Metallurgical Thermodynamics & Kinetics

[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM103101MM
[Pre-requisites: None]

Course Objectives
1. To understand the conditions for stability of a phase.
2. To provide a basis of feasibility of a reaction under given conditions.
3. Understating the solution behaviour. To calculate the rate of reaction.

Course Content
Unit-1
Revision of Basic Principles:Revision of first, second and third law of thermodynamics, Ellingham and Ellingham-
Richardson diagram, Clausius, Clapeyron equation, Statistical concept of entropy.

Unit-2
Solution Thermodynamics:Solution, mixture and compound, Raoult’s law: ideal solution, standard state, Partial
molar quantities, Gibbs-Duhem equation, chemical potential, fugacity, activity and equilibrium constant. Free energy
of mixing, excess and integral quantities.

Unit-3
Regular solutions, α-function, Dilute solutions: Henry’s and Sievert’s laws, Alternative standard states, Short and long
range ordering and their models, Elements of Gibbs Phase Rule and its applications. Free energy-composition
diagram.

Unit-4
Kinetics: Arrhenius equation, activation energy, homogeneous and heterogeneous reactions, order and molecularity
of reactions, adsorption, chemisorption, collision theory, absolute reaction rate theory, Diffusion: Fick’s laws;
applications to gas-solid reactions, kinetics of iron ore reduction.Topo-chemical reaction.

Course Materials
Required Text: Text books
1. Problems in Metallurgical Thermodynamics and Kinetics- G.S.Upadhyaya and R.K.Dube
2. A Textbook of Metallurgical Kinetics by Ahindra Ghosh and Sudipto Ghosh. PHI
3. Principles of Metallurgical Thermodynamics by S K Bose and S K Roy

Optional Materials: Reference Books

1. Chemical Thermodynamics of Materials by C.H.P. Lupis
2. Introduction of Metallurgical Thermodynamics by D.R. Gaskell
3. Thermodynamics of Solid by R.A. Swalin
4. Physical Chemistry of Metals by L.S. Darken and R.W. Gurry
5. Chemical Thermodynamics in Materials Science by Taishi Matsushita, Kusuhiro Mukai
Minerals, Ore Beneficiation and Refractories
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM103102MM
[Pre-requisites: None]

Course Objectives
1. Understanding minerals, their occurrence and properties.
2. To introduce the basic concepts of Ore Beneficiation.
3. To introduce the basic concepts of refractories used in industrial furnaces.

Course Content
Unit-1
Mineralogy: Define Minerals and Rocks. Classification of minerals. Mode of occurrence and origin of minerals.
Physical Properties of Minerals. Preliminary study ofsome common Rock Forming Minerals (Quartz, Feldspar, Mica,
Olivine, Pyroxenes, Amphibole, Garnet, Clay, Feldspathoids, Aluminosilicates, Calcite, Dolomite, Talc, Gypsum,
Barite) and Ore Forming Minerals of (Iron, Aluminum, Copper, Manganese, Lead, Zinc, Chromium, Tin);
Distribution, Association and Industrial uses of some important minerals and Ores.

Unit-2
Ore Beneficiation: Concept of Ore beneficiation. Various processes involved in ore beneficiation; Crushing, Grinding,
Screening, Sizing, Classification and Concentration. Choice of Mineral Processing method. Economics of Mineral
Processing. Processes with equipment used. Important controlling factors in operation.

Unit-3
Simple flow sheets for Beneficiation of ores of Fe, Mn, Cr, Cu, Pb, Zn and Beach Sands. Specifications of some
common ores used for different industries (Steel Industry, Cement Industry, Aluminium Industry, Cu industry etc.

Unit-4
Refractories: Definition and Classifications of Refractories. Manufacturing and properties of synthetic raw materials.
Insulating refractories of different kinds, their manufacturing and properties. Refractories in blast furnace, coke oven,
hot metal mixer, basic oxygen furnace, electric arc furnace, ladles and continuous casting, cement and lime, rotary
kiln, glass industry.

Course Materials
Required Text: Text books
1. Principles of Mineral Dressing, A.M.Gaudin,
2. Mineral Processing Technology – B.A. Wills
3. Courses in Mining Geology – R.N. P. Arogyaswamy
4. T. Rutley’s Elements of Mineralogy – C.D. Gribble
5. Refractories- A. Rashid Chesti, PHI

Optional Materials: Reference Books

1. Mineral Processing Technology, S. K. Jain

Transport Phenomena in Metallurgical
Processes
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM103103MM
[Pre-requisites: None]

Course Objectives
1. To introduce students to the physics and mathematical knowledge of momentum, heat, and mass transfer in
materials and metallurgical processes.
2. To develop the ability in students to formulate and solve the momentum, heat, and mass balance problem
related to materials and metallurgical process.
3. To introduce the knowledge to set up and solve the coupled phenomenon in metallurgical systems by transport
coupling.

