Metallurgical Engineering (Detailed Syllabus of 4th Semester)

L: Lecture, T: Tutorial, P: Practical, C: Credit

SEMESTER IV

CODE SUBJECT L T P C

MAT2212 Numerical Methods & Computing 4 1 - 5

MME2207 Fuels, Furnaces and Refractories 3 1 - 4

MME2208 Deformation Behavior & Testing of Materials 3 1 - 4

MME2209 Principle of Extractive Metallurgy 3 1 - 4

MME2210 Fuels, Furnaces & Refractory Lab - - 3 2

MME2211 Deformation Behavior & Testing of Materials

Lab

- - 3 2

MME2212 Non Destructive Testing Lab - - 3 2

PFD2204 Professional Development 2 - - 2

TOTAL 15 4 9 25

Assessment:

PRE

ESE TA Mid semester Total

20 30 50 50

PRE- Progressive Review Examination

TA- Teacher Assessment ESE-End Semester Examination

Semester: IV Branch: Metallurgical Engineering

Subject: Numerical Methods and Computing Code: MAT2212

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Course Description:

Mathematics is the language of science, the concise form of communication used to represent nature allowing the observations, dissection and hypothesizing of nature and all its ongoing processes. The Mathematical reasoning ignites the logical and critical thinking and enables to express the natural processes using quantifiable measures. The MAT2212 is the course related to Numerical Methods and Computing of both function of a single variable as well as functions of several variables. The numerical methods are applied to the problems where the analytical solution is

either not available or too complex. The purpose of studying Numerical Methods and Computing is to introduce the mind to the scientific method of analysis through which, the practical problems can be identified, explanations generated and logical solutions selected which in essence are requisites for the development of good engineering sense.

Course Objectives:

1. To make students proficient in solving the system of linear algebraic

equations.

2. To make students familiar with the process of approximating a tabulated function by a polynomial.

3. To make students learn the process of finding the derivatives and integrals of a tabulated function.

4. To make students familiar with the methods for the numerical solution of ordinary differential equations.

5. To make students learn the process of fitting standard curves to the tabulated

data.

Syllabus:

UNIT- 1: Roots of Algebraic and Transcendental Equations, Bisection, Regula- Falsi and Newton-Raphson Methods, System of linear algebraic equations, Consistency and Existence of Solutions, Direct Methods: Gauss Elimination and Gauss-Jordan Methods, Iterative Methods: Jacobi’s, Gauss-Siedal & Successive Over Relaxation Methods. C Programming of Newton’s iterative method.

UNIT-2: Finite Differences and Interpolation, Interpolation with equally and unequally spaced points, Interpolation Formulae based on forward, backward, central and divided differences, Lagrange’s Interpolation formula, Inverse Interpolation.

UNIT- 3: Numerical Differentiation, Derivatives using Forward, Backward and Central Difference Formulae, Numerical Integration, Newton-Cote’s quadrature formula, Trapezoidal rule, Simpson’s rules, Boole’s rule, Weddle’s rule. C Programming of Trapezoidal, Simpson’s 1/3 and 3/8th rule. UNIT- 4: Numerical Solution of Ordinary Differential Equations, Picard’s Method, Taylor’s Series Method, Euler’s Method, Euler’s Modified Method, Range-Kutta Methods, Predictor-corrector Methods, Milne’s Method, Adams-Bashforth Method. C Programming of Euler’s and Runge-Kutta method of order 4. UNIT-5: Curve Fitting, Method of Least Squares and group averages, fitting a Straight Line, Parabolic Curve, Fitting the Nonlinear Curves, Regression and Correlation.

Text Books:

1. Advanced Engineering. Mathematics by Erwin Kreyszig (8th edition) – John

Wiley & Sons.

2. Higher Engineering Mathematics by B.S. Grewal (38th edition)-Khanna

Publishers.

3. Numerical Methods in Engineering and Science by Dr. B.S. Grewal, Khanna

Publishers.

4. Numerical Methods for Scientific and Engineering Computation by M .K. Jain,

S. R. K. Iyengar& R. K. Jain, Wiley Eastern Limited

5. Higher Engineering Mathematics by B. V. Rammana-Tata Mc Graw Hill.

6. Numerical Methods for Scientists and Engineers by K. Shankar Rao, Prentice

Hall of India.

