3
RD
Duration of Semester
Student Contact Hours
Sl.
No.
SCHEME OF TEACHING AND EXAMINATION FOR
SEMESTER OF 3 YEARS DIPLOMA IN METALLURGICAL ENGINEERING – MT
This scheme is valid for the student taking admission in academic session 2009-10 & 2010-11
:
Sixteen weeks (15+1*)
:
34hrs (Per week)
Theory & Practical is of period 60 minutes each
Name of Subject
Subject
Code
Teaching
Scheme
Subject
Examination Scheme
1.
Metallurgical Process
MT301
Theory
4
0
0
3
100
20
80
Pass
Marks
Final / Ext.
Exam
28
2.
Material Science
MT302
Theory
4
0
0
3
100
20
80
28
35
3.
Metallurgical Analysis
MT303
Theory
4
0
0
3
100
20
80
28
35
4.
Mineral Processing
MT304
Theory
4
0
0
3
100
20
80
28
35
5.
Fuels and Refractories
MT305
Theory
4
0
0
3
100
20
80
28
35
6.
Mineral Processing Lab
MT306
Practical
0
0
6
6
100
20
80
32
40
7.
Fuels Lab
MT307
Sessional
0
0
4
-
100
40
60
-
25
8.
Metallurgical Analysis Lab
MT308
Sessional
0
0
4
-
50
20
30
-
25
20
00
14
Total Hours of Teaching per week :
Total Marks
Theory
:
L
:
Committee Marks *
:
500
Lecture,
L
T
P
Hours
of
Exam
Full
Marks of
Subject
Internal
Assessment
Final / External
Exam / committee
marks *
750
Practical
T
:
:
100
Tutorial
Sessional
P
:
:
Pass Marks
in Subjects
35
150
Practical
1. The practical subjects (External examination) will be evaluated by an internal committee for 40% of the full
marks and 40% of full marks by an external committee.
2.
The sessional subject will be evaluated by an internal committee for 30% of the full marks and 30% of full marks by an external
committee.
* one week is assigned for internal assessment examinations.
METALLURGICAL PROCESS
Theory
L
T
P
4
0
0
Total Contact Hours : 60
Curri. Ref. No. MT301
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RATIONALE :
The ultimate aim of metallurgy is to obtain the metals from the natural resources in purified from for the
use of mankind. This requires the knowledge of different processes involved in the benefication of
natural resources and various principles involved in the recovery of pure metals. Therefore, it is a very
important topic in metallurgical engineering.
OBJECTIVES :
On completion of this paper, the students will be able to :
1.
Understand the different types of extraction and refining process employed for the
recovery of pure metals from ores.
2.
Apply the principles of metallurgical thermodynamics and kinetics in extraction process.
Sl. No.
1
2
3
4
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Introduction
Principle of metal Extraction
Pre-Treatment of Ores for Metal Extraction
General Methods of Extraction
Period
5
20
20
15
1.
Introduction
Definition of metal and metallurgy.
Scope of metallurgy.
Different Branches of metallurgy.
Classification of metallurgical processes, their salient features and applications.
2.
Principle of Metal Extraction
2.1
Principle of metallurgical thermodynamics
2.2
Application of thermodynamics laws to metallurgical processes.
2.3
Concept of free energy, enthalpy, entropy and entropy change of chemical reaction.
2.4
Ellingham diagram and its application.
2.5
Henery’s Law and Sivert’s law
2.6
Reaction Kinetic
2.6.1 Factors affecting rate of chemical reaction.
2.6.2 First order reaction and its application to metallurgical processes.
3.
Pre-Treatment of Ores for Metal Extraction
3.1
Drying – Principle, mechanism and factors affecting drying rate.
3.2
Introduction of Calcination, Roasting & Smelting
4.
General Method of Extraction
4.1
Introduction of Pyrometallurgy
4.2
Introduction of Hydrometallurgy
4.3
Introduction of Electrometallurgy
Books Recommended :
Sl. No.
1.
2.
3.
4.
5.
6.
7.
Name of Books
Elements of Metallurgy
Extractive Metallurgy
Principles of Extractive metallurgy
Authors
D. Swarup
J. Newtan
A. Ghosh and H. S.
Roy
Principles of Extractive Metallurgy
T. Rosenquist
Physical Chemistry of Iron and Steel C. Boodsworth
making
An introduction of Physical chemistry R. G. Ward
of Iron and Steel making
Metallurgical Thermodynamics
R. H. Tupkary.
Publisher
MATERIAL SCIENCE
Theory
L
T
P
4
0
0
Total Contact Hours : 60
Curri. Ref. No. MT302
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
Rapid technological developments in the field of new materials and their alloys make the task of
engineer or technician who wishes to select material for a particular job no easy one. He is required to
take into account not only relative costs and strength but also the conditions under which his product
will be working having regards to its resistance to wear and abrasion, oxidation and corrosion fatigue
and creep. The ease of working of fabricating the material and the heart treatment required to give the
most favorable combination of properties are also to be considered. The syllabus of “Material Science
and Technology” has been aimed to provide the students the fullest knowledge of behavior of metals in
different service conditions, evaluation of properties, properly changing treatments, shaping and joining
of metals.