Course Content
Unit-1

Principles of transport phenomena, units and dimensions, Importance of transport phenomena to the materials
engineer. Vector and tensor operations in terms of components, vector and tensor differential operations, vector and
tensor integral operations.

Unit-2
Definition and classification of fluids. Viscosity, viscosity of gas, liquid metal and slag. Differential mass balance
(continuity equation). Differential momentum balance (equation of motion). Navier Stokes Equation. Application of
Differential Balance Equation. Overall mass balance and momentum balance, flow meters, Chimney draft. Flow
through packed and fluidized beds. Motion of gas bubbles

Unit-3
Modes of heat transfer. Thermal conductivity and heat Conduction, Fourier law, Steady and unsteady state of heat
conduction, Applications of heat conduction in metallurgical system. Convective heat transfer. Total energy balance
equation, Free and forced convection, Radiative Heat Transfer, Reflection, absorption and transmission of radiation.
Black body radiation. Planck's Law, Wein's distribution Law. Heat transfer between two bodies by radiation.
Lambert's Law, Flames and furnaces

Unit-4
Mass transfer, diffusion in gaseous, liquid and solid medium, General mass transport equation. Modes of mass
transfer. Film and boundary layer theories. Diffusion-diffusion convection. Generalized diffusion equation. Diffusivity
in gases, liquids and solids. Diffusion with moving phase boundary, Diffusion of gasses through porous solids,
gaseous oxidations of metals. Convective mass transfer, Mass transfer in fluid at solid-fluid interface. Mass transfer
between two fluids. Transport coupling, Analogy among heat mass and momentum transfer.

Course Materials
Required Text: Text books
1. Rate Processes in Metallurgy: A.K.Mohanty, PHI
2. Transport Phenomena: R.B. Bird, W.E. Stewart and J.F. Lightfoot
3. Fundamentals of Heat and Mass Transfer: F.P. Incropera and D.P. DeWitt

Optional Materials: Reference Books

1. J.S. Szekely and N.J. Themelis: Rate Phenomena in Process Metallurgy

2. C.J. Geankoplis, Transport Processes: Momentum, Heat and Mass
3. J.R.Welty, C.E. Wicks and R.E. Wilson: Fundamentals of Momentum, Heat and Mass Transfer
Physical Metallurgy
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM103104MM
[Pre-requisites: None]

Course Objectives

1. To introduce the basic concepts of crystallography.

2. Introducing the concept of alloying and the factors influencing alloying behaviour.
3. Introduction of Phase Diagram, applications and limitations. Introduction of Fe-C diagram and its
applications.

Course Content
Unit-1
Structure of Metals, Types of bonds, Space lattice, Crystal Structure, Allotropy, Miller indices for plane and directions,
planer/linear density, angle between the directions and planes. Diffusion in Solids, Atomistic Mechanism, Interstitial
and substitutional diffusion, Applications of Diffusion Concepts
Unit-2
Structure of Alloys and Compounds, Solid solutions, Hume-Rothery’s rule for solid solubility, intermediate phases,
Defects in crystals, Type of defects, Point, Line, Surface and Volume defects, Low angle, High angle, Tilt and Twin
grain boundaries, Introduction to Metallographic Techniques, Microstructure and its Quantitative Analysis.

Unit-3
Phases, Phase Rule, Phase diagram, Lever Rule, Tie-line Rule, Thermodynamics of Solution, Free energy composition
curve,Experimental techniques for construction of phase diagrams,Unary and binary phase diagrams (isomorphous,
eutectic system, peritectic, monotectic, syntactic, eutectoid etc.reactions), Binary phase diagrams of common
commercial alloys (Cu-Ni, Au-Cu, Al-Si, Al-Zn, Al-Ag, Pb-Sn, Cu-Zn, Cu-Sn, Cu-Al, Ti-Al, Ti-V),Uses of Phase
Diagrams, Limitations of Phase Diagrams

Unit-4
Study of Fe-Fe3C diagram, Invariant Reactions, Allotropy of Fe, Heating and Cooling Curves for Fe-C alloys, hypo-
eutectoid, eutectoid, hyper-eutectoid steel, Effect of Carbon on microstructure and mechanical properties, Different
types of Cast Irons-microstructure and mechanical property.

