for phase volume fraction by point counting and

linear intercept method 6. Observation and drawing of different morphologies of grains equiaxed

dendrites, columnar dendrites, cellular structure, equiaxed grains, polygonal grains, elongated grains.

7. Observation of microstructures using image analyzer, Quantitative Metallography software, models and tools for grain size, shape, phases distribution and porosity.

8. Estimation of phases and drawing of cooling curves for transformation of plain carbon steels with varying carbon contents using Fe-C diagram. Observation and description of microstructures of annealed plain carbon steels.

9. Observations and description of microstructures belonging to various cast irons, brasses, bronzes, wrought and cast aluminium alloys; measurement of their hardness.

10. Assessment of nonmetallic inclusions in steels as per ASTM E-45 11. Student will bring unknown metallic sample; prepare it for metallographic

observation; observe and describe the microstructure with identification of phases present in it.

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MT213 GEOLOGY AND ORE DRESSING LABORATORY



TERMWORK:

List of Experiments:

1. Identification of the following minerals in handspecimens: Quartz and its varieties, common varieties of cryptocrystalline and amorphous silica, orthoclase, plagioclase, muscovite, biotite, zeolites, calcite, icelandspar, gypsum, satinspar, fluorite, barites, tourmaline, beryl, graphite, asbestos, talc, kyanite, garnet, galena, magnetite, haematite, limonite, iron pyrites, chromite, bauxite, azurite, malachite, psilomelane.

2. Identification of the following rock type and the associated economic minerals in handspecimens

Granites, syenites, diorites, gabbros, rhyolites, trachytes, andesites, basalts, varieties of Deccan trap rocks, volcanic breccias, pegmatites, dolerites, graphic granites. Laterites, bauxites, conglomerates, breccias, sandstones, quartzites, grits, arkose, shales, mudstone. Chemical and organic limestones. Marbles, quartzites, varities of gneisses, slates, phyllites and varieties of schists.

Practical Work: Minerology 4 practicals Igneous rocks 3 practicals Secondary rocks 3 practicals Metamorphic rocks 2 practicals Ore Dressing: 4. Construction, Working Principle of Jaw Crushers and crushing of ores on Jaw

Crushers. 5. Construction, Working Principle of Ball mill and grinding of ores by wet and dry

grinding in a ball mill 6. Study of laboratory sizing techniques and reporting of sizing data

7. Study of settling cones, rake classifier, spiral classifier and cyclones Conduct separation of minerals by

a. Froth floatation, b. Magnetic separation c. Electrostatic separation

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MT215 ELECTRICAL AND INSTRUMENTATION TECHNOLOGY LABORATORY



List of Experiments: Instrumentation department will conduct following experiments.

1. Characterization of temperature measurement system.(RTD, Thermocouple) 2. Characterization of flow measurement system.(Orifice, Venturi)

3. Characterization of level measurement system.(Capacitive, Bubbler) 4. Characterization of pressure measurement system(Load cell)

Electrical department will conduct any 4 experiments from the following 5. External & internal characteristics of a D.C. shunt generator. 6. A) Speed control of D.C. shunt machine by

(i) Armature voltage control (ii) Field current control method

B) Study of motor starters (i) 3 point starter (ii) 4 point starter (iii) 2 point starter

7. Load test on D.C Shunt motor 8. Load test on 3ph and 1 ph Induction motor to determine its performance 9. Study of induction motor starters

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IS201 PROFESSIONAL SCIENCE COURSES



Institution level course

LIBERAL LEARNING COURSE




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Second Year B.Tech.(Metallurgical Engineering) Semester IV

MT203 HEAT TREATMENT TECHNOLOGY



OBJECTIVES: To understand the fundamentals of various Heat Treatments. To understand physical metallurgy of Alloy Steels and their Heat Treatments.

