Advanced Techniques & Industries

1 Review of Basic Metallurgy & Manufacturing Techniques

1.1 Basic Metallurgy
1.1.1 Atoms and electronic configurations
1.1.2 Atomic Bonds
1.1.3 Crystal structure of metals
1.1.4 Equilibrium diagrams
1.1.5 Equilibrium and non-equilibrium cooling of steel
1.1.6 Heat treatment processes of steel
1.1.7 Alloying of steels
1.1.8 Nonferrous metals and alloys
1.2 Basic Manufacturing Processes
1.2.1 Casting
1.2.2 Forming
1.2.3 Welding
1.2.4 Machining
1.3 Basic mechanical properties and testing of materials
1.3.1 Tensile properties
1.3.2 Flexure properties
1.3.3 Hardness properties
1.3.4 Impact properties
1.3.5 Fatigue properties
2 Metallurgy of welding
2.1 Metallurgical joining methods
2.2 Soldering
2.3 Brazing
2.4 Welding
2.5 Fusion welding and metal cutting
2.5.1 Electric arc welding
2.5.2 Gas welding and flame cutting
2.5.3 Electroslag welding
2.5.4 Welding using exothermic reaction
2.5.5 Welding using high energy beams
2.5.6 Resistance fusion welding
2.6 Solid phase welding
2.6.1 Butt welding
2.6.2 Friction welding
2.6.3 Indent lap welding
2.6.4 Diffusion welding
2.6.5 High frequency welding
2.6.6 Explosive welding
2.7 Structure of fusion welds
2.8 Thermal treatment of welds
2.9 Weldability of metals and alloys
2.10 Welding defects
2.11 Factors in design of weldments
2.12 Weldments vs. casting and forging
2.13 Adhesives
2.14 Special applications
2.14.1 Welding of cast iron
2.14.2 Welding of stainless steels
2.15 Industrial applications
2.15.1 Electronic circuits and printed circuits borders
2.15.2 Cemented carbide tips and machining tools
2.15.3 Built-up sections and steel structures

3 Metallurgy of casting
3.1 Inherent characteristic of casting
3.2 Casting design
3.3 Steel casting
3.4 Heat treatment of steel casting
3.5 Gray cast iron
3.6 Nonferrous castings
3.7 Permanent-mold castings
3.8 Shell-mold castings
3.9 Plaster mold castings
3.10 Die castings
3.11 Precision investment castings
3.12 Centrifugal castings

4 Powder Metallurgy
4.1 Powders manufacturing
4.1.1 Preparations of metal powders
4.1.2 Characteristics of metal powders
4.2 Powder Metallurgy processes
4.2.1 Mixing
4.2.2 Compaction
4.2.2.1 Die compaction
4.2.2.2 Isotactic compaction
4.2.2.3 High-energy-rate techniques
4.2.2.4 Forging and extrusion techniques
4.2.2.5 Vibratory compaction
4.2.2.6 Continuous compaction
4.2.2.7 Slip casting
4.2.2.8 Gravity compaction
4.2.2.9 Continuous pressureless compaction
4.2.3 Sintering
4.2.4 Hot pressing
4.2.5 Supplemental operations
4.3 Design of P/M parts
4.4 Special applications
4.4.1 Pours components
4.4.2 High temperature metals and alloys
4.4.3 Duplex and composite materials
4.5 Industrial applications
4.5.1 Tungsten filaments
4.5.2 Filters
4.5.3 Cemented carbide
4.5.4 High density penetrators

5 Failure & fracture analysis

5.1 Failure analysis procedure
5.2 Mode of fracture
5.2.1 Ductile fracture
5.2.2 Brittle Fracture
5.3 Stress and strength
5.4 Type of loading
5.5 Fatigue fractures
5.5.1 Effect of stress raisers
5.5.2 Effect of strength reducers
5.5.3 Effect of residual stresses
5.5.4 Other variables
5.6 Bending fractures
5.7 Torsional failures
5.8 Classification summery of failure causes

6 Metals at high & low temperatures (Option)

6.1 Metals at high temperatures
6.1.1 Elevated temperature tests
6.1.1.1 Creep tests
6.1.1.2 Stress-rupture tests
6.1.1.3 Short time tension tests
6.1.2 Creep properties of various alloys
6.2 Metals at low temperatures
6.2.1 Effect of low temperature on properties
6.2.2 Effect of temperature on notched-bar test
6.2.3 Metallurgical factors
6.2.4 Mechanical factors

7 Flat processing of steel (Option)

7.1 Steel making
7.1.1 Direct reduction vs. blast furnaces
7.1.2 Electric arc furnace
7.1.3 Crucible furnace and chemistry adjusting
7.1.4 Continuous casting
7.1.5 Hot rolling
7.2 Cold rolling complex
7.2.1 Pickling process
7.2.2 Cold rolling
7.2.3 Annealing
7.2.4 Skin passing
7.2.5 Galvanizing
7.2.6 Pre painting
7.2.7 Tin plating
7.3 Downstream processes
7.3.1 Straitening
7.3.2 Cut to length
7.3.3 Slitting
7.3.4 Corrugation
7.3.5 Sandwich panels
7.3.6 Composite panels
7.4 Downstream industries and applications
7.4.1 Car body manufacturing
7.4.2 White goods industry
7.4.3 Air condition ducting
7.4.4 Industrial building
7.4.5 False celling and false floor
7.4.6 Portable cabins
1.1.1 Luxury building cladding

8 Auxiliaries and annexes of Metallurgical Industries (Option)

8.1 Generation of gaseous
8.1.1 Hydrogen generation
8.1.2 Oxygen generation/separation
1.1.1 Nitrogen generation/separation
8.2 Storage, accumulation piping and handling of gaseous
8.2.1 Handling of natural gas
8.2.2 Handling of PLG
1.1.2 Handling of Liquid and gaseous ammonia
8.3 Water quality and waste treatment
8.3.1 Water treatment
8.3.2 Waste water treatment
8.3.3 Fumes exhaust and treatment
8.3.4 Environment control
8.4 Annexes
8.4.1 Steam generation
8.4.2 Compressed air station
8.4.3 Handling and conveying equipment (separate course in the 4th year m/c)