OBJECTIVES :
The students will be able to
I
Select the materials which give the best overall combination of properties for the least
cost.
II
Decide the heat-treatment process for the products
III
Ensure the quality and reliability of products.
Sl. No.
1
2
3
4
5
6
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Atomic Bonding and crystal structure
Electrical & Electronic properties of materials
Magnetic materials
Glass and Ceramics
Polymers
Composite materials
Period
10
10
10
10
10
10
COURSE CONTENT
Material Science
1.
Atomic Bonding and crystal structure, miller Indices and Planes and direction. Types of bonding
and their effect on properties of materials. Structure of metallic and molecular crystals.
Introduction to Imperfection in crystals.
2.
Electrical and Electronics properties of materials.
Energy bond model for electrical conduction and its applications to conductors, semi conductors
and insulators, super conductors and their properties.
3.
Magnetic materials.
Magnetic properties, permeability, magnetization and effect of temperature on magnetic
properties, B. H. curve magnetic domains and its application to magnetic materials.
4.
Glass and Ceramics
Classification, structure and composition of ceramics and glasses, Mechanical, Electrical and
Electronic properties of Ceramics.
5.
Polymers
Mechanism of polymerization, structure of polymers & elastomers, natural and synthetic
rubbers.
6.
Composite Materials
Introduction of composite materials, type of composites, dispersed and fibre strengthened
composite materials, cermets, properties and application of composites.
Books Recommended :
Sl. No.
1.
Name of Books
Material Science & Processes
Authors
B. S. Narang
2.
Material Science & Processes
3.
Basic workshop Practices
R. Khurmi &
R. S. Sedha
J. K. Gupta
4.
A text book of material science & O. P. Khanna
metallurgy
Publisher
CBS Publishers &
Distributors, Delhi.
S. Chand & Co. Ltd.
New Delhi
S. Chand & Co. Ltd.
New Delhi
S. Chand & Co. Ltd.
New Delhi
METALLURGICAL ANALYSIS
Theory
L
T
P
4
0
0
Total Contact Hours : 60
Curri. Ref. No. MT303
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RETIONALE :
The Quality of product depends on quality of input materials. This subject imparts the knowledge and
develops the skill of students so that they can apply the analytical test procedures to input materials,
intermediate products and final products.
OBJECTIVES :
The students will acquire the knowledge of :
1.
2.
Chemical principle applied to analytical chemistry.
Working principle and caliberation of chemical equipments and analyse qualitatively and
Quantitatively ores, metals and alloys, slag and bye-products.
Sl. No.
1
2
3
4
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Sampling
Classical methods of analysis
Instruments methods of analysis
Analysis of ores, Flux, Alloys and Slag
1.0
Sampling
1.1
Sampling and its importance
1.2
Methods of Sampling
1.3
Sampling of Metallurgical raw materials, and products.
2.0
Classical Methods of Analysis
2.1
Qualitative analysis
2.1.1 Dry and wet test for Basic radicals.
Dry and wet test for Acid radical
2.2
Quantitative analysis
2.2.1 Volumetic method of analysis.
2.2.2 Gravimetric methods of analysis.
3.0
Instrumental Methods of Analysis
3.1
Colorimetric method
3.2
Spectroscopic method
3.3
Polarographic method
3.4
Potentiometric method
3.5
Electrochemical method.
4.0
Analysis of Ores, Flux, Alloys and Slag
4.1
Complete analysis of Iron-ore
Period
8
8
8
8
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
Complete analysis of Lime stone.
Complete analysis of Blast Furnace Slag.
Analysis of pig Iron and Plain Carbon Steel.
Estimation of Ni, Cr, and w in stainless Steel.
Estimation of Copper in Brass
Estimation of Tin in Bronze.
Fire Assaying of Silver and Gold.
Gas Analysis.
Books Recommended :
Sl. No.
1.
2.
Name of Books
Authors
Publisher
A Text Book of Metallurgical B. C. Agarwal and S. Khanna Publisher.
Analysis
P. Jain,
Qualitative Analysis
V. Alexive,
MIR Publisher.
