MECHANICAL ENGINEERING
Year of
METALLURGY CATEGORY L T P Credits
Introduction
MET 205 & MATERIAL
SCIENCE
PCC 3 1 0 4 2019
Preamble:
Understanding of the correlation between the chemical bonds and crystal structure of metallic
materials to their mechanical properties.
Recognize the importance of crystal imperfections including dislocations in plastic deformation.
Learning about different phases and heat treatment methods to tailor the properties of Fe-C
alloys.
Examine the mechanisms of materials failure through fatigue and creep.
To determine properties of unknown materials and develop an awareness to apply this
knowledge in material design
Prerequisite: PHT 110 Engineering Physics and CYT 100 Engineering Chemistry
Course Outcomes - At the end of the course students will be able to
Understand the basic chemical bonds, crystal structures (BCC, FCC, and HCP), and
CO 1
their relationship with the properties.
Analyze the microstructure of metallic materials using phase diagrams and modify the
CO 2
microstructure and properties using different heat treatments.
CO 3 How to quantify mechanical integrity and failure in materials.
Apply the basic principles of ferrous and non-ferrous metallurgy for selecting materials
CO 4
for specific applications.
Define and differentiate engineering materials on the basis of structure and properties
CO 5
for engineering applications.
Mapping of course outcomes with program outcomes (Minimum requirements)
PO PO PO PO PO PO PO PO PO PO PO PO
1 2 3 4 5 6 7 8 9 10 11 12
CO 1 3 - - - - - - - - - -
CO 2 - 3 - - - - - - - - -
CO 3 - - 2 - - - - - - - -
CO 4 - - - 3 - - - - - - -
CO 5 - - - - - - - - - - 2
MECHANICAL ENGINEERING
ASSESSMENT PATTERN
Continuous Assessment Tests End Semester Examination
Bloom's (Marks)
Test 1 (Marks) Test 11 (Marks)
taxonomy
Remember 25 25 25
Understand 15 15 15
Apply 30 25 30
Analyze 10 10 10
Evaluate 10 15 10
Create 10 10 10
Mark distribution
Total Marks CIE marks ESE marks ESE duration
150 50 100 3 Hours
Continuous Internal Evaluation (CIE) Pattern:
Attendance 10 marks
Regular class work/tutorials/assignments 15 marks
Continuous Assessment Test (Minimum 2 numbers) 25 marks
End semester pattern:- There will be two parts; Part A and Part B. Part A contain 10
questions with 2 questions from each module, having 3 marks for each question. Students
should answer all questions. Part B contains 2 questions from each module of which student
should answer any one. Each question can have maximum 2 sub-divisions and carry 14
marks.
COURSE LEVEL ASSESSMENT QUESTIONS
Part -A
Course Outcome 1 (CO1): Understand the basic chemical bonds, crystal structures (BCC,
FCC, and HCP), and their relationship with the properties.
1. What are the attributes of atomic and crystalline structures into the stress - strain curve?
2. Explain the significance of long range and short range order of atomic arrangement on
mechanical strength.
3. What is the difference between an allotrope and a polymorphism?
4. Draw the (112) and (111) planes in simple cubic cell.
MECHANICAL ENGINEERING
Course Outcome 2 (CO2): Analyze the microstructure of metallic materials using phase diagrams
and modify the microstructure and properties using different heat treatments.
1. What is the driving force for recrystallisation and grain growth of metallic crystals?
2. What is the driving force for the formation of spheroidite.
3. What is tempered martensite?
4. Why 100 % pure metals are weak in strength?
Part -B
Course Outcome 3 (CO3): How to quantify mechanical integrity and failure in materials
1. A small hole is drilled through a steel plate ahead of a crack, whether it can stop the crack’s
progress until repairs can be made. Explain in detail and derive the equation for the principle.
2. Draw and explain S-N curves for ferrous and non-ferrous metals. Explain different methods to
improve fatigue resistance.
3. Explain different stages of creep; Give an application of creep phenomenon. What is
superplasticity?
Course Outcome 4 (CO4): Apply the basic principles of ferrous and non-ferrous metallurgy for
selecting materials for specific applications.
1. What are the classification, compositions and applications of high speed steel? identify 18:4:1
2. Describe the composition, properties, and use of Bronze and Gun metal.
3. Explain the importance of all the non-ferrous alloys in automotive applications. Elaborate on
the composition, properties and typical applications of any five non-ferrous alloys.
Course Outcome 5 (CO5): Define and differentiate engineering materials on the basis of structure
and properties for engineering applications.