7. Numerical Methods, by S. S. Sastry, Prentice Hall Inc. India.

Course Outcome:

After completion of the course, students will be able to:

1. Numerically estimate the roots of algebraic and transcendental equations.

2. Solve the system of linear algebraic equations by direct and iterative methods.

3. Approximate the tabulated function by a polynomial.

4. Find the derivatives and integrals of a tabulated function.

5. Obtain the numerical solution of Ordinary Differential Equations.

6. Fit the linear and non linear curves to the tabulated data.

Assessment:

Assessment can vary from course to course and can include a combination of class work, tutorials, assignments, laboratory work, quizzes, project work and exams.

Semester: IV Branch: Metallurgical Engineering Subject: Fuels, Furnaces and Refractories Code: MME2207

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Course Description:

The Fuels, Furnaces, Refractories course is to prepare students for careers in metallurgy engineering where knowledge of Fuels, Furnaces, Refractories can be applied to the advancement of technology. For different metallurgical processes heat treatment is an essential operation for which fuels and furnaces are used. To allow all these thermal processes in a furnace including use of refractory is a prominent issue to contain heat and protect the furnace structure. Study of fuels and

Refractories is thus a very significant topic in this course.

Course Objectives:

1. To understand a knowledge about solid, liquid and gaseous fuels.

2. To acquire idea about the manufacturing process and uses of the above fuels.

3. To acquire fundamental idea about Refractories and metallurgical furnaces.

4. To understand constructional and working principles of different types of furnaces and refractories.

Syllabus:

UNIT-1: Fuel: Define the Fuel, types of fuel, State the importance of Solid, Liquid and Gaseous fuels, Theory of coal, Characteristics and significance of its constituents. UNIT-2: Solid Fuel: Distinguish between proximate and ultimate analysis, Calorific value of coal, Carbonization of coal, high temperature carbonization and low temperature carbonization, Discuss the criteria of selection of metallurgical coal, Coke Testing. Define and explain Shatter and Mecum Index. UNIT-3: Gaseous Fuel: Constitution of petroleum; properties of petroleum product, production and uses of coal tar. Properties of gaseous fuels, production and utilization of following gaseous fuels: Water gas, producer, gas, carburetted water gas, Coke oven gas, blast furnace gas, Natural gas, Combustion and Combustion related numerical.

UNIT- 4:

Furnaces: Batch furnaces, Continuous furnaces. Construction and features of furnaces like Cupola, Induction furnace, Arc furnace, Rotary furnace, Muffle furnace etc, Evolution of heat and flame temperature. Sources of heat losses in furnace and heat balance, available heat. Natural, forced, induced and balanced draft. Chimney height, waste heat recovery. UNIT-5: Refractories: Classify Refractories, properties of Refractories, refractory selection parameters, methods of manufacturing and properties of silica, fire clay, magnesia, dolomite, chrome-magnesite, graphite Refractories and magnesia carbon bricks, special refractories, Castable Refractories Refractories applications.

Text Books:

1. Elements of Fuels, Furnaces and Refractories, O. P. Gupta, Khanna

publication.

2. Fuels, Furnaces and Refractories, J. D. Gilchrist

3. Fuels, Furnaces, Refractories and Pyrometry,-A.V.K. Suryanarayana, B. S. Publication

4. Refractories, M. L. Mishra

Reference Books:

1. Industrial Furnaces - Vol. I & II, W. Trinks and M. H. Mawhiney, Wiley

2. Refractories, F. H. Norton, McGraw-Hill.

Course Outcome:

After learning the course the students should be able to:

1. Explain various temperature measurement and control devices.

2. Compare different types of fuels and describe their testing methods.

3. Explain different aspects of Combustion process of fuels and Solve problems

based on this.

4. Classify and explain Construction and working of different furnaces.

5. Analyze causes of Heat losses in furnaces and suggest methods of

minimization it and Waste heat recovery.

6. Explain various Properties, manufacturing and testing of refractories.

7. Select the relevant refractory material for the metallurgical operations.

8. Demonstrate the ability to use the core concepts of engineering application in

Fuels, Furnaces, and Refractories.

9. Demonstrate the ability to select the proper type of furnace with relevant refractory material, use appropriate Fuel and temperature measurement device to obtain qualitative solutions of given metallurgical operation.

Assessment:

Assessment can vary from course to course and can include a combination of class work, tutorials, assignments, laboratory work, quizzes, project work and exams.

Semester: IV Branch: Metallurgical Engineering Subject: Deformation Behavior & Testing of Materials Code: MME2208

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Course Description:

This course Deformation behavior and Testing of material is principally aimed to introduce the students about mechanical properties, deformation behavior and testing of materials. This course comprises the concept of destructive as well as non destructive testing processes. The destructive testing processes will comprise tensile test, Torsion test, Fracture test, Fatigue and Creep test. The destructive testing processes will comprise Dye penetrant, Radiography, Magnetic particle and

Ultrasonic testing. The importance, scope advantages and disadvantages will be discussed.

