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