1. Carbon is allowed to diffuse through a steel plate 15 mm thick. The concentrations of carbon at
the two faces are 0.65 and 0.30kgC/m3Fe, which are maintained constant. If the pre-
exponential and activation energy are 6.2x10-7m2/s and 80,000 J/mol, respectively, compute
the temperature at which the diffusion flux is 1.43 x 10-9 kg/m2-s.
2. Explain the fundamental effects of alloying elements in steel on polymorphic transformation
temperatures, grain growth, eutectoid point, retardation of the transformation rates, formation
and stability of carbides.
3. Describe the kind of fracture which may occur as a result of a loose fitting key on a shaft.
SYLLABUS
MODULE - 1
Earlier and present development of atomic structure - Primary bonds: - characteristics of covalent,
ionic and metallic bond - properties based on atomic bonding: - Secondary bonds: - classification,
application. (Brief review only).
Crystallography: - SC, BCC, FCC, HCP structures, APF - theoretical density simple problems - Miller
Indices: - crystal plane and direction - Modes of plastic deformation: - Slip and twinning -Schmid's
law - Crystallization: Effects of grain size, Hall - Petch theory, simple problems.
MECHANICAL ENGINEERING
MODULE - II
Classification of crystal imperfections - forest of dislocation, role of surface defects on crack
initiation- Burgers vector –Frank Read source - Correlation of dislocation density with strength and
nano concept - high and low angle grain boundaries– driving force for grain growth and applications -
Polishing and etching - X – ray diffraction, simple problems –SEM and TEM - Diffusion in solids,
fick’s laws, mechanisms, applications of diffusion in mechanical engineering, simple problems.
MODULE - III
Phase diagrams: - need of alloying - classification of alloys - Hume Rothery`s rule - equilibrium
diagram of common types of binary systems: five types - Coring - lever rule and Gibb`s phase rule -
Reactions- Detailed discussion on Iron-Carbon equilibrium diagram with microstructure and
properties -Heat treatment: - TTT, CCT diagram, applications - Tempering- Hardenability, Jominy end
quench test, applications- Surface hardening methods.
MODULE - IV
Strengthening mechanisms - cold and hot working - alloy steels: how alloying elements affecting
properties of steel - nickel steels - chromium steels - high speed steels -cast irons - principal non
ferrous alloys.
MODULE - V
Fatigue: - creep -DBTT - super plasticity - need, properties and applications of composites, super
alloy, intermetallics, maraging steel, Titanium - Ceramics:- structures, applications.
Text Books
1. Callister William. D., Material Science and Engineering, John Wiley, 2014
2. Higgins R.A. - Engineering Metallurgy part - I – ELBS,1998
Reference
1. Avner H Sidney, Introduction to Physical Metallurgy, Tata McGraw Hill,2009
2. Anderson J.C. et.al., Material Science for Engineers, Chapman and Hall,1990
3. Clark and Varney, Physical metallurgy for Engineers, Van Nostrand,1964
4. Dieter George E, Mechanical Metallurgy, Tata McGraw Hill, 1976
5. Raghavan V, Material Science and Engineering, Prentice Hall,2004
6. Reed Hill E. Robert, Physical metallurgy principles, 4th edition, Cengage Learning,2009
7. Myers Marc and Krishna Kumar Chawla, Mechanical behavior of materials, Cambridge
University press,2008
8. Van Vlack -Elements of Material Science - Addison Wesley,1989
9. https://nptel.ac.in/courses/113/106/113106032
MECHANICAL ENGINEERING
MODEL QUESTION PAPER
METALLURGY & MATERIAL SCIENCE - MET 205
Max. Marks : 100 Duration : 3 Hours
Part – A
Answer all questions.
Answer all questions, each question carries 3 marks
1. What is a slip system? Describe the slip systems in FCC, BCC and HCP metals
2. NASA's Parker Solar Probe will be the first-ever mission to "touch" the Sun. The spacecraft,
about the size of a small car, will travel directly into the Sun's atmosphere about 4 million miles
from the earth surface. Postulate the coolant used in the parker solar probe with chemical
bonds.
3. What is the driving force for grain growth during heat treatment
4. What are the roles of surface imperfections on crack initiation
5. Explain the difference between hardness and hardenability.
6. What is tempered martensite? Explain its structure with sketch.
7. Postulate, why cast irons are brittle?
8. How are properties of aluminum affected by the inclusion of (a) copper and (b) silicon as alloying
elements?
9. What is the grain size preferred for creep applications? Why. Explain thermal fatigue?
10. Explain fracture toughness and its attributes into a screw jack?
PART -B
Answer one full question from each module.
MODULE – 1
11. a. Calculate the APF of SC, BCC and FCC (7 marks).
b. What is slip system and explain why FCC materials exhibit ductility and B C C a n d HCP
exhibit brittle nature with details of slip systems (7 marks).
