Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

M.Tech. Design Engineering
Digital LearningHandout

Summary
Course Title Materials Technology & Testing

Course No(s) DE ZG631

Credit Units 5

Credit Model 1-1-2

(32 Hours of Class-room Instruction + 32 Hours of
Case-studies/Tutorials/Laboratories + 64 Hours of Student
Preparation)
Content Authors P SRINIVASAN

Version No. 02

Date 22/07/2023

Course Objectives

No

CO1 The Course is for higher degree students, and intended to focus their attention to the nature of
different classes of the engineering materials.

CO2 Study
includescharacteristicsofmetals,polymers,composites,ceramicsandothermodernEngineering
materials,andtheirapplications.

CO3 To study the

methodsoftestingthematerials(destructiveandNDT),andselectionofthematerial,foragivenapplicat
ion.

Text Book(s)

T1 William D Calister Jr,” Material Science & Engineering, an Introduction”, John Wiley &
Sons, New York. 8th edition
T2 George E. Dieter, ‘Mechanical Metallurgy’, McGraw Hill, SI Metric Edition

Reference Book(s) & other resources

R1 William F. Smith, Javad Hashemi, ‘Material Science&Engineering”,In SIunitsFourth edition,
McGraw-Hill.
R2 Norman E. Dowling, Mechanical Behavior of Materials, Pearson Publications
 R3 Marc Andre Meyers, Krishan Kumar Chawla, Mechanical Behavior of
EngineeringMaterialsCambridgeUniversityPress (2009).
R4 Thomas H. Courtney,Mechanical Behavior of Materials, McGraw Hill Education

R5 Richard W. Hertzberg,Deformation and Fracture Mechanics of Engineering Materials, John

Wiley & Sons
R6 Ravi Prakash, Non-Destructive Testing Techniques, New Age International Private Limited

R7 Ian Hutchings, Philip Shipway, Tribology: Friction and Wear of Engineering Materials,
Butterworth-Heinemann publisher
R8 Joseph R. Davis,Corrosion: Understanding the Basics, ASM International

Part B: Learning Plan

Contact
Topics to be covered Description and Reference
Session*
Atomic bonding, Classification of materials,
structure and characteristics of metals
(ferrous and nonferrous), polymers,ceramics,
composites and advanced materials
1 Basic Engineering Materials
(Electronic materials, Smart materials,
Nanomaterials etc.)
T1(Ch1-4, Ch11-16), R1 (Ch1-3, 9-12),
R2(Ch3)
Importance of materials characterization,
Optical microscopy and Electron microscopy,
Structural characterization
2 grain size measurement, X-ray diffraction
techniques
fundamental
T1(Ch3-4), R1(Ch3-4), Lecture notes
Concept of stress and strain, Stress-strain
relationship for elastic behavior,elastic and
Elastic-plastic behavior of
3 plastic behavior of Materials (metals, ceramics,
materials -Review
polymers and composites)
T1(Ch6), T2(Ch2,3), R2(Ch5-6), R3 (Ch2-3),
R4,R5
Tensile testing and test standards for metals,
polymers and composites, Engineering stress
strain curve, true stress strain curve,
Testing of materials- Tensile
4-5 determination of mechanical propertied from
testing
tensile test, Poison’s ratio, Instability in tension,
Effect of temperature and strain rate.
T2(Ch8), R2(Ch4)

6 Hardness Testing
7-8 Fracture Behavior of materials
Impact testing, Torsion testing,
9-10 Compression testing and Bend
test
11-12 Fatigue behavior of materials
13 Creep and Stress rupture
Hardness of materials, hardness testing of
metals, polymers and composites, hardness test
standards, Analysis of indentation, Brinell
hardness, Meyer Hardness, Vickers hardness,
Rockwell hardness, Shore hardness, Micro-
hardness tests, nanoindentation
T2 (Ch 9), R2(Ch4)
Fundamentals of fracture, Types of fractures in
metals, Theoretical cohesive strength of metals,
Theory of ductile and brittle fracture, Crack
initiation and growth, stress concentration and
fractures, Metallographic aspects of fracture,
Fracture under combined stress, case studies
T2(Ch7, Ch11), R2 (Ch 7-8), R4(Ch9-10)
Fracture toughness of materials, Fracture
mechanics, Notch bar impact testing,
Bending (Flexure) Tests, Heat-Deflection Test,
Torsion Test, Testing of Thin-Walled Tubes in
Torsion
Mechanical properties in torsion, Torsion
failure,
Test Methods for Compression, Materials
Properties in Compression, Trends in
Compressive Behavior
Test Standards for compression, impact, bend
and torsion tests
T2(Ch10-11, Ch14), R2(Ch4), R3 (Ch10,
Ch14)
Fatigue of metals, Stress cycles, S-N curve,
standards for fatigue test and determination of
S-N curve, Theories of fatigue, Paris law,
Factors affecting fatigue and mitigation
methods, Origin of residual stress, Effect of
residual stress, Residual stress measurement
methods, Stress relief
T2(Ch12), R2 (Ch9-11, Ch14)
High temperature behavior of materials, Creep
curve, Creep and stress rupture test and test
standards, Deformation at elevated temperature,
Factors affecting creep behavior, Interpretation
of creep data, Larson Miller Parameter
T2(Ch13), R2 (Ch 15), R3(Ch13)
 Overview of the Non-Destructive Testing,
Detection of surface flaws, Detection of internal
flaws,Visual inspection, Liquid Penetrant
Nondestructive testing of Testing, Magnetic Particle Testing,
14
materials Thermography, Eddy Current Testing,
Radiography, Ultrasonic Testing, Acoustic
emissionR1(Ch7), R6