MINERAL PROCESSING
Theory
L
T
P
4
0
0
Curri. Ref. No. MT304
Total Contact Hours : 60
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RATIONALE :
Ores and minerals are the sources of all metals and alloys. Ores and minerals, as available in nature are
mixed with various other substances and of odd sizes which are not suitable for various extraction
processes. Useable quality and size of ores/minerals are obtained by different processes called mineral
processing. Thus this subject is of great importance in the study of metallurgy.
OBJECTIVES :
After the completion of the course students should have the idea about the following :
1.
Ores and minerals of the metals and their resources.
2.
Size reduction operation of minerals
3.
Concentration methods based on the different physical and chemical/surface properties of ores.
Sl. No.
1
2
3
4
5
6
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Introduction
Communition
Sizing and Seperation
Gravity concentration
Flotation & Flocculation
Dewatering
Period
4
10
8
15
15
8
COURSE CONTENTS :
1.0
INTRODUCTION
1.1
Concept of ore, Mineral, Mineral Processing
1.2
Mineral resources in India.
1.3
Scope and objectives of mineral processing
1.4
Classification of mineral processing operation
2.0
COMMUNITION
Introduction of Communition & its their Mechanism.
Primary breaking operation and breaking units.
Intermediate Crushing
Grinding and Tumbling mills
Close and open circuit operation- advantages and limitations.
Reduction ration, machine specification, Cost and Capacity, Law of communition, Law or
product formula and problem based on them.
3.0
SIZING AND SEPARATION
Objectives of sizing, Methods and scale of sizing in laboratory.
Screen analysis, Methods of plotting and interpreting sizing curves, Industrial sizing.
Screening – types methods of capacity and limitation.
Classification – Law of classification, wet and dry methods, types of classifiers etc.
Magnetic Separation – Principle and application, dry and wet magnetic separations.
Electrostatic separation – Principle and application
4.0
GRAVITY CONCENTRATION
4.1
Principle of gravity concentration
4.2
Jigging – Theory of bedding and bed action during Jigging, Type of Jigs, there
performance and application.
4.3
Theory of Tabling
4.4
Heavy Media Separation.
4.5
Sprial concentrators.
5.0
FLOTATION AND FLOCCULATION
Physio – chemical principle of Flotation
Chemistry of Flotation reagents.
Flotation processes and Flotation Machine
Concentration of Copper, Lead and Zinc.
Flotation of Non-Sulphide ores of Copper, Lead, Dolomite etc.
Principle of Flocculation
Factors affective Flocculation
6.0
DEWATERING
Thickening and Sedimentation and Thickness.
Filtration
Driers – Hearth and Rotary Driers
Books Recommended :
Sl. No.
1.
2.
Name of Books
Principle of Mineral Dressing
Non-Ferrous Metallurgy
3.
4.
Mineral Processing Technology
Ore Processing
Authors
A. M. Gaudin
H. S. Ray, Shridhar
and Abraham
B. A. Wills
Jain
Publisher
FUELS AND REFRACTORIES
Theory
L
T
P
4
0
0
Total Contact Hours : 60
Curri. Ref. No. MT305
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RATIONALE :
For different metallurgical processes starting from extraction of metals from ores down to shaping and
treatment of metals, heating is an essential operation for which fuel is uses. To allow all these thermal
processes in a furnace, use of refractory is a must to contain heat and protect the furnace structure. Study
of fuel and refractory is thus a very important topic in Metallurgy.
OBJECTIVE :
After completion of this subject students will have knowledge about solid, liquid and gaseous fuels. He
will acquire idea about the manufacturing process and user of the above fuels. They will also acquire
idea about refractories as these refractories are essential for metallurgical furnaces. On completion of
study the students will have a knowledge about fuels and refractories.
Sl. No.
1
2
3
4
5
6
7
8
9
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Introduction
Solid Fuels
Liquid Fuels
Gaseous Fuels
Combustion of Fuels
Classification of Refractories
Furnaces
Insulating Materials
Application of Refractories
COURSE CONTENT
1.0
Introduction
1.1
Definition of Fuels
1.2
Classification of Fuels
1.3
Solid, Liquid and Gaseous Fuels – their advantages and disadvantages.
2.0
Solid Fuels
2.1
Classification of Solid Fuel
2.2
Wood, Charcoal, Peat, Lignite, Bituminous and Anthracite.
2.3
Coal
2.2.1 Origin of coal
2.2.2 Composition, Characteristics and significance of constituents.
2.2.3 Analysis of coal
2.2.4 Calorific value of coal
2.2.5 Classification of coal
2.4
coke
2.3.1 Coking and Non-coking coal
2.3.2 Carbonisation of coal
Period
5
5
5
5
8
8
8
8
8
2.3.3
2.3.4
2.3.5
2.5
Gasification of coal
Selection of Metallurgical coal
Testing of Coke
Pulvensed Fuel.