OR
12. Explain the effect of: (i) Grain size; (ii) Grain size distribution and (iii) Grain orientation (iv)
Grain shape on strength and creep resistance with neat sketches. Attributes of Hall-Petch
equation and grain boundaries (14 marks).
MODULE – 2
13. a. Describe step by step procedure for metallographic specimen preparation? Name different
types etchants used for specific metals and methods to determine grain size (7 marks).
MECHANICAL ENGINEERING
b. Carbon is allowed to diffuse through a steel plate 15 mm thick. The concentrations of carbon
at the two faces are 0.65 and 0.30 kgC/m3Fe, which are maintained constant. If the pre-
exponential and activation energy are 6.2x10-7m2/s and 80,000 J/mol, respectively, compute the
temperature at which the diffusion flux is 1.43 x 10-9 kg/m2-s (7 marks).
OR
14. a. Explain the fundamental differences of SEM and TEM with neat sketches (7 marks).
b. A beam of X-rays wavelength 1.54Å is incident on a crystal at a glancing angle of 8o35’
when the first order Bragg’s reflection occurs calculate the glancing angle for third order
reflection (7 marks).
MODULE – 3
15. Postulate with neat sketches, why 100% pure metals are weaker? What are the primary
functions of alloying? Explain the fundamental rules governing the alloying with neat sketches
and how is it accomplished in substitution and interstitial solid solutions (14 marks).
OR
16. Draw the isothermal transformation diagram of eutectoid steel and then sketch and label (1) A
time temperature path that will produce 100% pure coarse and fine pearlite (2) A time
temperature path that will produce 50% martensite and 50% bainite (3) A time temperature
path that will produce 100% martensite (4) A time temperature path that will produce 100%
bainite (14 marks).
MODULE – 4
17. Explain the effect of, polymorphic transformation temperature, formation and stability of
carbides, grain growth, displacement of the eutectoid point, retardation of the transformation
rates, improvement of corrosion resistance on adding alloy elements to steel (14 marks).
OR
18. Give the composition, microstructure, properties and applications of (i) Gray iron and SG iron.
(ii) White iron and Gray iron. (iii) Malleable iron and Gray iron. (iv) Gray iron and Mottled
iron, (v) SG iron and Vermicullar Graphite Iron (14 marks).
MODULE – 5
19. a A small hole is drilled through a steel plate ahead of a crack, whether it can stop the crack’s
progress until repairs can be made or not? Explain in detail and derive the equation
(7 marks).
b What is ductile to brittle transition in steel DBTT? What are the factors affecting ductile to
brittle transition? Narrate with neat sketch (7 marks).
OR
20. Classify ceramics with radius ratio with neat sketches. Explain with an example for each of the
AX, AmXp, AmBmXp type structures in ceramics with neat sketch (14 marks).
MECHANICAL ENGINEERING
COURSE CONTENT AND LECTURE SCHEDULES.
No.
Course
Module TOPIC of
outcomes
hours
Earlier and present development of atomic structure; attributes of ionization
energy and conductivity, electronegativity; correlation of atomic radius to
strength; electron configurations; - Primary bonds: - characteristics of
covalent, ionic and metallic bond: attributes of bond energy, cohesive force,
density, directional and non-directional - properties based on atomic
1.1 2 CO1
bonding:- attributes of deeper energy well and shallow energy well to melting
temperature, coefficient of thermal expansion - attributes of modulus of
elasticity in metal cutting process -Secondary bonds:- classification- hydrogen
bond and anomalous behavior of ice float on water, application- specific
heat, applications. (Brief review only).
Crystallography:- Crystal, space lattice, unit cell- SC, BCC, FCC, atomic
1.2 packing factor and HCP structures - short and long range order - effects of 2
crystalline and amorphous structure on mechanical properties. CO1
CO2
Coordination number and radius ratio; theoretical density; simple problems -
1.3 1
Polymorphism and allotropy.
Miller Indices: - crystal plane and direction - Attributes of miller indices for
1.4 slip system, brittleness of BCC, HCP and ductility of FCC - Modes of plastic 1
deformation: - Slip and twinning. CO5
Schmid's law, equation, critical resolved shear stress, correlation of slip
1.5 1
system with plastic deformation in metals and applications.
Mechanism of crystallization: Homogeneous and heterogeneous nuclei
formation, under cooling, dendritic growth, grain boundary irregularity -
1.6 Effects of grain size, grain size distribution, grain shape, grain orientation on 2 CO2
dislocation/strength and creep resistance - Hall - Petch theory, simple
problems.