Course Objectives:

1. At some point of time an engineering problem involves issues related to

material selection. The objective of this course to understanding the behavior of materials, particularly Mechanical properties correlation, will help selecting suitable materials for a particular application.

2. To provide a basic understanding of the underlying principles that determines the evolution of structures in metals and alloys during their processing and its relation with their properties & performance in service.

3. The students will get basic concept of different destructive and non-destructive testing.

4. This course provides a smooth link between the basic knowledge of science and engineering courses.

Syllabus:

UNIT- 1:

Tension Test: Mechanical properties, Dislocation theory, Stress and strain measurement, Elasticitc, Anelastic and Viscoelastic of materials, Yield stress, Proof stress, Ultimate tensile stress, Flow curve, Engineering and true stress-true strain curve; Necking phenomenon and conditions of necking; Universal testing machine; Numerical problems on test data.

UNIT-2:

Torsion Test: Types of Torsion failures, Torque, Determination of strength of a solid and hollow shaft under torsion; Hardness test: Principles and machines used – Brinell, Vickers, Rockwell, Scleroscope and micro hardness testing.

UNIT- 3:

Fracture: Types of fracture, theoretical cohesive strength of metal, Griffith theory of Brittle fracture, Impact Test, Notched bar impact tests, DTBT; Metallurgical factors affecting ductile to brittle transition.

UNIT- 4:

Fatigue and Creep Testing: Basics of fatigue phenomenon; S – N curve and corrosion fatigue; Fatigue testing; Signification of Creep; Testing procedure; Creep curve and its interpretation; Metallurgical and mechanical factors affecting creep and fatigue failures.

UNIT-5:

Non-destructive testing: Importance, scope, advantages and limitations – Dye penetrant, Radiography, Magnetic particle, Ultrasonic and electrical methods of testing and their application.

Text Books:

1. Mechanical Metallurgy: George E. Dieter.

2. R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering

Materials", John Wiley and Sons, 1976.

3. Material Science & Engineering, W. D. CalisterJr. Willy India Pvt. Ltd.

4. Physical Metallurgy ,Vijendra Singh, SPD, Pvt Ltd.

5. Testing of Metallic Materials: A. V. K. Suryanarayan.

Reference Books:

1. Testing and Inspection of Engineering Materials- Davies, Taroxall and Wiscosil.

2. Mechanical Testing of Metallic Materials: D. A. Beument.

3. Engineering Materials Science: C. W. Richards.

4. Non Destructive testing: Louis Cartz, ASM International Materials Park.

5. Destructive testing: ASM International Materials Park.

Course Outcome:

After successful completion of the course students should be able to:

1. Know about Elastic and plastic deformation of metallic materials.

2. Understand effect of deformation behavior of ductile & brittle material.

3. Able to understand various strengthening methods of metals & alloys.

4. Able to understand various concepts of creep, fatigue behaviors in metals, ceramics and polymers.

5. Able to have understanding on various destructive and non-destructive tests,

their advantages and disadvantages in finding deformation behavior of materials from macro to atomic level.

Assessment:

Assessment can vary from course to course and can include a combination of class work, tutorials, assignments, laboratory work, quizzes, project work and exams.

Semester: IV Branch: Metallurgical Engineering Subject: Principle of Extractive Metallurgy Code: MME2209 ……………………………………………………………………………………………………….

Course Description:

This course is aimed to introduce the students about different method of extraction of metals from ores. Metal extraction through various routes is discussed in detail. Basic principle and kinetics involved in the extraction is deliberated. Practical issues related extraction and their remedies will be addressed and extensive knowledge will be provided. Green routes for the extraction of precious metals from urban ores (E-Waste) will be introduced.

Course Objectives:

1. To develop students’ knowledge of current methods to recover base metals

from natural ores and man-made raw materials.

2. To develop students’ individual skills at performing relevant heat, mass and thermodynamic calculations for the extraction of base metals.

3. To apply the fundamental knowledge for design of a reactor and process flow sheets.

4. To be able to select the correct process routes, reactors and be able to optimize and control them.

5. To develop the leaders for coming future who are able to bring new and economic technologies for metal extraction.

Syllabus:

UNIT- 1: Introduction, type, advantages and limitations of different extraction processes. Beneficiation steps in ore processing like comminution, classification, separation methods, comparison in pyrometallurgy and hydrometallurgy.