3.0
Liquid Fuels
3.1
Introduction and Classification of Liquid fuel.
4.0
Gaseous Fuels
4.1
Producer Gas
4.2
Water Gas
4.3
Coal Gas.
4.4
Liquified Petroleum Gas (LPG).
5.0
Combustion of Fuels
5.1
Principle of Combustion
5.2
Types of Combustion Process.
5.3
Simple Combustion calculation.
5.4
Gas Analysis and calorific value determination.
6.0
Classification of Refractories
6.1
Properties of refractories.
6.2
Classification of refractories.
6.3
Outline of the process of manufacturing a refractory brick.
6.4
Properties and uses of refractory Bricks.
6.4.1 Fire clay bricks.
Silica Bricks
Alumina Bricks
Chromite Bricks
Magnetise Bricks
Dolomite Bricks
Graphite Bricks
7.0
Furnaces
7.1
Introduction, Application of Furnaces
7.2
Different types of Furnaces
7.2.1 Muffle Furnace
7.2.2 Cupola Furnace
7.2.3 Electric arc Furnace
7.2.4 Induction Furnace
8.0
Insulating Materials
8.1
Properties and uses of Insulating Material.
9.0
Application of Refractories
9.1
Criteria for selection of refractory
9.2
Selection of refractories for various Furnaces/Industries.
Books Recommended :
Sl. No.
1.
2.
3.
4.
Name of Books
Authors
Elements of Fuels, Furnaces and O. P. Gupta,
Refractories
Refractories
Cheisty
Refractories
M. L. Mishra
Fuels and Combustion
Samir Sarkar
Publisher
Khanna Publisher
MINERAL PROCESSING LAB
L
T
P
0
0
4
Total Contact Hours : 60
Curri. Ref. No. MT306
Total Marks :100
Practical :
End Term Exam : -80
(Int. comm. :40,EXt. comm. :40)
I.A. : 20
RATIONALE AND OBJECTIVES :
Same as Theory Paper.
Any five experiments are to be performed from the following –
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
To study the working of laboratory Jaw crusher and determine the efficiency and capacity of the
crusher and reduction ration.
To study the working of laboratory Roll crusher and determine the efficiency and capacity of the
crusher and reduction ratio.
To study the working of a Ball mill and the effect of critical speed, time and ball charges on
grinding.
To compare the efficiency of different sampling methods used according to size and mass of the
sample.
To study the working principle of a dry magnetic separator and determine the efficiency of the
separation.
To study the principle of flotation and concentration of Lead Zinc ore and Copper ore by this
method.
To study the working principle of wilfley table and determine the efficiency of the process,
effect of inclination and flow rate of water.
Size Analysis by dry and wet sieving and comparison of process.
To study the setting characteristic of different minerals.
To study the effect of pulp density and size analysis of solid on the filtration characteristic of
different minerals.
To study the working principle of a wet magnetic separate and determine the efficiency of the
process, effect of magnetic field intensity feed rate and pulp density on separation.
To study the working of a Hydraulic classifier and the water sizing of a given ore sample.
To study the working principle of Jig and concentration of an ore by Jigging process.
Books Recommended :
Same as theory paper.
FUELS LAB
L
T
S
0
0
4
Total Contact Hours : 60
Curri. Ref. No. MT307
Total Marks :100
Practical :
End Term Exam : -(Int. comm. :30,EXt. comm. :30)
I.A. : 40
LIST OF EXPERIMENTS :
Any Seven of the following experiments are to be performed :1.
2.
3.
4.
5.
6.
7.
8.
9.
Determination of Calorific value of Coal.
Proximate analysis of coal.
Determination of Viscosity of a liquid fuel.
Determination of flash point and fire point of a fuel oil.
To study the Inedibility characteristics of different coal samples.
To study the washability characteristics of different coal sample.
Determination of Coking property of different coking coal samples.
Determination of swelling Index of different types of coal samples.
To study the effect of pulsion and suction cycle on separation by Jigging.
Books Recommended :
Same as theory paper
METALLURGICAL ANALYSIS LAB
L
T
S
0
0
4
Total Contact Hours : 60
Curri. Ref. No. MT308
Total Marks :50
Practical :
End Term Exam : -(Int. comm. :15,EXt. comm. :15)
I.A. : 20
RATIONALE AND OBJECTIVES :
The students will be able to develop the skill of :1.
Caliberating the analytical instruments.
2.