To understand working principle of different Heat treatment Furnaces. Unit 1 (06)

Heat treatment of plain carbon steels: Annealing, Isothermal and subcritical Annealing types, Normalizing. Hardening Heat Treatment: Quenching process, characteristics and kinetics of martensitic transformation, Bain model, Retained austenite and its effect, Tempering and subzero treatment. Hardenability: Mass effect, Grossman method, Critical and ideal critical diameter, Jominy End Quench method, Use and Significance of Hardenability data, Effect of grain size and composition, Residual stresses, Quench cracking, case studies of design changes for hardening. Unit 2 (06)

Classification of alloying elements and their effects on IronIron carbide phase diagram, TTT Diagram and CCT Diagram, General Heat treatments such as Annealing, Normalizing, Hardening, Tempering, Austempering, Martempering. Hardenability concept, Stages of Quenching and their effects, Types of quenching media such as oils, polymers; Cooling characteristics of quenching media, Control of quenching parameters, quenching fixtures, Dimensional changes during hardening and tempering Unit 3 (06)

Introduction to classification and Heat treatment of Low alloy steels: Micro- alloyed (HSLA), Dual phase steels, Free cutting steels, Spring steels; bearing steel, Tool Steel: Selection criteria and properties of Tool steels, Classification of Tool Steels: Cold work, Hot Work Tool Steels, High Speed Steels and Stellites; Heat treatments of Die and Tool steels, Secondary hardness and Red Hardness, Subzero treatment, Super High Speed Steels, TRIP Steels. Unit 4 (06)

Stainless Steels: Fe-Cr, Fe-Ni Phase Diagram, Schaeffler Diagram and its modifications, Classification of Stainless Steels, sensitization, Heat treatment of

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stainless steels, Precipitation Hardening Stainless Steels, Marageing Steels, Superalloys and their heat treatment. Unit 5 (06)

Surface hardening: Carburizing, Carburizing atmosphere and Heat treatment after Case Hardening, Bainite control in case, Case depth measurement, ASTM E1077-01 Depth of carburization, Drip Feed Carburizing, dimensional changes during case hardening; Nitriding, Carbonitriding, Tufftriding, Nitrocarburising, Plasma Nitriding; Induction Hardening, Flame Hardening, Laser Hardening, Selection of steels for these treatments and their applications. Unit 6 (06)

Classification of atmospheres for heat treatments, Generation of atmospheres and their applications. In situ atmosphere generation, Thermodynamics and Kinetics of atmospheres, Control and monitoring of Furnace Atmospheres: Infrared controller, Gas chromatography, Dew point analyzer and Oxygen probe analyzer Unit 7 (04)

Heat treating furnaces: Salt bath furnace, Fluidized bed furnace, Sealed Quench furnace, Vacuum furnace, Heat Treatment Defects such as Distortion, Residual stresses, quench cracks and Design for Heat treatment TEXT BOOKS:

1. Heat Treatment of Metals, Vijendra Singh, 2007, Standard Publishers and Distributors, New Delhi

2. R.A. Higgins, Engineering Metallurgy, Part I, App. Physical Met, ELBS, 5th ed., 1983

REFERENCE BOOKS:

3. Steel and its Heat Treatment -K.E Thelning, Butterworth, London 4. Handbook of Heat Treatment of Steels Prabhudev-Tata Mc Graw Hill.

New Delhi, 1988 5. Heat Treatment of Ferrous Alloys, Brooks, Washington: Hemisphere

Pub., 1979 6. ASM Metals Handbook Heat treatment Vol. Metals Park Ohio 7. ASM Metals Handbook Steels Vol. Metals Park Ohio

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MT206 METALLURGICAL THERMODYNAMICS


Lectures: 3 hrs/week Tutorial: 1hr/week

Test I20 marks Test II 20 marks End Sem exam 60 marks

OBJECTIVES:

To teach the students the importance of thermodynamic concepts with reference to metallurgical systems.

