MATERIAL TECHNOLOGY

Chapters

Session I

1.0   Material Technology

• 1.            Historical perspective: Role of engineering material. 
• 2.            Classification: - List and the different types of ferrous metals - pig iron - cast iron - wrought iron - steel
• 3.            Materials applicable to metal working:Different metals used in metal working - Ferrous metals - Non ferrous metals

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2.0   Properties of materials:

• 1.            Classify the properties of material: physical properties of material - chemical properties of material –mechanical properties of material. Enumerate the physical properties:  specific gravity - specific heat - conductivity - magnetic properties - electrical properties. Enumerate the chemical properties:  resistance against acid - resistance against alkalis - resistance against oxidations. Enumerate the mechanical properties: strength - elasticity - stiffness - toughness - resilience - ductility   and malleability - hardness - hardenability - fatigue – creep

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3.0   Atomic bonds

• 1.            Explain the atomic bond.
• 2.            Classification of atomic bond: primary bond -secondary bond
• 3.            Primary Bond:  Ionic bond - covalent bond - metallic bond 
• 4.            Secondary Bond: Dispersion bond -dipole bond -hydrogen bond
• 5.            Compare the different types of bond: Ionic and metallic - covalent and metallic

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4.0   Crystalline structure.

• 1.            Introduction - Types of solids: crystalline solid - non-crystalline solid - explanation of crystal and crystal structure
• 2.            Space lattice  - Explain unit cell and space lattice - Classify the space lattice: body centered cubic lattice - face centered cubic lattice-closed packed hexagonal lattice
• 3.            Crystal planes of direction - Explain: crystal plane - miller indices - identify miller indices - Use of miller indices in finding out the crystal direction
• 4.            Crystal imperfection-Explain crystal imperfection-effect of crystal imperfection on the mechanical properties of metals-Types of crystal imperfections- point defects-line defects-surface defects. 

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5.0   Solid solution

• 1.  Solid solutions - classify - explain
• 2.  Solid phases and its types: single phase solids- multiphase solids - Phase diagram - explain alloy - classify the phase diagram: unary phase diagram - binary phase diagram

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6.0  Solidification of metals

• 1.Explain the solidification process of metals - Explain the structural change in the metal with rate cooling curve 

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Session II

7.0   Deformation of crystals

• 1.Explain    different   types   of   crystal   deformations:  deformation by slip - deformation by truing

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8.0   Ferrous metals

• 1. Meaning - Different types: Pig iron - Cast iron -Wrought iron - steel.

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9.0   Cast iron

• 1.            Process of manufacturing cast iron-Classification: grey cast iron-white cast iron-malleable cast iron-chilled cast iron- alloy cast iron.  Properties and use of different cast iron 

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10.0  Steel

1. 1.            Composition of steel: Iron-carbon-other elements. Influence of following constituents:  carbon - silicon - manganese - sulphur -phosphorous. Classification of steel according to:  carbon contents - purpose - method of manufacture. Plain carbon steel - Composition and application: low carbon steel- medium carbon steel - high carbon steel - tool steel

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11.0  Alloying elements

1. 1.            Alloying elements - classification of alloy steel: chemical composition- purpose -types of steel-alloy structural steel -alloy tool steel - alloy steel with special physical properties. Effects of different alloying elements: chromium - nickel-manganese-vanadium - molybdenum -silicon - tungsten - sulphur- copper - cobalt. Composition properties and uses of alloy steel: nickel steel-chromium steel - nickel chrome steel- molybdenum steel- chromium molybdenum steel - nickel chrome- molybdenum steel - manganese steel - silicon steel. Special alloy steel - composition properties and uses: heat resisting steel - magnet steel - shock resisting steel - stainless steel - high speed steel. I.S.I. Specification:  plain carbon steel - alloy steel - tool steel.

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12. Different steels and uses -

1. 1.            Identify the metals used for: Press tool- jigs and fixtures  - moulds - hand tools

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13.0  Non Ferrous metals and alloys

1. 1.            Need-Different non-ferrous metals- Uses. Aluminum: Uses - Aluminum alloy -Cast aluminum -Application. Copper: Uses - Copper Zinc alloy-Copper Tin alloy-Copper Aluminum alloy - Copper Nickel alloy-Copper Nickel Zinc alloy- Applications.

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Session III

14.0  Testing of Material

• 1.            Mechanical Testing:  Explain - Need - Types: Routine test - Exploratory tests - Destructive test - Nondestructive test  - Scale model test - Fall scale test - Tests by inspection.
• 2.            Destructive test: Explain -Types: Tensile test- Compression test - Hardness test  (Brinell, Rockwell, Vickers) - Impact test - Fatigue test - Creep test.
• 3.            Nondestructive Test:  Explain - Types: Visual Examination-Radiographic tests-Ultra sonic testing- Liquid penetration test - Magnetic particle test.

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15.0  Organic material

• 1.            Introduction to organic material: Application – Different materials used in engineering: Natural materials -synthetics
• 2.            Polymers: Monomers and polymers- Types: Naturally occurring - Synthetic polymers.
• 3.            Mechanism of Polymerization: Describe - Types: Additional polymerization - Condensation.
• 4.            Additives to Polymers: Uses - Advantage- Types: Plasticizer - Fillers - Catalysts - Initiators - Dyes - Pigments 
• 5.            Classification of Polymer structure: Linear and frame work structure - Branch and chain structure - Cross link chain structure - Crystalline structure.
• 6.            Strengthening of Polymers - Methods - Crystallization - Cross-linking - Chain stiffening.

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16.0  Ceramics

• 1.            Introduction to Ceramic material: Explain - Materials: Abrasives - White ware - Chemical stoneware - Porcelain Enamel - Electrical porcelain - Glass - Bricks - Tiles - Cement & concrete - Refractories - Slag and fluxes -Insulators
• 2.            Properties of ceramics: Mechanical properties; Compressive strength - Tensile strength - Torsional strength - Impact strength - Modules of elasticity. Electrical property: Insulation property - Die electric property - Conducting property.
• 3.            Thermal Property: Thermal capacity -Thermal conductivity - thermal shock resistant
• 4.            Application of Ceramics in industry.

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17.0  Semiconductors

• 1. Properties of Semiconductor material: Electronic property - list different semiconductor material
• 2.  Properties of super conducting materials: Thermal magnetic property - list different super conductivity material.

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18.0  Manufacturing processes

• 1.Casting: Process of casting - Advantages and disadvantages of casting - Explain types: Sand casting - Investment casting - Slush casting - Centrifugal casting - Die casting
• 2.Mechanical working of metals: Hot working - cold working - merits and demerits-Types of hot working: Rolling - Forging  - Piercing-Drawing- Spinning- Extrusion- Types of cold work:  Cold rolling - Cold drawing - Bending - Squeezing - Peening  - Spinning 
• 3.Powder metallurgy:  Process - Manufacturing of powder: Character of powder - Safety in handling - Size of powder - Bleeding of powder - Compacting – Pre-sintering- sintering - secondary operation.  Product produced - advantages - disadvantages - limitations. 

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