Performing the quantitative as well as quantitative analysis of common, ores, metals, alloys, flur
slag etc.
LIST OF EXPERIMENTS :
The following experiments are required to be performed :
1.
Complete analysis of Iron-ore.
2.
Complete analysis of line stone.
3.
Estimation of C and S in Pig-Iron or Steel.
4.
Estimation of Si and P in Pig-Iron or Steel.
5.
Estimation of sulphor in pig-Iron or Steel.
6.
Estimation of Mn in pig-Iron or Steel.
7.
Estimation of Cu & Zn in Brass.
8.
Estimation of Cu & Sn in Bronze.
9.
Estimation of Ph & Sn in Solder alloy.
10.
Complete analysis of Blast Furnace slag.
Books Recommended :
Same as in the theory paper.
4
th
Duration of Semester
Student Contact Hours
Sl.
No.
SCHEME OF TEACHING AND EXAMINATION FOR
SEMESTER OF 3 YEARS DIPLOMA IN METALLURGICAL ENGINEERING – MT
This scheme is valid for the student taking admission in academic session 2009-10 & 2010-11
:
Sixteen weeks (15+1*)
:
34hrs (Per week)
Theory & Practical is of period 60 minutes each
Name of Subject
Subject
Code
Teaching
Scheme
Subject
Examination Scheme
L
T
P
Hours
of
Exam
Full
Marks of
Subject
Internal
Assessment
Final / External
Exam / committee
marks *
1.
Iron Making
MT401
Theory
4
0
0
3
100
20
80
Pass
Marks
Final / Ext.
Exam
28
Pass Marks
in Subjects
2.
Physical Metallurgy
MT402
Theory
4
1
0
3
100
20
80
28
35
3.
Material Testing
MT403
Theory
4
0
0
3
100
20
80
28
35
4.
Phase Transformation in
MT404
Theory
4
1
0
3
100
20
80
28
35
35
metals & alloys
5.
Physical Metallurgy Lab
MT405
Practical
0
0
4
6
100
20
80
32
40
6.
Material Testing Lab
MT406
Sessional
0
0
4
-
100
40
60
-
50
7.
Metallurgical sketches &
MT407
Practical
0
0
4
6
100
20
80
32
40
MT408
Sessional
0
0
4
-
50
20
30
-
25
16
02
16
calculation
8.
Technical Seminar
Total Hours of Teaching per week :
Total Marks
Theory
:
L
:
Committee Marks *
:
400
Lecture,
750
Practical
T
:
:
200
Tutorial
Sessional
P
:
:
150
Practical
1. The practical subjects (External examination) will be evaluated by an internal committee for 40% of the full
marks and 40% of full marks by an external committee.
2.
The sessional subject will be evaluated by an internal committee for 30% of the full marks and 30% of full marks by an external
committee.
* one week is assigned for internal assessment examinations.
IRON MAKING
Theory
L
T
P
4
0
0
Total Contact Hours : 60
Curri. Ref. No. MT 401
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RATIONALE :
It is very difficult to imagine life without iron and steel, which forms the back bone of modern society.
The whole frame work of the present day industrialization, mechanized agriculture, transport,
communication and construction works is based on iron and steel, Therefore the knowledge of various
types of extraction methods or iron and its physical-chemical concept are essential for a metallurgical
diploma holders. This paper aims at providing the basic knowledge and practical adopted in our Indian
iron and steel plants for the production of various grades of commercial iron.
OBJECTIVES :
The subject matter in this paper has been designed to provide the knowledge of :
1.
Lay-Out of a blast furnace shop
2.
Raw materials and their chemical analysis
3.
Constructions and operational details of Blast furnace
4.
Burden calculation and slag analysis
5.
Powering and teeming Practice
6.
Blast furnace irregularities and their remedial measures.
7.
Ultimately the students will develop the following skills :a)
Operate the Blast furnace
b)
Control the chemical composition of raw materials and pig iron and slag.
c)
Calculation the burden for the Blast furnace
d)
Control the process governing parameters.
Sl. No.
1
2
3
4
5
6
7
8
9
10
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Introduction
Raw Material for Iron making
Agglomeration of Iron types
Blast Furnace and its Accessories
Blast Furnace operation
Blast Furnace Reaction
Blast Furnace irregularities
Modern development of Blast Furnace operation
Blast Furnace Products
Production of Fe-alloys
Period
3
5
5
5
10
8
6
6
6
6
COURSE CONTENT
Topic 1 INTRODUCTION – Iron & Steel making in India with special reference to present capacity
and technology adopted by them.
2.
RAW MATERIALS FOR IRON MAKING :- Iron ores, coal and coke, flaxes and its types,
Beneficiation of Iron ores.