Unit 1: [07]

Thermodynamics systems, Classification, thermodynamic variables, State functions, Process variables, Extensive and intensive properties, Energy and first law of thermodynamics, Heat capacity, Enthalpy, Heat of reactions, Hesss law, Kirchoffs equation, Thermochemistry. Unit 2: [08]

Second law of thermodynamics, Entropy, Effect of temperature on entropy, Statistical nature of entropy, Combined statements of first and second law of thermodynamics, Gibbs free energy, Helmholtzs free energy, Maxwells equations, Gibbs-Helmholtz equation, Clausius-Ciapeyrons equation and its application to phase changes, Free energy as criterion for equilibrium and its applications to metallurgical reactions, Third law of thermodynamics. Unit 3: [07 ]

Activity, Equilibrium constant, Le-Chateliers principle, Chemical potential, Law of mass action, Effect of temperature and pressure on equilibrium constant, Vant Hoffs isotherm, Free energy-temperature diagrams, oxygen potential and oxygen dissociation pressure, Gibbs phase rule and its applications, Free energy composition diagram. Unit 4 [07 hrs]

Solutions, Partial molar quantities, Ideal solutions, Raoults law, Non ideal solutions, Gibbs-Duhem equation, Free energy of formation of solution, Regular solutions, application to phase equiibria, excess thermodynamic quantities. Unit 5 [06 hrs]

Electrochemical cell, Determination of thermodynamic quantities using reversible electrochemical cell, EMF cell, electrode potential, Electrode potential-pH diagrams and their applications Unit 6 [04 hrs]

Reaction kinetics: Arrhenius equation, order of reactions TEXT BOOKS: 1. D.R.Gaskell, Introduction to Thermodynamics of Materials, III Edition, MCGraw Hill Book

Co.Inc. 2. Ahindra Ghosh, Text book of Materials & Metallurgical Thermodynamics, Prentice Hall

India. REFERENCE BOOKS:

1. L.S.Darken and R.W.Gurry, Physical Chemistry of Metals, McGraw- Hill, 1958.

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2. R.H.Parker, An Introduction to Chemical Metallurgy: Pergamon Press, Inc. 3. G.S.Upadhya and R.K.Dubey, Problems in Metallurgical Thermodynamics and Kinetics,

Pergamon Press, Inc. 4. Thermodynamics of Materials Volume I and II, David V.Ragone, John Wiley & Sons,

Inc.1995

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MT204 PRINCIPLES OF METALWORKING



OBJECTIVES:

To make the students aware of strength of materials and their processing by mechanical working. To introduce the students about the improvement in metallurgical quality obtained by mechanical working.

Unit 1: [06]

Types of loading in materials used in engineering. Basic ideas about stress, direct stress, and shear stress. Hookes law for three dimensions. Stresses and strains in bodies under variety of loads and with varying dimensions. Thin cylinders under pressure. Hoop stress and longitudinal stress, Concept and determination of two dimensional principal planes and principal stresses, maximum shear stress. Unit 2: [06]

Mohrs circle of stress- two dimensions, numerical problems based on analytical and Mohrs circle method. System of a body under three dimensional stresses. Matrix representation of the state of stress under three dimensions, determination of principal stresses, principal planes and maximum shear stress for three dimensional state of stress, hydrostatic and deviator component of stress relationship, strain energy, stress concentration. Unit 3: [06]

Plastic deformation, flow curve, yielding criteria- Von Mises & Tresca, plastic stress-strain relations, plastic deformation of single crystal, CRSS, strain hardening, cold, hot and warm working processes, strain rate effect, metallurgical structure, friction and lubrication, hydrostatic pressure and workability. Unit 4 [06]

Classification of forming processes. Forces and geometrical relations in rolling. Projected length of contact. Neutral point. Forward slip and backward slip. Rolling force and rolling load. Angle of contact and angle of friction. Material spread in rolling. Torque and horsepower in rolling. Problems and defects in rolled products. Unit 5 [06]

Forging. Classification of forging processes. Forging equipment. Forging in plane strain. Open and closed die forging. Calculations of forging loads in closed die forging. Significance of flow lines, Residual forces in forging. Forging defects. Drawing of rods wires and tubes. Analysis of tube drawing, Temperature increase in wire drawing. Die wear. Water-cooling of dies. Residual stresses in drawn products. Unit 6 [6]

