Unit I :Overview of Metallurgy
Methods of metal extraction (Principle only of pyro , hydro & electro metallurgy), cast v/s wrought products, Related terms and their definitions : System, Phase, Variable, Component, Alloy, Solid solution, Hume Ruther's rule of solid solubility, Allotropy and polymorphism, Concept of solidification of pure metals & alloys, Nucleation : homogeneous and heterogeneous,Dendritic growth, super cooling, equiaxed and columnar grains, grain & grain boundary effect.Cooling curves, Plotting of Equilibrium diagrams, Lever rule, Coring, Eutectic system, Partial eutectic and isomorphous system. (Chapter - 1)
Unit II : Micro & Macroscopic Study of Metals
Classification of metal observations : their definition, difference & importance.Microscopy : Various sampling techniques, specimen preparation, specimen mounting (hot & cold mounting) electrolytic polishing, etching procedure and reagents, electrolytic etching. Microscopic techniques : optical microscopy, electron microscopy, Transmission Electron Microscopy (TEM), Scanning Electron Microscopy (SEM), Scanning Probe Microscopy
(SPM ), AFM etc. ( principal & application only )Study of Metallurgical microscope. Measurement of grain size by different methods & effect of grain size on various mechanical properties.Macroscopy : Sulphur printing, flow line observations, spark test. (Chapter - 2)
Unit III :Iron-Carbon Alloy System & Cast Iron
Iron-iron carbide equilibrium diagram, critical temperatures, solidification and microstructure of slowly cooled steels, structure & property relationship, classification and application of steels.Cast Irons: Classification, Manufacturing, Composition , Properties & applications of white C.I., Grey cast iron, malleable C.I., S.G. cast iron, chilled and alloy cast iron, effect of various parameters on structure and properties of cast irons. Specific applications such as machine tools, automobiles, pumps, valves etc.
Introduction to non-equilibrium cooling of steels, widmanstaten structure.
(Chapters - 3, 4)
Unit IV :Heat- Treatment of Steels
Transformation products of Austenite, Time Temperature Transformation diagrams, critical cooling rate, continuous cooling transformation diagrams. Heat treatment of steels: Annealing, Normalising, Hardening & Tempering, quenching media, other treatments such as Martempering, Austempering, Patenting, Ausforming. Retention of austenite, effects of retained austenite. Elimination of retained austenite (Subzero treatment). Secondary hardening, temper embrittlement, quench cracks, Hardenability & hardenability testing, Defects due to heat treatment and remedial measures.
Classification of surface hardening treatments, Carburising, heat treatment after Carburizing, Nitriding, Carbo-nitriding, Flame hardening, and Induction hardening. (Chapters - 5, 6)
Unit V :Engineering Alloy Steels & Designation
Classification of alloy steels & Effect of alloying elements, examples of alloy steels, stainless steels, sensitization & weld decay of stainless steel, tool steels, heat treatment of high speed steel, special purpose steels with applications, super alloys. Heat affected zone. Designation (for plane & alloy steels) : IS, AISI, SAE, DIN etc. (Chapter - 7)
Unit VI :Non Ferrous Metals
Classification of nonferrous metals. Importance of nonferrous metals in engineering applications & compositions, study of different mechanical properties: Cu & Cu based alloys, Al and Al based alloys, Ni and Ni based alloys, Co and Co based alloys, Titanium & its alloys, Tin & Lead base alloys, Bearing materials: important properties & applications. (Chapter - 8)