Course Materials
Required Text: Text books

1. Physical Metallurgy – Robert E.Reedhill

2. Materials Science and Engineering, An introduction. WD Callister, Jr., Adapted by R. Balasubramaniam,
John Wiley & Sons, NY, Indian edition, 2007
3. Introduction to Physical Metallurgy – S.H.Avner, Tata McGraw Hill ,1997
4. Metallurgy for Engineers- Clark and Varney

Optional Materials: Reference Books

1. Engineering Physical Metallurgy and Heat treatment – Y. Lakhtin

2. C. Suryanarayana, Experimental Techniques in Mechanics and Materials, John Wiley, John Wiley, NJ,
USA,2006
3. Foundations of Materials Science and Engineering – W.F. Smith
4. Metallographic Laboratory Practice – Kehl
5. Essentials of Materials Science Engineering, Donald R. Askeland , Pradeep P. Phule , Cengage learning
(INDIA).
6. Materials Science and Metallurgy C.DanielYesudian, D.G.Harris Samuel, Scitech Publications.
7. Engineering Materials V.S.R Murthy, A.K. Jena , Tata McGraw Hill
8. Engineering Materials and Metallurgy, R. Srininasan, Tata McGraw Hill
Casting and Solidification
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM103105MM
[Pre-requisites: None]

Course Objectives
1. Introduce and explain various moulding, casting techniques and equipment used.
2. Explain the Principles of Solidification of casting.
3. Introducing possible defects in castings.Suggesting various remedial measures to avoid defects in casting.

Course Content
Unit-1

Scope and development of foundry, Types of foundries. Introduction to Foundry - Steps involved in casting,
advantages, limitations and applications of casting process. Pattern types, allowances for pattern, pattern materials,
color coding and storing of patterns.

Unit-2
Moulding methods and processes-materials, equipment, Moulding sand ingredients, essential requirements, sand
preparation and control, testing, cores and core making-its types. Sand castings-Green and dry, pressure die casting,
Gravity die casting, permanent mould casting, centrifugal casting, precision investment casting, shell Moulding, CO 2
Moulding, Recent developed process-V-forming, full mould process: Furon-no-bake sand moulds and cores.
Continuous casting-squeeze casting, Cold setting and self-setting processes.

Unit-3
Purpose of the gating system, Components of gating system and its functions, Design of gating system, Types of gates,
Gating ratio and its functions, Gating systems and their characteristics. Solidification of metals, Homogeneous and
heterogeneous nucleation, Growth mechanism, Solidification of Pure metals and alloys, Constitutional Super-cooling,
Coring or Segregation, Solidification time and Chvorinov’s rule, concept of progressive and directional solidifications,
Metallurgical aspects of Castings.

Unit-4
Melting furnaces-crucibles oil fired furnaces-electric furnaces-cupola, selection of furnace, calculation of cupola
charges-Degasification, inoculation, pouring techniques. Gray Cast iron-effect of chemical composition, carbon
equivalent, and effect of alloying. Production of gray cast iron, ductile iron and malleable iron castings. Melting of
Aluminium and Copper alloys. Casting defects arising due to moulding, coring, melting and pouring practice.

Course Materials
Required Text: Text books

1. Heine, Loper and Rosenthal, Principles of Metal Casting, Tata McGraw Hill Publishing Co, Ltd; New Delhi,
1995.
2. Solidification Processing: M.C.Fleming
3. Foundry Technology - Devendra Kumar and S. K. Jain
4. Foundry Technology-Jain.
5. Foundry Technology Principle- Raman Rao.

Optional Materials: Reference Books

1. Metals Hand book Vol.5 published by ASM, Ohio.

Mathematics-III
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Department of Mathematics 4 / 40 Periods Core MM103001MA
[Pre-requisites: Mathematics-I, Mathematics-II]

Course Objectives

1. Introduce the concepts of Laplace Transform and its application in solution of differential equations and
improper integrals.
2. Able to form and solve the partial differential equations using different analytical techniques with application in
solution of wave and Laplace equations.
3. Introduce to probability and basic statistical data analysis in engineering and sciences. Introduction of tensors
and its properties.

Course Content
Unit-1 Laplace Transform

Laplace Transform: Definition, Transform of elementary functions, Properties of Laplace transform, Transform of
derivatives and integrals, Multiplication by t^n , Division by t, Evaluation of Integrals, Periodic functions, Inverse
Laplace transform, Convolution theorem, Application of Laplace transform to solutions of ordinary differential
equations.

Unit-2 Partial Differential Equation

Formation, Solutions by direct integration method, Linear equations of first order, Homogeneous linear equations
with constant coefficients, Non-homogeneous linear equations, Method of separation of variables with application in
solution of Wave, Heat and Laplace equations.

Unit-3 Introduction to Probability and Statistics

Definitions of Probability, Conditional Probability, Random Variables, Discrete and continuous probability
distributions, Expectation, Mean & Standard deviation, Moment Generating Function, Binomial, Poisson and Normal
distributions, Descriptive Statistics: Collection and classification of data, Measure of Central Tendency, Measure of
Dispersion, Correlation, Line of Regression.

