Material Science
Course Objective
To analyze the relationship between the structure and properties of ferrous alloys, non-ferrous alloys, polymer, ceramic and composite materials. Students will be able to select suitable material for different applications on the basis of their properties.
- Introduction to Materials(1 hour)
- Types of Materials
- Relationship among structures, processing and properties
- Material selection for design
- Atomic Structure, arrangement of atoms(8 hours)
- Structure of atom, periodic table, binding energy and bonds
- Atomic arrangements
- Crystal and amorphous
- Crystal geometry
- Unit cell
- Lattices, points, directions, planes in a unit cell
- Millers’ indices
- Allotropic and polymorphic transformation
- Imperfections in the atomic arrangement
- Imperfections
- Point defects, surface defects, dislocation
- Deformation by slip and twinning
- Schmid’s Law
- Movement of atoms in materials
- Fick’s First Law and Second Law
- Mechanical Properties and their tests (9 hours)
- Tensile Test
- Load- Deformation Diagrams
- Engineering stress-strain diagram for ductile and brittle materials
- True stress-strain diagram
- Properties tested from tensile test, temperature effects
- Brittle behavior and notch effects.
- Hardness Test
- Main hardness testing methods
- Brinell, Rockwell, Vickers, Knoop test
- Microhardness test, Hardness conversion table
- Impact Test
- Toughness
- Types of impact test, Charpy and Izod test
- Significance of Transition - Temperature curve, Notch sensitivity
- Fatigue Test
- Fatigue failure
- S-N curve, Endurance limit, Fatigue strength versus fatigue limit
- Preventions
- Creep Test
- Creep failure
- Creep and stress rupture curve
- Effect of temperature and stress level on creep life
- Preventions
- Deforming process for materials(6 hours)
- Cold work
- Cold work and its types
- Strain Hardening and the stress-strain curve
- Properties versus degree of Cold-work
- Microstructure and residual stress in cold worked metals
- Treatment after Cold-work
- Annealing
- Three stages of annealing (recovery, recrystallization and graingrowth)
- Hot-work
- Hot-work process and its types
- Comparison between Hot-work and Cold-work
- Solidification, Phase Relations and Strengthening Mechanism(7 hours)
- Solidification
- Nucleation and grain growth
- Dendrite formation
- Cooling curve
- Under-cooling Cast structure
- Solidification defect
- Solid solutions, Solid solutions strengthening
- Phase relations and equilibrium
- Phase, phase rule
- Phase diagram containing three- phase reactions
- Lever rule, four important three phase reactions, and Eutectic phase diagram
- Strengthening Mechanism
- Alloys strengthening by exceeding solubility limit
- Age hardening or precipitation hardening
- Residual stress during quenching and heating
- Iron – Iron Carbide diagram and Heat Treatment of Steels (10 hours)
- Iron – Iron Carbide Diagram
- Applications and limitations of Iron– Iron Carbide Diagram
- Different mixtures and phases ( ferrite, austenite, pearlite, martensite)
- Classification of steels and cast iron referring to Iron- Iron Carbide Phase diagram
- Simple Heat Treatments
- Annealing and its types ( Full annealing, homogenizing, spheroidizing), their method, applications
- Normalizing method and its application, comparison between annealing and normalizing.
- Quenching ( method and application), quenching medium, hardenability, Jominy test, TTT diagram, CCT diagram
- Tempering, its types, applications
- Different types of surface hardening processes, nitriding, carburizing, cyaniding
- Types of steels and cast iron(3 hours)
- Types of alloy steels
- High-strength Low Alloy (HSLA) steel, Stainless steel, Tool Steel
- Weldability of steels, Embrittlement phenomenon of steels
- Cast Iron
- Types of Cast Iron (gray, white, malleable, ductile)
- Properties and application of Cast Iron
- Environmental Effects (1 hour)
- Galvanic and Stress corrosion, Corrosion protection
- Non-ferrous Alloys(3 hours)
- Aluminum alloys
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