2.1 Classification of crystal imperfections: - types of point and dislocations. 1
Effect of point defects on mechanical properties - forest of dislocation, role of CO2
2.2 1
surface defects on crack initiation - Burgers vector.
Dislocation source, significance of Frank-Read source in metals deformation -
2.3 Correlation of dislocation density with strength and nano concept,
applications. 3 CO2
Significance high and low angle grain boundaries on dislocation – driving
2.4
force for grain growth and applications during heat treatment.
Polishing and etching to determine the microstructure and grain size-
2.5
Fundamentals and crystal structure determination by X – ray diffraction, 2
CO2
simple problems –SEM and TEM.
CO5
Diffusion in solids, fick’s laws, mechanisms, applications of diffusion in
2.6 1
mechanical engineering, simple problems.
MECHANICAL ENGINEERING
Phase diagrams: - Limitations of pure metals and need of alloying -
3.1 classification of alloys, solid solutions, Hume Rothery`s rule - equilibrium 2
diagram of common types of binary systems: five types. CO2
CO5
Coring - lever rule and Gibb`s phase rule - Reactions: - monotectic, eutectic,
3.2 1
eutectoid, peritectic, peritectoid.
Detailed discussion on Iron-Carbon equilibrium diagram with microstructure
3.3 and properties changes in austenite, ledeburite, ferrite, cementite, special
features of martensite transformation, bainite, spheroidite etc. CO2
3
Heat treatment: - Definition and necessity – TTT for a eutectoid iron–carbon CO5
3.4 alloy, CCT diagram, applications - annealing, normalizing, hardening,
spheroidizing.
Tempering:- austermpering, martempering and ausforming - Comparative
3.5 study on ductility and strength with structure of pearlite, bainite, spherodite, 1 CO2
martensite, tempered martensite and ausforming.
Hardenability, Jominy end quench test, applications- Surface hardening
methods:- no change in surface composition methods :- Flame, induction, laser
3.6 2
and electron beam hardening processes- change in surface composition
methods :carburizing and Nitriding; applications. CO2
Cold working: Detailed discussion on strain hardening; recovery; re-
4.1 crystallization, effect of stored energy; re- crystallization temperature - 1
hot working, Bauschinger effect and attributes in metal forming.
Alloy steels:- Effects of alloying elements on steel: dislocation movement,
polymorphic transformation temperature, alpha and beta stabilizers, formation
4.2 and stability of carbides, grain growth, displacement of the eutectoid point, 1 CO4
retardation of the transformation rates, improvement in corrosion resistance,
mechanical properties
Nickel steels, Chromium steels etc. – change of steel properties by adding
alloying elements: - Molybdenum, Nickel, Chromium, Vanadium, Tungsten,
Cobalt, Silicon, Copper and Lead - High speed steels - Cast irons:
Classifications; grey, white, malleable and spheroidal graphite cast iron etc, CO4
4.3 4
composition, microstructure, properties and applications - Principal Non CO5
ferrous Alloys: - Aluminum, Copper, Magnesium, Nickel, study of
composition, properties, applications, reference shall be made to the phase
diagrams whenever necessary.( Topic 4.3 may be considered as a assignment).
Fatigue: - Stress cycles – Primary and secondary stress raisers - Characteristics
4.4 1
of fatigue failure, fatigue tests, S-N curve.
Factors affecting fatigue strength: stress concentration, size effect, surface CO3
roughness, change in surface properties, surface residual stress - Ways to
4.5 2
improve fatigue life – effect of temperature on fatigue, thermal fatigue and its
applications in metal cutting.
MECHANICAL ENGINEERING
Fracture: – Brittle and ductile fracture – Griffith theory of brittle fracture –
Stress concentration, stress raiser – Effect of plastic deformation on crack
5.1 propagation - transgranular, intergranular fracture - Effect of impact loading on 2
ductile material and its application in forging, applications - Mechanism of
fatigue failure. CO3
Structural features of fatigue: - crack initiation, growth, propagation - Fracture
toughness (definition only), applications - Ductile to brittle transition
5.2 1
temperature (DBTT) in steels and structural changes during DBTT,
applications.
Creep: - Creep curves – creep tests - Structural change:- deformation by slip,
sub-grain formation, grain boundary sliding - Mechanism of creep deformation
5.3 2 CO3
- threshold for creep, prevention against creep - Super plasticity: need and
applications
Composites: - Need of development of composites; fiber phase; matrix phase;
5.4 2
only need and characteristics of PMC, MMC, and CMC.
Modern engineering materials: - only fundamentals, need, properties and CO3
applications of, intermetallics, maraging steel, super alloys, Titanium- CO5
5.5 3
Ceramics:-coordination number and radius ratios- AX, AmXp, AmBmXp type
structures – applications.