Unit- 4 Tensor Analysis

Introduction, Summation Convention, Transformation of Coordinates, Tensor of order zero, Kronecker delta,
Contravariant vectors, Covariant vectors, Tensors of higher order, symmetric and skew symmetric tensors, Tensors of
higher order, Addition, Outer product, contraction, Inner product of tensors, Christoffel symbols, Covariant
differentiation of covariant and contravariant vectors.

Course Materials
Required Text: Text books

1. Higher Engineering Mathematics by B. S. Grewal (42thedition)- Khanna Publishers

2. Advanced Engineering Mathematics by Erwin Kreyszig (8th edition)- John Wiley & Sons

Optional Materials: Reference Books

1. Advanced Engg. Mathematics by R. K. Jain and S. R. K. Iyengar–Narosa Publishing House

2. Applied Mathematics by P. N. Wartikar& J. N. Wartikar. Vol- II– Pune VidyarthiGrihaPrakashan, Pune
3. Applied Mathematics for Engineers & Physicists by Louis A. Pipes TMH
 Physical Metallurgy Laboratory
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 2 Core MM103401MM
[Pre-requisites: None]

Course Objectives

1. To understand the effect of alloy composition on its microstructure

2. Developing skills on metallography
3. Application of lever rule for quantitative phase analysis

Course Content

Laboratory Experiments

1. Study of Metallurgical Microscope including Dark Field and Bright Field Imaging
2. Metallic sample preparation for microstructural study
3. Single phase (Pure Cu and alpha brass) and two phase materials and three phase materials microstructure
demonstration
4. Inclusion rating studies
5. Studying the microstructure of low carbon, medium carbon and high carbon steel
6. Studying the microstructure of cast irons
7. Microstructural studies of Aluminum (Al-Si) based Alloys
8. Microstructural studies of Copper (Cu-Zn, Cu-Sn) based Alloys
9. Quantitative phase analysis (linear intercept, point count method)
10. Experimental determination of a binary phase diagram

Course Materials
Required Text: Text books

1. Introduction to Physical Metallurgy – S.H. Avner, Tata McGraw Hill ,1997

Optional Materials: Reference Books

1. ASM Metals Handbook (Microstructure, Vol-1)

Casting and Solidification Laboratory
[3rd Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 2 Core MM103402MM
[Pre-requisites: None]

Course Objectives

1. Develop skills to cast metals and alloys.

2. Understanding of casting defects and solidification structures.
3. Accruing knowledge to minimize or eliminate such defects.

Course Content

Laboratory Experiments:

1. Introduction to foundry hazards, safety instruction and demonstration

2. To design and make a 3D pattern of the given drawing by any suitable pattern making material (introduction
to runner and riser)
3. To prepare a sand mould from the pattern made above by suitable binder (introduction of cope and drag),
Permanent mould.
4. Particle size distribution by sieve analysis, Permeability and Green Strength Measurement of mould.
5. To make the mould cavity dry, smooth and moisture free for casting
6. To melt a low temperature alloy in an electric furnace/muffle furnace and cast in the mould cavity.
7. To examine the casting defects and find out the reasons responsible for the defects.
8. To grind, polish and paint the cast material surface for improving the surface finish
9. To re-melt/recycle the scrap generated during the casting process into a reusable ingot.

Course Materials
Required Text: Text books

1. Heine, Loper and Rosenthal, Principles of Metal Casting, Tata McGraw Hill Publishing Co,
Ltd; New Delhi, 1995
Optional Materials: Reference Books

1. Metals Hand book Vol.5 published by ASM, Ohio.

 Mechanical Behavior of Materials
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM104101MM
[Pre-requisites: Physical Metallurgy]

Course Objectives
1. To analyze mechanical deformation of the materials under tensile and compressive loading.
2. To understand the role of dislocations, stacking faults and other defects in deformation behavior of
materials.
3. To investigate the role of various strengthening mechanisms in engineering materials.
4. To inherit the basic concepts of crystal plasticity in view of continuum mechanics.

