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ME 501 |
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Lecture |
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4 |
Year |
: II |
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Tutorials |
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0 |
Part |
: I |
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Practical |
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3/2 |
Course Objective:
To analyze the relationship between the structure and properties of ferrous alloys, non-ferrous alloys, polymer, ceramic and composite materials. Students will be able to select suitable material for different applications on the basis of their properties.
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1. |
Introduction to Materials |
(1 hour) |
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1.1 |
Types of Materials |
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1.2 |
Relationship among structures, processing and properties |
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1.3 |
Material selection for design |
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2. |
Atomic Structure, arrangement of atoms |
(8 hours) |
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2.1 |
Structure of atom, periodic table, binding energy and bonds |
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2.2 |
Atomic arrangements |
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2.2.1 |
Crystal and amorphous |
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2.2.2 |
Crystal geometry |
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2.2.3 |
Unit cell |
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2.2.4 Lattices, points, directions, planes in a unit cell |
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2.2.5 |
Millers’ indices |
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2.2.6 Allotropic and polymorphic transformation |
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2.3 |
Imperfections in the atomic arrangement |
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2.3.1 |
Imperfections |
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2.3.2 Point defects, surface defects, dislocation |
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2.3.3 Deformation by slip and twinning |
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2.3.4 |
Schmid’s Law |
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2.4 |
Movement of atoms in materials |
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2.4.1 |
Fick’s First Law |
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2.4.2 |
Fick’s Second Law |
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3. |
Mechanical Properties and their tests |
(9 hours) |
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3.1 |
Tensile Test |
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3.1.1 Load- Deformation Diagrams |
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3.1.2 Engineering stress-strain diagram for ductile and brittle materials |
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3.1.3 True stress-strain diagram |
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3.1.4 Properties tested from tensile test, temperature effects |
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3.1.5 Brittle behavior and notch effects. |
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3.2 |
Hardness Test |
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3.2.1 Main hardness testing methods |
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3.2.2 Brinell, Rockwell, Vickers, Knoop test |
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3.2.3Microhardness test, Hardness conversion table
3.3Impact Test
3.3.1Toughness
3.3.2Types of impact test, Charpy and Izod test
3.3.3Significance of Transition – Temperature curve, Notch sensitivity
3.4Fatigue Test
3.4.1Fatigue failure
3.4.2S-N curve, Endurance limit, Fatigue strength versus fatigue limit
3.4.3Preventions
3.5Creep Test
3.5.1Creep failure
3.5.2Creep and stress rupture curve
3.5.3Effect of temperature and stress level on creep life
3.5.4Preventions
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4. |
Deforming process for materials |
(6 hours) |
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4.1 |
Cold work |
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4.1.1 |
Cold work and its types |
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4.1.2 |
Strain Hardening and the stress-strain curve |
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4.1.3 |
Properties versus degree of Cold-work |
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4.1.4 |
Microstructure and residual stress in cold worked metals |
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4.2 |
Treatment after Cold-work |
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4.2.1 |
Annealing |
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4.2.2 |
Three stages of annealing (recovery, recrystallization and grain |
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growth) |
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4.3 |
Hot-work |
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4.3.1 |
Hot-work process and its types |
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4.3.2 |
Comparison between Hot-work and Cold-work |
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5. |
Solidification, Phase Relations and Strengthening Mechanism (7 hours) |
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5.1 |
Solidification |
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5.1.1 |
Nucleation and grain growth |
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5.1.2 |
Dendrite formation |
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5.1.3 |
Cooling curve |
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5.1.4 |
Under-cooling Cast structure |
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5.1.5 |
Solidification defect |
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5.1.6 |
Solid solutions, Solid solutions strengthening |
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5.2 |
Phase relations and equilibrium |
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5.2.1 |
Phase, phase rule |
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5.2.2 |
Phase diagram containing three- phase reactions |
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5.2.3 |
Lever rule, four important three phase reactions, and Eutectic phase |
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diagram |
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5.3 |
Strengthening Mechanism |
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5.3.1 |
Alloys strengthening by exceeding solubility limit |
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5.3.2 |
Age hardening or precipitation hardening |
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5.3.3Residual stress during quenching and heating
6.Iron – Iron Carbide diagram and Heat Treatment of Steels (10 hours)
6.1Iron – Iron Carbide Diagram
6.1.1Applications and limitations of Iron– Iron Carbide Diagram
6.1.2Different mixtures and phases ( ferrite, austenite, pearlite, martensite)
6.1.3Classification of steels and cast iron referring to Iron- Iron Carbide
Phase diagram
6.2Simple Heat Treatments
6.2.1Annealing and its types ( Full annealing, homogenizing, spheroidizing), their method, applications
6.2.2Normalizing method and its application, comparison between annealing and normalizing.