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Extrusion. Classification of extrusion processes. Extrusion equipment. Hot and Cold extrusion. Deformation and lubrication in extrusion. Analysis of extrusion process. Hydrostatic extrusion. Extrusion of tubing. Extrusion defects. Sheet metal forming and forming methods. Rubber forming. Shearing and blanking, Bending, Stretch forming, Deep drawing. Forming limit criteria. Defects in formed parts. Concept of machinability. TEXT BOOKS: 1. Mechanical Metallurgy, George E. Dieter, SI Metric Edition,1988, McGraw-Hill Book

Company. 2. Manufacturing Science Ghosh A., Mallik A.K., 1985, Affiliated East-West Press (P) Ltd.,

New Delhi. 3. Manufacturing Engineering and Technology, Serope kalpakjian, Steven R. Schmid,

International Edition, Fourth Edition, 2001, Prentice Hall International.

4. Metal Forming Process, Nagpal G.R., First Edition, 2000, Khanna Publishers, New Delhi. REFERENCE BOOKS:

1. Mechanical Working of Metals, Harris J. N., 1983 Jan 01, Pergamon Press, Elmsford, NY. 2. Principles of Industrial Metalworking Processes, Rowe G. W, 1977, Edward Arnold

Publishers, London. 3. ASM Metals Handbook Vol. IV (Forming), Metals Park, Ohio

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MT 208 Modeling of Engineering Materials


Lectures: 2 hrs/week Practical : 2 hr

100 marks: Assignment/Quiz -20, MSE 30(Theory), T/W 20, ESE 30(Practical)

OBJECTIVES: To understand the basics of modeling and computational simulation in

materials science and engineering

To study different tools such as matlab/scilab/spreadsheet for solving mathematical problems in materials and their processing

To find approximate solutions to the problems, to interpret and visualize the solutions.

Unit 1 (06) Introduction of modeling:

Setting up of mathematical model, Simple linear model:; Non-linear model and breakdown of analytical solutions; Integrated Computational Materials Engineering (ICME), structural scale, macroscale, mesoscale, microscale, nanoscale and electronic scale, solid mechanics and transport phenomena problems and their solutions by finite element, finite volume and finite difference partial differential equation Unit 2 (05)

Interpolation: Lagrange Interpolation, Newtons forward, backward and Stirlings central difference method, Newtons divided difference method, Inverse Interpolation. Applications. Numerical Differentiation: Forward, Backward and Central Difference Methods. Applications. Unit 3 (05)

Numerical Integration: Trapezoidal Rule, Simpson 1/3 and 3/8th Rule, Weddles Rule, Gauss Quadrature - Two and Three Point Formula. Applications. Curve Fitting: Least square criteria- 1st and 2nd Degree. Applications. Unit 4 (05) Partial Differential Equations:

Types of equations, Elliptic equations: Laplaces equation, Hyperbolic equations: Wave equations, Parabolic Equations: Diffusion, The Equation of continuity, The Diffusion equations: Applications in diffusion and mass transport in materials. Unit 5 (05) Monte Carlo Methods: Monte Carlo Random Number Generators, Monte-Carlo Integration, , Monte Carlo Method for simulating nucleation and growth of grains in materials

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TERMWORK:

List of Experiments (ANY 08):

1. Curve fitting and interpolation using spreadsheet program for finding relation between dependant variable and independent variable.

2. Linear models: Hooks Law, Hall-Petch Equation, Lever Rule, Arrhenius Equation for activation energy

3. Finding activation energy by Arrhenius equation, vacancy concentration, rate of reaction, Effect of temperature on diffusion coefficient

4. Application of Ficks law for carburizing and doping of semiconductors, use of interpolation of error function data.

5. 2 D model of conductive heat transfer 6. Data structure: Hume-Rothery rules for substitutional solid

solution 7. Curve plotting: Engineering stress-strain curve; determination of

different properties from it; plotting true stress-strain curve and determination of work hardening exponent. Effect of variation of work hardening exponent.