Course Content
Unit-1
Elements of theory of elasticity: Elastic and plastic behavior; Concept of Strain and Stress; States of Stress in 2-D and
3-D; Elastic Stress-Strain Relations; Mohr’s circle, Plastic response of materials - different types of uniaxial stress-
strain curves. Equivalent stress and strain.
Unit-2
Tresca and Von-misess yield criteria, Levy-Mises yield criteria, Modes of Plastic Deformation, Mechanisms of slip and
twinning, Deformation of single crystals and polycrystals, Theoretical cohesive strength, Flow curve in single crystal.
Unit-3
Dislocation Theory, Types of dislocations, their elastic properties. Observation, movement and multiplication of
dislocations. Dislocation intersection and reactions. Partial dislocations. Dislocation forces and elastic strain
energy.Jogs and Kinks, Dislocation interactions.
Unit-4
Critical resolved shear stress in single crystals. Work hardening in single and poly-crystals, Strengthening
Mechanisms: Grain boundary, solid solution and martensitic strengthening, Precipitation and dispersion hardening.
Yield point, strain ageing and work hardening. Elevated temperature deformation mechanisms-cross slip, climb and
grain boundary sliding.

Course Materials
Required Text: Text books
1. Thomas H. Courtney: Mechanical Behaviour of Materials, Second edition, PressIndiaPvt.ltd.
2. Mechanical Behaviour of Materials, Marc Andre Meyers and Kishan Kumar Chawala, Second Edition, 2009,
Cambridge University Press, U.K.
3. Mechanical Metallurgy– George E. Dieter, SI Metric Edition, 1988, McGraw Hill Book Co Ltd, U.K.
4. Basic Engineering Plasticity Butterworth-Heinemann, David W. A. Rees, 2006
5. Dislocations and Mechanical Behaviour of Materials, M.N. Shetty, 2013 , PHI

Optional Materials: Reference Books

1. R.W. Herzberg: Deformation and Fracture Mechanics of Engineering Materials,Fourth Edition, John
Wiley & Sons INC, USA
2. R.W.K. Honeycombe: The Plastic Deformation of Metals, Edward Arnold
3. D.Hull: Introduction to Dislocations, Pergamon.
4. F. Garofalo: Fundamentals of Creep and Creep Rupture in Metals, MacMillan.
5. M.A. Meyers and K.K. Chawla: Mechanical Behaviour of Materials, PrenticeHall.
6. Metals Handbook, Mechanical Testing, Ninth Edition, Vol 8, ASM
7. Metal Handbook, Non Destructive Evaluation and Control, Ninth Edition, Vol 17,ASM
 Heat Treatment and Phase Transformation
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM104102MM
[Pre-requisites: Physical Metallurgy]

Course Objectives

1. To understand the Thermodynamics and Kinetics of different solid state Phase Transformations.
2. To introduce the need of heat treatment to tailor the microstructure for desired mechanical property.
3. To introduce the heat treatment processes of commercially significant alloys.
4. To introduce primary surface treatment technologies and recent trends in Heat Treatment Technology.

Course Content
Unit-1
Introduction and purpose of Heat Treatment, Revising the basics of Fe-C diagram-effect of alloying elements on Fe-C
diagram, Principles of Heat Treatment of steels: Formation of Austenite on heating, Austenitic grain size,
determination and decomposition of austenite, Annealing, Normalizing, Hardening and Tempering, Tempering and
its stages.

Unit-2
Diffusional transformation, Thermodynamics and Kinetics of nucleation and growth- Homogeneous and
Heterogeneous nucleation in solids, Overall Transformation, Concept of TTT curve, Precipitation reaction, particle
coarsening, recovery, recrystallization, grain growth, Cellular Precipitation, PearliticandBainitic Transformation,
Ordering, Diffusionless transformation: Martensitic Transformation. Martensite; Nucleation and Growth, Spinoidal
decomposition.

Unit-3
TTT curve, CCT curve, Effect of alloying elements on TTT curves, Hardenability of steels, Factors affecting
hardenability and its determination,Austempering, Martempering, Subzero treatment, Patenting. Heat Treatment
Defects and Remedies.

Unit-4
Thermo mechanical treatments: Ausforming, Isoforming, Cryoforming. Heat-Treatment of Cast Iron; Heat Treatment
of Non Ferrous Alloys-Age Hardening (in Al, Mg and Ti alloys). Surface Heat Treatment: Carburizing, Nitriding,
Cyaniding and Carbonitriding, Flame and Induction hardening. Recent developments in heat treatment techniques.

Course Materials
Required Text: Text books
1. Phase Transformations in metal and Alloys: D.A. Porter and K. E. Easterling, Second edition, Reprint 2001.
2. Solid state phase transformation by V. Raghavan.
3. Physical metallurgy by Robert E. Reed-Hill

Optional Materials: Reference Books

1. Heat Treatment of Metals – Zakharov
2. Heat Treatment Principle and Techniques – Rajan& Sharma
3. Physical Metallurgy – Lakhtin
4. Physical Metallurgy - Clark and Varney
5. Introduction to Physical Metallurgy-Sidney H. Avner, TMH
6. Physical Metalllurgy: Vijendra Singh
Non Ferrous Metal Extraction
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM104103MM
[Pre-requisites: Metallurgical Thermodynamics and kinetics]

Course Objectives
1. To understand the basic principles of Pyrometallurgy, Hydrometallurgy and Electrometallurgy.
2. Introduction to extraction processes of commercially important metals including copper, zinc, aluminum
and titanium.