6.2.3Quenching ( method and application), quenching medium, hardenability, Jominy test, TTT diagram, CCT diagram
6.2.4Tempering, its types, applications
6.2.5Different types of surface hardening processes, nitriding, carburizing, cyaniding
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7. |
Types of steels and cast iron |
(3 hours) |
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7.1 |
Types of alloy steels |
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7.1.1 |
High-strength Low Alloy (HSLA) steel, Stainless steel, Tool Steel |
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7.1.2 |
Weldability of steels, Embrittlement phenomenon of steels |
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7.2 |
Cast Iron |
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7.2.1 |
Types of Cast Iron (gray, white, malleable, ductile) |
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7.2.2 |
Properties and application of Cast Iron |
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8. |
Environmental Effects |
(1 hour) |
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8.1 |
Galvanic and Stress corrosion, Corrosion protection |
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9. |
Non-ferrous Alloys |
(3 hours) |
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9.1 |
Aluminum alloys |
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9.2 |
Magnesium alloys |
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9.3 |
Copper alloys |
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9.4 |
Nickel alloys |
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9.5 |
Cobalt alloys |
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9.6 |
Titanium alloys, their properties and applications |
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9.7 |
Refractory metals and their alloys |
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10. |
Organic and Composite Materials |
(12 hours) |
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10.1Polymers
10.1.1Types of Polymer ( thermoplastic, thermosetts, elastomers),
10.1.2Comparison between them by structure, properties and applications
10.1.3Chain formation ( addition, condensation)
10.1.4Degree of polymerization
10.1.5Forming of polymers
10.1.6Additives to polymers
10.1.7Adhesives to polymers
10.2Ceramic Materials
10.2.1Crystalline Ceramic Structures and imperfections in it
10.2.2Silicate Structures
10.2.3Glasses and other non- crystalline ceramic materials
10.2.4Deformation and failures, Processing of Ceramics, Applications of ceramics
10.3Composite Materials
10.3.1Dispersion strengthening
10.3.2True particulate composites
10.3.3Fiber- Reinforced composites
10.3.4Laminar composite materials, examples and their application
10.3.5Wood, Concrete, Asphalt, types and uses
10.3.6Nanocomposites, types, examples and applications
Practical:
1.Macro examination of metals: Macrography to determine uniformity of composition, method of manufacture, physical defects.
2.Micro examination (metallography)
A.Selection and preparation of the specimen.
B.Application of heat treatment (full annealing, normalizing, quenching, tempering), etching, observation through metallurgical microscope to different specimens of ferrous and non-ferrous alloys.
3.Examination of Failure: Fatigue, Creep
4.Tests: Hardness Test (Brinell, Rockwell, Micro-hardness)
5.Mechanical Testing (tensile, compressive, impact) for ceramics and polymers
6.Strength Testing of Adhesives
References:
1.D. R. Askeland, “The Science and Engineering of Materials”, PWS- Kent Publishing Co., Boston,
2.Westerman Table ( IS Standard)
Evaluation Scheme:
The questions will cover all the chapters of the syllabus. The evaluation scheme will be as indicated in the table below:
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Unit |
Chapter |
Topics |
Marks |
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1 |
1, 2 & 7 |
all |
16 |
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2 |
3 & 9 |
all |
16 |
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3 |
4 & 5 |
all |
16 |
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4 |
6 & 8 |
all |
16 |
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5 |
10 |
all |
16 |
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Total |
80 |