Basic understanding of Friction and wear, Laws

of friction,Archard law’s &equation, different
Introduction to wear &
type of wear, overviewof Pin-on-disc wear test.
15-16 corrosion behavior of the
Corrosion Electrochemistry, Nernst equation,
materials
forms ofcorrosion, Cathodic Protection.
T1(Ch17), R1(Ch13), R3(Ch16), R7, R8

* Each contact session mentioned above will be of 1.5 hr duration.

In addition to this there will be 4 sessions of 2 hrs each for case studies and problem
solving.

Contact
Topic Description
Session

Case studies and Problem

1 Deformation and Fracture of materials
Solving

Case studies and Problem

2 Fatigue failure of materials
Solving

Case studies and Problem

3 Creep and stress rupture at high temperature
Solving

Case studies and Problem

4 Corrosion and Wear in engineering materials
Solving
Learning Outcomes: Students will be able to

LO1 Acquire knowledge of different materials that are useful in Engineering application

LO2 Apply various destructive and non-destructive techniques in evaluating various

materials

LO3 Select the optimum material for a given application

LO4 Detect material Defects, dislocationsand Deformationmechanism

Experiential Learning Components:

1. Lab: Onramp, Virtual lab (J-Octa)

2. Case study: Failure analysis and investigation
3. Work integrated Learning Exercise: Identifying suitable project and executing in the industry
4. Design work/Field work: None

Project Activity/ Experiential Lab:

Sr No Lab Details/ Project Details Access

01 J-Octa On-ramp Through online portal
02 Virtual Lab: J-Octa software: – 16 hours of practice – Graded Through online portal
for 20%

5. Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date,

Component (Quiz, Lab, Project, Mid- book, Closed Session, Time
term exam, End semester book,
exam, etc.) Online, etc.)
Quiz Online 10% September 1-10,
2023
Lab Assignment Online 16% October 1-10,
EC - 1
2023
Lab Quiz Online 04% November 1-10,
2023
Mid-Semester Test Closed Book 30% 2 hours Saturday,
EC - 2
23/09/2023 (FN)
Comprehensive Exam Open Book 40% 2½ hours Saturday,
EC - 3
25/11/2023 (FN)

Important links and information:

eLearn portal: https://elearn.bits-pilani.ac.in

Students are expected to visit the eLearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.

Contact sessions: Students should attend the online lectures as per the schedule provided on
the eLearn portal.

Evaluation Guidelines:
1. EC-1 consists two Assignments and one Quiz. Students will attempt them through the
course pages on the eLearn portal. Announcements will be made on the portal, in a
timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material
(filed or bound) is permitted. However, loose sheets of paper will not be allowed. Use
of calculators is permitted in all exams. Laptops/Mobiles of any kind are not allowed.
Exchange of any material is not allowed.

Material Testing and Technology: Simulation Lab

1. Scope of the lab
Material testing and technology lab enable the students to simulate and visualise the
various material behaviour and through their corresponding testing simulation

2. Objectives of Lab
To simulate the molecular behaviour of soft materials such as plastics, rubber and so on. And also to test
various mechanical properties of soft materials through simulation.

3. List of simulation experiments

Software Tool used: J-Octa

Tut. Tutorial Name Solving Chapter No.

No. Time
1. Polymerization of Low Density Polyethylene 1.5
26-30
(LDPE) hours
2. Polymerization of High Density Polyethylene 1.5 26-30
(HDPE) hours
3. Polymerization of Linear Low Density 1.5 26-30
Polyethylene (LLDPE) hours
4. Polymerization of Poly Vinyl Chloride (PVC) 1.5 26-30
hours
5. Polymerization of Poly Carbonate (PC) 1.5 26-30
hours
6. Polymerization of Poly methyl methacrylate 1.5 26-30
(PMMA) hours
 7. Dissipative Particle Dynamics (DPD) of Poly 1.5 26-30
Styrene Butadiene (PSB) hours
8. Dissipative Particle Dynamics (DPD) of Poly 26-30
1.5
Ethylene Propylene Diene Monomer rubber
hours
(EPDM)

4. Learning Outcome of the lab

 Molecular dynamics of polymer
 Stress and strain evaluation in polymer
 Atomic modelling of monomers
 Create various type of polymer and test the same
 Check the bonded and non-bonded behaviour of polymer.

Note: After completion of every practice tutorial problem, take a snapshot and include the
same in the final assignment PPT lastly. Quiz questions will be based on the practice tutorial
problems and results

Instruction Schedule

Lab Class work Instructions Online TBA 2 Hrs

Delivery

Evaluation Scheme
Evaluation Name Type Marks Dates Lab Exam Date Duration
Componen
t

Quiz based Online 04

on virtual lab

Assignment Online 16 Regular                          TBA

based on TBA
EC - I virtual lab
(12 for Makeup                          TBA
assignment TBA
and 4 for
practice
screenshots)

Link for lab dates and other details (copy the link and paste it in your browser).

Instructor-in-Charge