Course Content
Unit-1
Introduction to Pyro-metallurgy, Hydrometallurgy and Electrometallurgy. General methods of extraction in Pyro-
metallurgy - Drying, Calcination, Roasting, Smelting, Carbothermic and Metallothermic reduction.

Unit-2
Principles of hydro and electrometallurgy with suitable examples. Leaching techniques, Leaching solvents, Theory of
leaching, Bacterial leaching, Electrochemical nature of leaching, Pressure leaching.

Unit-3
Gold and silver extraction, Sherritt-Gorden process for Copper, Nickel, Cobalt; Solvent extraction, Ion exchange.
Electrometallurgy - Electrolysis of aqueous solutions and fused salts, Cell design. Recovery of metals by Cementation,
Electro-winning, Electro-refining etc.

Unit-4
Extraction of metals from oxides-Magnesium and Titanium extraction, Aluminum extraction-Bayer’s process and
Hall-Heroult process. Extraction of metals from sulphides; Extraction of Copper, Lead, Zinc, Nickel. General methods
of refining, Principles of Refining, Sublimation, Distillation and Vacuum Distillation, fractional distillation,
crystallization, chemical precipitations, Ion exchange, Fire Refining and Liquation.

Course Materials
Required Text: Text books

1. Extraction of Non- Ferrous Metals – H.S.Ray, K.P. Abraham and R. Sridhar, Affiliated
East-West press Pvt, ltd, New Delhi,1985.
2. Principles of Extractive Metallurgy, H.S.Ray and A. Ghosh, New Age International (P)
limited, 1995
Optional Materials: Reference Books

1. Rosenquist T; Principles of Extractive Metallurgy; McGraw Hill Koga Kusha, 1985

2. Jackson Eric; Hydrometallurgical Extraction; John Willy & Sons, 1986
3. Bray J.L.; Extraction of Non-ferrous Metals; John Willy & Sons, 1959
4. Dr. Venkatachalam; Hydrometallurgy;Narosa Publishing House, 1998
5. C. B. Gill, Non- Ferrous Extractive Metallurgy, John Wiley and Sons, 1980
6. FathiHabashi, Hand Book of Extractive Metallurgy, Vols. II and III, Wiley- VCH, 1997
7. Michel L. Free, Hydrometallurgy: Fundamentals and Application, Wiley publication, 2013
Iron and Steel Making
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM104104MM
[Pre-requisites: Metallurgical Thermodynamics and kinetics]

Course Objectives
1. Introduction of the evolution of Iron making and Steel making in chronological order.
2. Applications of thermodynamics and kinetics in production of Iron and Steel Making.
3. Design of Iron and Steel making furnaces.
4. It will introduce the current opportunities and challenges in the Iron and Steel industry

Course Content
Unit-1
History of Iron making, Raw materials for Iron making. Occurrence and distribution of iron ores, fuels and fluxes.
Agglomeration Techniques: Sintering and pelletisation. Blast Furnace profile and design considerations. Furnace
cooling system. Blast Furnace Stoves. Blast Furnace gas cleaning system. Blast Furnace operation and irregularities,
Blast Furnace reactions.
Unit-2
Thermodynamics of iron oxide reduction by CO + CO2 and H2 and H2O mixtures. Control of C, Si, S, P in metals and
slags. Blast furnace slags. Burden calculations. Modern trends in blast furnace: High top pressure, humidification of
blast, Oxygen enrichment, hot blast temperature, Blast Furnace additives and top charging systems. Alternative
routes of iron making: Sponge iron making: HYL, Rotary Kiln, Midrex process. Smelting and reduction methods such
as Corex process.
Unit-3
History of steel making in India and world, Indian and world steel production scenario. Physical chemistry of carbon,
silicon, manganese, phosphorus and sulphur reactions. Deoxidation and dephosphorization techniques. Basic oxygen
steel making (BOF): Principle, raw materials, vessel design, nozzles and jet-bath interaction, operation, turndown and
corrective practices.

Unit-4
Electric steel making: Arc and Induction furnace: principle, type, construction, refractory lining, melting practice,
merits and limitations. Secondary steel making: Clean steel, Stirring techniques- ladle metallurgy, Vacuum
treatments & Decarburizing techniques: Argon oxygen decarburization (AOD), Vacuum oxygen decarburization
(VOD), degassing processes (RH & REDA process), Vacuum Induction Melting (VIM). Control of nitrogen and
hydrogen in steel. Continuous casting Process.