3.
AGGLOMERATION OF IRON ORES :- Sintering and Pelletization – their effect on
operation of Blast Furnace.
4.
BLAST FURNACE AND ITS ACCESSORIES :- Construction of Blast furnace, Hot Blast
stores, B/F Gas cleaning plant.
5.
BLAST FURNACE OPERATION :- Blowing in, Blowing out, Tapping, Fanning, Back
drafting.
6.
BLAST FURNACE REACTION :- Thermal, Chemical and Physical profile of Blast furnace,
Reaction in Upper, Middle, lower and combustion zone.
7.
BLAST FURNACE IRREGULARITIES :- Their causes and remedies.
8.
MODERN DEVELOPMENT OF BLAST FURNACE OPERATION :- Bell – less charging,
High- Top Pressure, Humidified Blast, Oxygen Enrichment, External Desiliconisation, External
Desulphurisation etc.
9.
BLAST FURNACE PRODUCTS :- Hot metal, Blast Furnace slag, Blast Furnace Gas.
10.
PRODUCTION OF FE-ALLOYS :- Production of Fe-Cr, Fe-Si, Fe-Mn, Fe-Ti. Etc.
PHYSICAL METALLURGY
Theory
L
T
P
4
1
0
Total Contact Hours : 75
Curri. Ref. No. MT402
Total Marks : 100
Theory :
Theory : 60
Tutorial : 15
End Term Exam : 80
I.A. : 20
RATIONALE :
The metallurgical technician has to select and develop various metals and alloys for the various
purposes. Therefore the knowledge of Physical and structure properties metals and alloys are essential.
This subject aims to provided them required knowledge and skill.
OBJECTIVES :
The study of this paper will help the students to know :
1.
The physical properties and related mechanical properties of metals and alloys.
2.
Solidification, Crystal structures and equilibrium diagrams of metals and alloys.
3.
Technique of preparing sample for macro and micro examination.
4.
Phase Transformation mechanism.
5.
Chemical properties and uses of commercial Ferrous and Non-Ferrous metals/alloys.
6.
Different types of microscopes used in metallography.
Sl. No.
1
2
3
4
5
6
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Structure of Alloys
Solidification of Pure Metals and Alloys
Equilibrium diagram
Iron-Carbon System
Commercial Ferrous & Non-Ferrous Alloys
Metallography
Period
10
10
10
10
10
10
COURSE CONTENT
1.0
Structure of Alloys
1.1
Types of Solid solution
1.2
Factors governing formation of Solid solution.
1.3
Concept of chemical compound, Hume-Ruthery compound, Intermediate phases,
Mechanical mixture and intermetallic compound.
2.0
Equilibrium Diagram
2.1
Introduction
2.2
Phase Rule and Lever Rule and their application
2.3
Types of Invariant Reactions
2.4
2.5
3.5.1
3.5.2
3.5.3
3.5.4
2.4
Construction and interpretation of equilibrium diagram.
Types of equilibrium diagram.
Isomorphous
Eutectic
Eutectoid
Peritectic
Some typical equilibrium diagram of Fe-C, Cu-Zn, Cu-Sn and Al-Si, Al-Cu
3.0
Iron – Carbon System
3.1
Allotropic modification of Iron.
3.2
Micro-Constituents of Cast Iron and Steel.
3.3
Construction and interpretation of Iron-Carbon Equilibrium diagram.
4.0
Commercial Ferrous and Non-Ferrous Alloys
Chemical Composition, Properties, Metallographic studies and ISI and BS code of4.1
Plain Carbon Steels
4.2
Alloy Steels
4.3
Cast Iron
4.4
Brasses
4.5
Bronzes
4.6
Beaning Metals
4.7
Solder Alloys.
5.0
Metallography
5.1
Introduction and definition of metallography.
5.2
Types of Metallography.
5.3
Instruments of Metallography.
5.3.1 Construction and working principle of metallurgical microscope.
Construction and working principle of Electron microscope.
Elementary principle of photomicrography.
Preparation of Sample for micro examination.
Preparation of Sample for macro examination.
Books Recommended :
Sl. No.
1
2
3
4
5
Name of Books
Engineering Physical Metallurgy
Physical Metallurgy
Physical Metallurgy for Engineers
Principles
of
Metallographic
Laboratory Practice
Practical Physical Metallurgy
Authors
Lakhtin
Read Hill
Clark and Varney
G. H. Kehl.
S. Bhan
Publisher
MATERIAL TESTING
Theory
L
T
P
4
0
0
Curri. Ref. No. MT403
Total Contact Hours : 60
Total Marks : 100
Theory : 60
Theory :
End Term Exam : 80
I.A. : 20
RATIONALE :
The practical applications of materials and alloys depend upon its mechanical and structural properties
like tensile strength hardness toughness, cracis, brittleness, fatique, creep strength etc. This subject aims
at dealing with the theory and methodology lasting procedure of various metals alloys.
