PEMP

EMM2512

EMM512

Engineering Materials and

Manufacturing Technology

Module Leader
Dr. N S Mahesh
Professor and Head
Dept of Mechanical and Manufacturing Engg

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Module Learning Objectives

On completion of this module the student should be able to:
• Arrive at material properties for the given application
and select appropriate materials
• Recommend suitable manufacturing process to produce
a component
• Analyse and match materials and manufacturing
processes
• Analyse the cause for component failure and suggest
suitable remedies from materials and process perspective
• Use CES software to select appropriate combination of
materials and manufacturing process for a specified
application
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Indicative content
• Materials in Manufacture of Engineering Components:
Materials in different service conditions, Material behaviour in such
conditions, Typical materials, Need for alternative materials,
Grouping/classification, Generic features and criteria for usage of
such materials.
• Introduction to Materials, Mechanical Behaviour and
Manufacturing Properties: Overview of materials and
manufacturing, classification of materials, Importance of
microstructure, Properties, Processing and performance, Integration
of design and manufacturing processes
• Structure and Strengthening Mechanisms in Metals:
Introduction to Dislocations, Strengthening mechanisms, Grain size
and grain boundary effects, Solid solution strengthening,
Precipitation strengthening, Cold working, Effect of strength by
heating or annealing, heat treatment processes.
• Ferrous Alloys : Ferrous alloys and its classification, Iron-Iron
Carbide diagram, AISI/SAE and UNS Designation Systems,
Manufacture of steel coil and sheet for the automobile industry,
Steel, High strength steel types, Ultra high strength steel, Cast iron
and types  M.S Ramaiah School of Advanced Studies - Bangalore 3
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Indicative content Contd…
• Nonferrous Alloys: Al alloys, Ti alloys, Mg alloys, Future
materials, Shape memory alloys, Nanomaterials.
• Polymers, Ceramics and Composites: Structure of polymers,
Different type of polymers, Properties of polymers, Applications of
polymers, Analyse the selection of manufacturing techniques for
different components, Different types of ceramics, Properties of
ceramics, Application of ceramics, Different forming techniques for
ceramics, Powder metallurgy process, Advantages of powder
metallurgy process, Composites materials, Classification, Properties,
Applications of composites, Manufacturing processes for PMC.
MMC, CMC
• Metal Casting Processes: Fundamentals of metal casting, Metal
casting processes, Sand casting, Die casting, Investment casting,
Continuous casting, Case studies
• Forming and Shaping Processes: Rolling, Forging, Extrusion,
Drawing, Sheet-metal forming, Sheet metal cutting and Bending,
Significance of Forming Limit Diagram (FLD),Different
technologies of tube and sheet hydro forming, Other forming
processes.
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EMM2512
Indicative content Contd…
• Material Removal Processes: Cutting tool materials and fluids,
Machining processes, Abrasive machining, Finishing processes
and Advanced machining processes- USM, EDM, ECM, PAM,
LBM, EBM.
• Joining Processes: Solid-state welding, Details of spot, Arc and
fusion welding technologies traditionally used for steel for the
assembly of panels into the body structure, Brazing and
Soldering techniques, Adhesive bonding and mechanical
fastening processes.
• Selection of Engineering Materials and Manufacturing
Processes: The basics of the material selection, Strategy for the
optimum selection of a material for a particular application
based on the case studies, Function, Shape, Process based
material selection criteria, Materials selection charts.