Course Materials
Required Text: Text books
1. Iron making and steel making – Theory and practice, AhindraGhosh and Amit Chatterjee, PHI.
2. Making, Shaping and Treating of Steel: Iron and Steel Making.

Optional Materials: Reference Books

1. Steel Making, A.K. Chakarabarti, PHI.
2. Beyond the B.F.–Amit Chatterjee
3. Sponge Iron production by direct reduction of Iron ores - Amit Chatterjee, P & H. publications, 2010
4. Hot metal production by smelting reduction of Iron ore - Amit Chatterjee. P & H publications, 2010
5. J.M. Gaines (ed.): BOF Steelmaking, Vols. 1&2, The Iron and Steel Society.
6. G.R. Bashforth: The Manufacture of Iron and Steel, Vol 2, Chapman & Hall
Mathematics-IV (Numerical Methods)
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Department of Mathematics 4 / 40 Periods Core MM104001MA
[Pre-requisites: Mathematics-I, Mathematics-II]

Course Objectives

1. Introduce the method to solve the algebraic, transcendental and simultaneous linear equations and its
application.
2. Introduce the method to solve the problems related to data appear equal or unequal intervals and to obtain a
functional relationship between the observed values.
3. Introduce the method to calculate the derivative of the function and evaluate the definite Integral from set of
numerical values.
4. Introduce the method to solve the ordinary differential equations using different numerical techniques.

Course Content
Unit-1
Numerical Solution of Algebraic, Transcendental and Simultaneous Linear Equations: Errors in numerical
computation, Error type, Bisection Method, Regula – Falsi Method, Secant Method, Newton-Raphson Method, Direct
Methods - Gauss Elimination, Gauss-Jordan &Crout’sTriangularisation Method, Iterative Methods -Jacobi’s, Gauss-
Seidel & Relaxation Method

Unit-2
Interpolation and Curve Fitting: Finite differences, Forward, Backward & Central Difference Interpolation Formulae,
Lagrange’s Formula and Newton’s Divided Difference Formula, Principle of Least Squares, Fitting a Straight Line,
Filling a Parabola, Exponential Function, Method of Group Averages.

Unit-3
Numerical Differentiation and Integration: Derivatives using Forward, Backward and Central Difference Formulae,
Derivatives using unequally spaced values, Newton-Cote’s Quadrature Formula, Trapezoidal rule, Simpson’s 1/3
rules, Simpson’s 3/8 rules, Weddle’s rule.

Unit-4
Numerical Solution of Ordinary Differential Equations
Picard’s Method, Taylor’s Series Method, Euler’s Modified Method, Runge-Kutta Method of Fourth Order, Milne’s
Method, Adams –Bashforth Method, Simultaneous First Order Differential Equations.

Course Materials
Required Text: Text books

1. M. K. Jain, S. R. K. Iyengar& R. K. Jain Numerical Methods for Scientific and Engineering Computation, New Age
International (P) Limited, Publisher
2. B. S. Grewal, Numerical Method in Engineering and Science, Khanna Publisher
3. J. D. Hoffman, Numerical Methods for Engineers and Scientists, McGraw-Hill, Inc. Publisher

Optional Materials: Reference Books

1.P. Kandasamy, K. Thilagavathy, & K. Gunavathi, Numerical Methods, S. Chand Publisher.

2. E. Kreyszig, Advanced Engineering Mathematics, John Wiley & Sons Inc. Publisher.
3. S. S. Sastry, Introductory methods of numerical analysis, PHI, Publisher.
Testing of Materials
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 4 / 40 Periods Core MM104105MM
[Pre-requisites: None]

Course Objectives
To understand the basic principles and testing methods for Tensile, Compressive and Torsion Tests
2. To understand the basic principles and testing methods for Hardness, Impact, Creep and Fatigue Tests
3. To introduce the basic principles of Non Destructive Testing

Course Content
Unit-1
Tensile Testing : Importance of tensile testing and effect of various parameters measured in the test Necking during
tension test, instability in tension, stress distribution at the neck, ductility measurement in tensile testing – effect of
gauge length. Effect of strain rate and temperature on flow properties, Machine stiffness in tensile testing. Torsion
Test: Theory of torsion in materials. Torsional stresses in large plastic deformation, failure mechanisms in torsion,
Torsion vs. Tension test.

Unit: 2
Hardness Test: Hardness testing system, elastic and plastic behaviour during hardness testing. Critical factors such as
indenter size, shape, type of loading etc. in hardness testing. Major hardness testing systems such as Rockewll,
Brinell, Vickers, Concept of micro hardness, Special hardness tests such as superficial, shore etc. Nanoindentation
tests, Indentation fracture toughness.