OBJECTIVE :
1.
In give knowledge of a.
Testing operation of machine and equipment
b.
Principle and methods of various destructive and non-destructive testing.
c.
Calibration of machines and interpretation of test result.
2.
To develop skill of a.
Operation and various destructive and non-destructive testing machines.
b.
Report preparation and data analysis etc.
Sl. No.
1
2
3
4
5
6
7
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Introduction
Tensile Test
Hardness Test
Impact Test
Fatigue Test
Creep Test
Non-Destructive Tests
Period
2
8
8
8
8
8
18
COURSE CONTENT
1.
1.1
1.2
Topic 1 INTRODUCTION
Importance of material testing
Destructive and Non-Destructive tests- Comparison, Advantages and Disadvantages, and
Application.
2.
2.1
2.2
2.3
Topic 2 TENSILE TEST
Concept of stress, Strain, Elasticity, Plasticity and Hooke’s law.
Steady of tensile testing machine.
Procedure and Interpretation of test result.
3.
3.1
3.2
3.3
Topic 3 HARDNESS TEST
Brinell hardness testing machine. Operation and testing procedure Brinell hardness test.
Rock well hardness testing machine. Operation and testing procedure.
Vicker’s diamond testing machine, Shore and Micro hardness testing machine-process and
limitation.
4.
4.1
4.2
4.3
Topic 4 IMPACT TEST
Concept and Importance of Impact Strength
Procedure of Charpy and Izod Impact test.
Factors affecting Impact value.
5.
5.1
5.2
5.3
5.4
Topic 5 FATIGUE TEST
Concept of different Stress cycles.
S-N curve and Endurance Limit.
Fatigue testing machine and test procedure.
Metallurgical factors affecting Fatigue behavior of metals and Alloys.
6.
6.1
6.2
6.3
6.4
6.5
Topic 6 CREEP TEST
Concept and importance of Creep Properties.
Creep discussion of engineering Creep curve.
Description of Creep testing machine and test procedure.
Factors affecting Creep properties and metals and loys.
Stress – Rupture Test.
7.
Topic 7 NON-DESTRUCTIVE TESTS
Description of the following Non-Destructive tests with reference to test procedure, advantages,
disadvantages and applications.
Visual test
Leakage test
Magnetic particle testing
Dye penetration test
Acoustic methods and ultrasonic testing
Eddy current testing
X-ray diffraction.
a.
b.
c.
d.
e.
f.
g.
Books Recommended :
Sl. No.
1
2
3
4
5
Name of Books
Testing of Metallic Material
Mechanical Metallurgy
Introduction to Physical Metallurgy
X-ray diffraction
Experimental Technique in Physical
Metallurgy by
Authors
Surya Narayan
Dieter
Avner
B. D. Culity
V. T. Cherepis & A. K.
Mallick.
Publisher
PHASE TRANSFORMATION IN METAL & ALLOYS
Theory
L
T
P
4
1
0
Total Contact Hours : 75
Curri. Ref. No. MT404
Total Marks : 100
Theory :
Theory : 60
Tutorial: 15
End Term Exam : 80
I.A. : 20
RATIONALE :
The practical applications of materials and alloys depend upon its mechanical and structural properties
like tensile strength hardness toughness, cracis, brittleness, fatique, creep strength etc. This subject aims
at dealing with the theory and methodology lasting procedure of various metal alloys.
OBJECTIVES:
1.
In give knowledge of a.
Testing operation of machine and equipment
b.
Principle and methods of various destructive and non destructive testing.
c.
Calibration of machines and interpretation of test result.
2.
To develop skill of a.
Operation and various destructive and non-destructive testing machines.
b.
Report preparation and data analysis etc.
Sl. No.
1
2
3
4
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Solidification of Pure Metals and Alloys
Mechanism of solidification
Diffusion in solids
Solid State Phase Transformation
Period
15
15
15
15
1.0
Solidification of Pure Metals and Alloys
1.1
Alloys, Solid solution
1.2
Solidification and Crystallization
1.3
Role of Free energy Thermodynamic potential in conversion of liquid to solid.
1.4
Super cooling, Under cooling, Degree of super cooling.
2.0
Mechanism of solidification
2.1
Crystallization, Nucleation, Critical size nucleus.
2.2
Spontaneous nucleation.
2.3
Relation between rate of nucleation and grain growth.