8. Application of lever rule on binary equilibrium diagram; Estimating microsegragation due to fast cooling rate.

9. Sieverts law for solubility of gases in liquid metal. 10. Pilling Bedworth model for oxide film growth 11. Application of Stokes law for slag removal in molten metal, 12. Bournaullis theorem: Application in gating system design for

casting 13. Finding surface area, volume and modulus of different shapes,

application of Chvorinovs rule for riser design, (casting software) 14. Image analysis tools for quantitative metallography (Source: ASM

Handbook) 15. Degree of polymerization 16. Design of energy efficient furnace 17. Estimation of MS, Mf, A3, temperature from composition of alloy

steels 18. Application of Monte Carlo methods for simulating nucleation and

growth of grains in materials 19. Determination of crystal structure (cubic) using Braggs law of X

ray diffraction 20. Phase field models of phase transitions and microstructure

formation, 21. molecular dynamics (MD), molecular statics (MS), 22. Monte Carlo (MC), and kinetic Monte Carlo (KMC) formulations, 23. Schrdinger equations, density functional theory, 24. Computational thermodynamics for prediction of equilibrium phase

diagrams

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Text Book: Chapra, S.C. & Canale, R. P., Numerical Methods for Engineers, Tata McGraw Hill

Publication ( 5th Edition ) Computational Materials Engineering, 1st Edition An Introduction to Microstructure Evolution,

Authors: Janssens, Raabe, Kozeschnik, Miodownik, Nestler, Published: 03 Aug 2007, Academic

Press ISBN: 9780123694683

Integrative Computational Materials Engineering Concepts and Applications of a Modular Simulation Platform, Edited by G.J. Schmitz and U. Prahl, Wiley, ISBN: 978-3-52733-081-2

Reference Books:

Balagurusamy, E., Numerical Methods, Tata McGraw Hill Publication. Rajaraman, V., Computer Oriented Numerical Methods, Prentice Hall of India Ltd. Sastry, S. S., Introductory Methods of Numerical Analysis, Prentice Hall of India Ltd.

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MT210 MECHANICAL TECHNOLOGY



OBJECTIVES: To apply fundamentals of Thermodynamics to various power producing and

power absorbing devices. To understand basic principle of fluid mechanics & application to pumps. To understand basic modes of heat transfer & to evaluate performance of heat

exchangers. Unit 1 (07) IC Engines: Air standard Otto, Diesel cycles, systems classifications of I.C. engines such as fuel supply system for SI & CI engines, ignition system, cooling system, lubrication system, Performance of IC Engine Indicated power, Brake power, Thermal efficiency, Specific fuel consumption. Unit 2 (07) Fuels: Boilers & steam Turbines: Boilers: Classification, Essential of a good boiler, Mounting and accessories, Efficiency calculations. Steam turbines: Types, construction, Working, Compounding, Velocity diagram, Calculation of diagram efficiency Unit 3 (07) Compressor & Gas turbine:

Compressor: Uses of compressed air. Reciprocating compressors- effect of clearance, FAD calculation, efficiency calculation, multistaging, Rotary compressors-elementary treatment. Gas Turbine: Classification, Brayton cycle, thermal efficiency Unit 4 (06) Pumps & Water turbine: Pumps: Rotary & reciprocating pumps,-construction & operation, pumps performance, their selection. Water Turbine: Types, constructional details Unit 5 (07) Machining of Materials: Machining basics, tool geometry, depth of cut, feed, speed, chip formation, machine tools like lathe, turning, knurling, screw cutting, drilling, milling, planning, grinding machines, factors affecting machinability, coolants, non-conventional machining processes like EDM, ECM, water jet and ultrasonic cutting.

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Unit 6 (06) Metrology: Interchangeability, limits, fits and tolerance, linear measurement, comparators, slip gauges, angular measurements, screw thread measurements, Surface roughness measurements, interferometer, profile projector. TEXT BOOKS: 1. R.K .Rajput, Thermal Engineering, Laxmi Publications. 2. Modi, Seth , Hydraulics And Hydraulics Machinary. 3. R. K. Jain, Engineering Metrology, Khanna Publisher, Delhi. 4. Nakra Choudhary, Instrumental Measurement and analysis, Tata McGraw Hill. 5. D. S. Kumar, Mechanical measurement and control ,Metropolitan N Delhi. 6. Chapman, Workshop technology vol. I,II & III, Edward Arnold Publication Ltd.