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Evaluation
• Assignment : 100 Marks (50% weightage)
• Written Exam : 100 Marks (50% weightage)

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Module Resources EMM2512

• Module Notes
• Reference Books:
[1] H Yamagata, “The science and technology of materials in
automotive engines”, Yamaha Motor Co Ltd, Japan
Woodhead Publishing Limited, 2005
[2] George E Dieter, “Mechanical Metallurgy”, SI Metric
Edition, McGraw-Hill, 1988
[3] Serope Kalpakjian, Steven R Schmid, Manufacturing
engineering and technology, Pearson Education 2003
[4] William D Callister, “Materials Science and Engineering an
Introduction”, sixth edition, John Wiley and sons, 2005
[5] S.H.Avner, “Introduction to Physical Metallurgy”, second
edition,Tata McGraw-Hill,2005
[6] J Geoff Davies, “Materials for automobile
bodies”,Butterworth-Heinemann publications, 2003
[7] James Brown,”Advanced Machining”, Tata McGraw-
Hill,1998
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[8] Lindberg, Roy A ,Processes and Materials of Manufacture,

4th Edition, Allyn and Bacon, 1990
[9] K. G. Budinski and M. K. Budinski, Engineering Materials
- Properties and Selection. Prentice-Hall,2006
[10] J A Charles, F A A Crane, J A G Furness, Selection and
use of engineering materials, third edition, Butterworth-
Heinemann publications, 2003
[11] M.F. Ashby, Materials Selection in Mechanical Design,
2nd Ed., Butterworth-Heinemann, 1999
[12] Mikell P. Groover, Fundamentals of Modern
Manufacturing: Materials, Processes, and Systems, 2nd
Edition Wiley Publication, 2005
13] James Brown,Advanced Machining, Tata McGraw-
Hill,1998
[14] Otsuka K, Wayman C, Shape Memory Materials,
Cambridge University Press, 1998
[15] R K Springborn, Non-traditional machining processes,
American society of tool and manufacturing engineers,
1967
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[16] R K Springborn, Non-traditional machining processes,, second

edition, E J Weller, Society of manufacturing engineers, 1984
[17] John Brydson, Plastic Materials, seventh edition, Butterworth-
Heinemann publications, 1999
[18] C A Harper, Handbook of plastics, elastomers and composites,
fourth edition, Tata McGraw-Hill,2002
[19] M. Van de Voorde, “Nanomaterials Characterization and Issues
to Address”, www.nanomaterials.com/voorde/, 2006
[20] T. Filetin, “An Overview of the Development and Application
of Advanced Materials”, Croatian Welding Soc, 2001
[21] Coatings for High-temperature Structural Materials: Trends
and Opportunities, 1996
[22] J. A. Brydson, “Plastic Materials”, Butterworth-Heinmann,
1999“Composites, ASM International -- The materials
Information Society”, Vol. 21, Materials park, Ohio, 2001.
[23]Suresh S., Mortensen A., Needleman A., “Fundamentals of
Metal Matrix Composites”, Butterworth-Heinemann, Boston,
MA, 1999.

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[24] Michael C.Y. Niu, “Composite Airframe structures”, Conmilit

Press Ltd, Hong Kong, 1992
[25] Jones R.M., “Mechanics of Composite Materials”, Taylor &
Francis Washington, 1999.
[26] Isaac M. Daniel, Ori Ishai,. “Engineering Mechanics of
Composite Materials”, Oxford University Press, New York,
1994.
[27] M. F. Amateau, ” Engineering Composite Materails”, 2003
[28] Aradhya K.S.S., Surappa M.K., “Scripta Metallurgica”, 1991,
Vol. 25, pp 817.
[29] Karl U. Krainer, “Metal Matrix Composites”, Wiley-VCH,
Verlag GmbH & Co.2006
[30] M. W. Barsoum, “Fundamentals of Ceramics”, McGraw-Hill,
1997
[31] G W Meetham and M H Van de Voorde, Materials for High
Temperature Engineering Applications, Springer,2000

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Journals EMM2512

• Journal of materials processing technology, Elsevier

publications
• ASME journal of manufacturing engineering, American Society
of Mechanical Engineers
• Manufacturing science and technology, Maney publications
• International journal of materials engineering innovations,
Inderscience publications
• International journal of materials sciences, Research India
publications
• International journal of materials and product technology,
Inderscience publications

Some useful sites

• www.sme.org
• www.asm.org
• www.asme.org
• www.alcoa.com

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