2.4
Homogenous and Heterogeneous Solidification.
3.0
Diffusion in solids
3.1
Introduction
3.2
3.3
3.4
3.5
3.6
4.0
Concept, importance and types of diffusion.
Laws of diffusion
Diffusion Mechanism
Variables affecting diffusion.
Application of diffusion
Solid State Phase Transformation
4.1
Types of phase transformation
4.2
Formation of Austenite
4.3
Austenitic Grain size
4.4
Pearlitic Transformation.
4.5
Bainitic Transformation.
4.6
martensitic Transformation.
4.7
Precipitation and Age Hardening
4.8
Recovery, Recrystallization and Grain Growth.
PHYSICAL METALLURGY LAB
L
T
P
0
0
4
Total Contact Hours : 60
Curri. Ref. No. MT405
Total Marks :100
Practical :
End Term Exam : 80
(Int. comm. :40,EXt. comm. :40)
I.A. : 20
RATIONAL AND OBJECTIVES :
The purpose of performing the practicals in this subject will impart the students to develop the following
skills.
1.
To operate metallurgical microscope
2.
To draw equilibrium diagram and interpret the effect of temperature and chemical composition
on the properties of metals and alloys.
3.
To identify and estimate approximately the micro and macro constituents in the given sample of
metals and alloys.
4.
To prepare test sample for macro and micro studies.
LIST OF EXPERIMENTS :
The following experiments are required to be performed :
1.
Study of metallurgical microscope and a specimen polishing machine.
2.
Study of mounting press and mounting specimen.
3.
Preparation of sample for macro work.
4.
Preparation of sample for micro work.
5.
Study of micro structure of at least twenty sample of ferrous and Non-Ferrous metals and alloys
under different conditions.
Books Recommended :
Same as in the theory paper.
MATERIAL TESTING LAB
L
T
S
0
0
4
Total Contact Hours : 60
Curri. Ref. No. MT406
Total Marks : 100
Sessional :
End Term Exam : (Int. comm. :30,EXt. comm. :30)
I.A. :40
RATIONAL AND OBJECTIVES :
Same as Theory Papers.
At least Five Experiments out of the following should be performed :
1.
2.
3.
4.
5.
6.
7.
8.
9.
To study the universal testing machine and to determine the tensile strength of steel and NonFerrous metals and alloys.
To study Brinell Hardness machine and to determine the Brinell Hardness of steel and NonFerrous metals and loys.
To study the Vicker’s Hardness machine and to determine the vicker’s Hardness of metals and
loys.
To study the Rock well Hardness machine and to d etermine the Rock well Hardness of metals
and loys.
To study Charpy Impact testing machine and to determine the Charpy Impact Value of Steel and
cast Iron.
To study Izod Impact testing machine and to determine the Izod Impact Value of Steel and Cast
Iron.
To study the ultrasonic testing machine and to determine the Flaws in a given material.
To study the Magnetic Particle testing machine and to determine the defects in a given materials.
To study the Fatigue Testing machine and to determine the Fatigue strength of a given metal or
an alloy.
Books Recommended :
Same as Theory papers
METALLURGICAL SKETCHES & CALCULATIONS
L
T
P
0
0
4
Total Contact Hours : 60
Sl. No.
1
2
1.
2.
Curri. Ref. No. MT407
Total Marks :100
Practical :
End Term Exam : 80
(Int. comm. :40,EXt. comm. :40)
I.A. : 20
TOPIC WISE DISTRIBUTION OF PERIODS
Topic
Sketches
Calculation
Sketches :











Cupola furnace
Blast furnace
Reverberatory furnace and air furnace
Converter
Open hearth furnace
Induction furnace
Pit furnace
Low shaft furnace
Muffle furnace
Crucible furnace
Rotary kiln





Calculation – Calculation based on following Burden calculation based on Blast Furnace
Calculation based on Calorific value and Combustion of Fuels.
Calculation based on melting and heating furnaces.
Calculation based on Cupola and LD converter.
Calculation based on Rolling and Forging operations.
Period
35
25
TECHNICAL SEMINAR & LIBRARY
L
0
T
0
S
4
Total Contact Hours : 60
Curri. Ref. No. MT 408
Total Marks : 50
Technical Seminar Topics :
1.
2.
3.
4.
5.
6.
7.
8.
9.
Industrial safety
Environment
Any technical topic and their application
Any processing industries
Industrial visit
Newer technology
Energy conservations and renewable energy
Synopsis of forth coming project work.
Any relevant topic with concerned to department
Sessional :
End Term Exam : (Int. comm. :15,Ext. comm. :15)
I.A. : 20