London 7. Hajara Chaudhari S.K., Workshop Technology, Vol. I & II, Media Prom &

Publication, Mumbai.. 8. R. K. Jain, Production technology, Khanna Publications. REFERENCE BOOKS: 1. Y.A. Cengel, Thermodynamics an Engineering approach, Tata McGraw Hill. 2. Eastop, Mcconkey, Applied Thermodynamics, Addison Wesley Longman

Publishers. 3. IS codes for vernier caliper, micrometers, slip gauges, angle gauges, limits, fits,

tolerances, gauges, geometrical tests etc. 4. Collette & Hope,Engineering Measurement, ELBS publisher 5. HMT Hand book- Production Technology 6. P. C. Sharma, Production Engineering, Khanna Publications.

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MT212 HEAT TREATMENT TECHNOLOGY LABORATORY


Laboratory: 2 hrs/week Term work: 50 Marks Oral: 50 Marks

Objective:

Correlation of equilibrium diagram, heat treatment, microstructure and properties,

student will be able to draw heat treatment cycles and predict resultant microstructure and properties

Instructions:

Student are not expected to draw microstructures, instead they will take digital microphotographs on image analyzer and describe them along with the properties achieved.

Wherever required, heat treatment thermal cycle must be drawn. List of Experiments: (Completing any 08 from given below)

1. Observation and description of microstructure of various stainless steels. 2. Observation and description of microstructure of typical alloy steels such as

micro-alloyed steel, dual phase steel, free cutting steel, bearing steel and maraging steel.

3. Performing annealing, normalizing and hardening heat treatment of steel samples; observation of microstructures and hardness.

4. Hardenability determination by Jominy End Quench test as per ASTM standard; estimation of hardenability using composition of steel.

5. Designing of Spheroidizing annealing cycle for eutectoid steel. 6. Performing Hardening and multiple tempering of High speed steel. 7. Design of isothermal heat treatment cycle using TTT/CCT diagram using

fluidized bed and salt bath furnace. 8. Performing surface heat treatments like carburizing, nitriding on steels;

estimating resultant case depth. 9. Design of precipitation hardening treatment of age hardenable aluminium alloys. 10. Case Study of defects due to heat treatment and remedial design changes.

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MT 214 PRINCIPLES OF METALWORKING LABORATORY




1. Effect of cold working and process annealing on microstructure and properties. (Set of 3 experiments by using 3 processes like cold rolling, swaging, wire drawing, and raw materials from copper, alpha brass, plain carbon steel and stainless steel.)

2. Effect of hot working on microstructure and properties (by using rolling process and 3 materials like alpha-beta brass, plain c steel and stainless steel.)

3. Study of open- and closed die forging processes. To perform open die forging of steel samples; observation of flow lines pattern of forged parts.

4. To determine formability of sheet metal using cupping test; to study and perform sheet metal working operations like deep drawing, stretch forming, shearing, blanking and bending.

5. Study of rolling mill, effect of rolling parameters on final product; defects in rolled products and their remedial measures.

6. Study of extrusion of aluminium and its alloys 7. Numerical problems based on strength of materials, plastic deformation, and

metal working processes.

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MT 216 MECHANICAL TECHNOLOGY LABORATORY




1. Study of Solex carburettor & Bosch type fuel injector pump. 2. Test on Diesel/Petrol engine to determine BP, bsfc, Brake thermal efficiency 3. Study of boiler mountings & accessories 4. Trial on reciprocating air compressor 5. Trial on centrifugal pump 6. Machining on Lathe , milling machine and drilling machine 7. Surface roughness, Angular, screw thread measurement (Any Two) 8. Interferometer, profile projector measurements (Any Two)

AS 204 PROFESSIONAL COMMUNICATION




ML 202 ENVIRONMENTAL STUDIES




Documents

SY BTech Metallurgy July2013