UNIT-2: Calcination, roasting, sintering, pelletisation, smelting, converting, refining, pyrometallurgical process using vacuum. Thermodynamic principle and stability diagram (Ellingham diagram in pyrometallurgy), limitation of Ellingham diagram, metallic reduction by C, CO, Hydrogen and metals, principle of metallothermic

reduction and halide metallurgy.

UNIT- 3:

Principle, general considerations kinetics, leaching, reagent kinetics, role of oxygen, pressure leaching, bacterial leaching, solvent extraction, ion exchange. gaseous reduction of aqueous solution.

UNIT- 4: Eletrowinning, and electrorefining of metal from aqueous anode fused salt systems. Physico-chemical principle of fused salt electrolysis.

UNIT- 5: Simplified flow sheet for the production of aluminum copper, zinc lead, tin and magnesium. Order of reaction, theories of reaction kinetics, role of activation energy,

theory of absolute reaction rate.

Text Books:

1. Principles of Extractive Metallurgy Terkel Rosenqvist, McGraw-Hill Book Company.

2. Principles of Extractive Metallurgy, H.S. Ray and A. Ghosh, WEL Publishing.

3. Extractive Metallurgy of Copper, W.G. Davenport, A.K. Biswas, PERGAMON

publishing company.

4. Handbook of Extractive Metallurgy: Fathi Habashi; Wiley-VCH.

Course Outcome:

After successful completion of the course students should be able to:

1. Know about various extraction processes of metals.

2. Understand basic principles of the extraction process.

3. Able to understand low grade ores and problems related to extraction.

4. Able to understand various concepts and apply them to design the reactor for economical extraction of metals.

Assessment:

Assessment can vary from course to course and can include a combination of class work, tutorials, assignments, laboratory work, quizzes, project work and exams.

Semester: IV Branch: Metallurgical Engineering Subject: Fuels, Furnaces and Refractories Laboratory Code: MME2210

…………………………………………………………………………………………………

Course Objectives:

1. To understand a knowledge over practical phenomenon of solid, liquid and

gaseous fuels.

2. Well-rounded individuals who both understand the principles and can undertake the practice of the about the properties and uses of the above fuels.

3. To acquire practical fundamental ideas about Refractories and metallurgical furnaces.

4. Able to operate as effective engineers or scientists in metallurgical and

materials industries or related fields.

Syllabus:

(At least six experiments are to be performed by each student)

List of Experiments:

1. Determination of flash & fire point of given oil by Pensky Martin Apparatus.

2. Determination of flash & fire point of given oil by Able's Apparatus.

3. Determination of viscosity using Redwood Viscometer.

4. Determination of Calorific value of a solid fuel using Bomb Calorimeter.

5. Study of different types of furnaces.

6. Study of different types of Refractories.

7. Determination of Spalling resistance of Refractories.

8. Determination of Refractoriness under load.

9. Determination of thermal conductivity of Refractory.

10. Determination of Porosity of a coal sample.

Equipment Required:

1. Pensky Martin Apparatus.

2. Able's Apparatus.

3. Redwood Viscometer.

4. Bomb Calorimeter.

5. Sieve Analyzer.

6. Pot Mill.

Course Outcome:

1. Conduct and analyze a fuel.

2. Ability to select a fuel for their specific application.

3. Perform of the problem through experiments to reach the sustainable solution

related to specified solid or liquid fuels.

4. Provide continuing professional development and self learning.

5. Overall understanding about the different types of furnaces and refractories.

Semester: IV Branch: Metallurgical Engineering Subject: Deformation behavior and Testing of Materials Lab Code: MME2211

……………………………………………………………………………………………………

Course Objectives:

1. To understand the mechanical behaviour of materials under deferent loading

condition.

2. To provide a basic understanding of different hardness testing process.

3. The students will get basic concept of different destructive test.

4. To understand the concept for designing suitable material for a particular

application.

Syllabus:

(At least six experiments are to be performed by each student)

List of Experiments:

1. To determine the tensile properties of ductile and brittle materials.

2. To determine hardness of materials by Brinell hardness Test.

3. To determine hardness of materials by Vicker hardness Test.

4. To determine hardness of materials by Rockwell hardness Test and study of different scale.

5. To determine the impact strength of materials by Izod and Charpy impact

Test

6. To determine the twisting properties of materials by torsion test.

7. To determine the fatigue limit of material by Fatigue test.

8. To determine the ductility of material by Bend test.

9. To study of Creep and creep failure of material.

10. To study the spring test.

Equipment Required:

1. Universal testing machine

2. Impact testing machine

3. Torsion testing machine

4. Fatigue testing machine

5. Hardness testing machine

6. Spring testing machine

Course Outcome:

The course on deformation behaviour and testing of material will help the student to understand the mechanical properties and different mechanical testing process such as destructive test. They may know the behaviour of materials under sound as well as defect condition. They may know the basic concept to enhance the mechanical properties of material and they may understand the way to overcome the problem existing in the manufactured materials. This will provide a smooth link between the basic knowledge of science and engineering courses.