Unit: 3
Impact testing for brittle fracture. Notched bar tests, instrumented charpy test. Drop weight crack arrest test,
Introduction to fracture toughness testing. Fatigue Tests: Stress cycles and S-N curve analysis. Effect of mean stress,
stress ratio, pre-crack size and surface condition on fatigue. Fatigue testing machines and equipment.
Creep stress rupture tests. Creep cure and its analysis. Stress rupture test. Presentation of engineering creep data.
Equipment test set up in creep testing.

Unit: 4
Non – destructive Testing: Methods and classification. Elements and instrument in visual magnetic, radiographic,
ultrasonic, electromagnetic, penetrant tests, their applications in quality control and inspection.

Course Materials
Required Text: Text books
1. Mechanical Behaviour of Materials, Marc Andre Meyers and Kishan Kumar Chawala, Second Edition,
2009 , Cambridge University Press, U.K.
2. Basic Engineering Plasticity Butterworth-Heinemann, David W. A. Rees, 2006
3. Dislocations and Mechanical Behaviour of Materials, M.N. Shetty, 2013 , PHI Learning Pvt Ltd, New Delhi
-110092
4. Thomas H. Courtney: Mechanical Behaviour of Materials, Second edition, PressIndiaPvt.ltd.
5. Mechanical Metallurgy– Geroge E. Dieter , SI Metric Edition ,1988, McGraw Hill Book Co Ltd , U.K.

Optional Materials: Reference Books

1. R.W. Herzberg: Deformation and Fracture Mechanics of Engineering Materials, Fourth Edition, John
Wiley & Sons INC, USA
2. R.W.K. Honeycombe: The Plastic Deformation of Metals, Edward Arnold
3. D.Hull: Introduction to Dislocations, Pergamon.
4. F. Garofalo: Fundamentals of Creep and Creep Rupture in Metals, MacMillan.
5. M.A. Meyers and K.K. Chawla: Mechanical Behaviour of Materials, PrenticeHall.
6. Metals Handbook, Mechanical Testing, Ninth Edition, Vol 8, ASM
7. Metal Handbook, Non Destructive Evaluation and Control, Ninth Edition, Vol 17,ASM
Testing of Materials Laboratory
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 2 Core MM104401MM
[Pre-requisites: None]

Course Objectives
Exposure to various mechanical testing techniques.

Course Content

List of Experiments

1. Conduct Tension test on Steel, Aluminium, Copper and Brass and compare their Load-Elongation plots
2. Converting Load-Elongation data to engineering stress-strain plot and true stress strain
3. Materials Toughness evaluation through Charpy and Izod Impact Test of Steel and Aluminum sample
4. Rockwell hardness test of Steel and Al alloys
5. Brinell, and Micro Vicker hardness test of Steel and Al alloys
6. Micro-hardness Testing of the metallic samples.
7. Friction and Wear Testing of metallic samples

Course Materials
Required Text: Text books

1. Fenner, Mechanical Testing of Materials, George Newnes Ltd. London.

2. K. Suryanarayana, Testing of Metallic Materials, Prentice Hall of India Pvt. Ltd. New Delhi

Optional Materials: Reference Books

1. C.B. Kukreja, K. Kishore, Chawla, Material Testing Laboratory Manual, Standard Publishers & Distributors 1996
Heat Treatment and Phase Transformation
Laboratory
[4th Semester, Second year]

Course Description

Offered by Department Credits Status Code

Metallurgical and Materials Engineering 2 Core MM104402MM
[Pre-requisites: None]

Course Objectives

1. The students should be able to design the heat treatment cycle to obtain desired microstructure of the
metallic materials.
2. Introducing heat treatment to tailor the microstructure for desired mechanical property.
3. To introduce the heat treatment processes of commercially significant alloys

Course Content

Laboratory Experiments:

1. Study the effect of undercooling on solidification of pure metal and alloys

2. Phase change and microstructures in alpha-beta brass (Cu-40 wt%Zn alloy)
3. Microstructural features of discontinuous precipitation and coarsening
4. Determination of boundary diffusion coefficient and Arrhenius parameters
5. Annealing and normalizing of proeutectiod, eutectoid and hyper-eutectoid steel
6. Study of age hardening of Al-Cu alloy
7. Hardening and tempering of rail steel
8. Carburizing of low carbon steel
9. Study of austempered ductile cast iron
10. Jominy end quench test

Course Materials
Required Text: Text books

1. Introduction to Physical Metallurgy-Sidney H. Avner, TMH

2. Heat Treatment Principle and Techniques – Rajan& Sharma

Optional Materials: Reference Books

1. Heat Treatment of Metals – Zakharov

2. Physical Metallurgy - Clark and Varney