Semester: IV Branch: Metallurgical Engineering Subject: Non Destructive Testing Lab Code: MME2212

………………………………………………………………………………………………………….

Course Objectives:

1. Fully qualified as entry-level materials engineers, with an ability to adapt and

progress in a rapidly changing field.

2. Well-rounded individuals who both understand the principles and can undertake the practice of the science and engineering of materials.

3. Able to operate as effective engineers or scientists in materials industries, academia, or related fields.

Syllabus:

(At least six experiments are to be performed by each student)

List of Experiments:

1. To perform visual inspection

2. To perform liquid/dye penetrant test

3. To perform Ultrasonic test

4. To perform Magnetic particle test

5. To perform Spark test

6. Study of Radiography test

7. Study of Eddy current test

Equipment Required:

1. Die penetrants

2. Ultrasonic transducer

3. Cathode ray oscilloscope

4. Magnetic particle testing machine

Course Outcome:

1. Conduct and analyze various types of defects.

2. Understand the need for non-destructive test.

3. Better understanding on requirement of quality control and its importance in industry.

4. Provide continuing professional development and self learning.

Semester: IV Branch: Metallurgical Engineering Subject: Effective Speaking Skills Code: PFD2204

………………………………………………………………………………………………………….

Course Objectives: The main objective of the course is to improve the students’ spoken English and enable them to acquire the art of public speaking. The course is heavily practice oriented and has been designed to develop the skills of speech through presenting papers, giving seminars, participating in group discussions and appearing at interviews, etc.

Course Content:

UNIT- 1: Speaking- An overview Speaking: an Overview, Listening Effectively, Non-Verbal Communication, Art of Persuasion.

UNIT- 2: Dynamics of Professional Speaking Introduction, Combating Stage Fright, Describing Objects/Situations/People, Delivering Just-a-minute Sessions, Delivering Different Types of Speeches.

UNIT- 3: Professional Presentations Planning of a Presentation, Designing of a Presentation, Preparing Power Point Slides for Presentations, Individual and Group Presentations, Making Presentation.

UNIT- 4: Group Discussions Introduction, GD and Debate, Types of GD, Personality Traits to be evaluated, Dynamics of Group Behaviour, DOs and DON’Ts of GD.

UNIT -5: Job Interviews Introduction, Process, Stages in Job Interviews, Types, Desirable Qualities,

Preparation, Tips for Success.

Course Outcome: Upon successful completion of the course, students will be able to:

1. Choose a topic and formulate the speech according to the purpose, audience, and time constraints.

2. Employ vocal variety in rate, pitch, and intensity as suitable to the message, occasion, and audience.

3. Use strategies and skills to manage communication anxiety.

4. Present speeches using an extemporaneous style with effective transitions that, establish connectedness, movement from one idea to another, and clarify relationships.

5. Use knowledge of digital presentation tools to create and make effective presentations.

6. Participate in GD effectively.

7. To face interviews confidently.

Recommended Text Books:

5. Jeff Butterfield, Soft Skills for Everyone, CENAGE LEARNING, Delhi, 2014.

6. Sanjay Kumar and Pushp Lata, Communication Skills, New Delhi: Oxford

University Press, 2011.

7. Pushp Lata and Sanjay Kumar, Communicate or Collapse: A Handbook of Effective Public Speaking, Group Discussion and Interviews, New Delhi: Prentice Hall of India, 2007.

8. Dale Carnegie, The Art of Public Speaking, New Delhi: Ocean Paperbacks, 2016.

References:

9. Stephen E. Lucas, The Art of Public Speaking, Third Edition, Singapore:

McGraw-Hill, 1989.

10. Sonya Hamlin, How to Talk so People Listen, New York: Throson, 1993.

11. Jeff Davidson, The Complete Guide to Public Speaking, Manjul Books PVT. Bhopal, 2006.

12. Turk, Cristopher, Effective Speaking, Second Indian Reprint, Taylor and

Francis Group, Delhi, 2010