Course Details

Subject {L-T-P / C} : CR3416 : Metallurgical Processes { 3-0-0 / 3}

Subject Nature : Theory

Coordinator : Prof. Partha Saha

Syllabus

Module 1: Extractive metallurgy: Pyrometallurgical operations, Principles of pyro, hydro and electrometallurgical operation, extraction of aluminum, purification of bauxite, Serpek’s process, Baeyer’s process purification, Electrolysis of pure alumina, Hall- Heroult process, Refining of aluminum metal, Hoope’s process extractive metallurgy of zinc, advantages/disadvantages of pyro and hydrometallurgical processes, roasting-leaching-electrolysis (RLE) process, imperial smelting, horizontal retort merits/demerits pyrometallurgical extraction of copper, concentration, roasting, smelting, conversion, refining, hydrometallurgical extraction of copper advantages/disadvantages, ore preparation, leaching, solute purification, metal recovery, oxidative/non-oxidative leaching, role of Thiobacilli (direct/indirect mechanism), electrowinning and electrorefining.
6 Hours

Module 2: Iron and Iron-Carbon (Fe-Fe3C) Phase Diagrams: Iron-Carbon phase diagram, eutectoid/hypoeutectoid/hypereutectoid transformations in carbon-steels, nucleation & growth of pearlite, understanding ferrite, cementite, austenite formation in carbon-steel, TTT diagram, determination of TTT diagram for eutectoid steel, transformation of austenite to pearlite or bainite or martensite, role of solute, effect of cooling rate, diffusionless transformation, factors affecting TTT diagrams, end-quench method, Jominy test, the effect of cooling rate, critical cooling rate (CCR), factors affecting CCR.
8 Hours

Module 3: Heat treatment of steel: Theory and purpose of heat treatment, stages of heat treatment, Annealing, full annealing, process annealing, causes of residual stress, stress relief, partial annealing, spheroidization annealing, advantages, recovery, recrystallization, grain growth, recrystallization annealing, difference between annealing and normalizing, objectives of hardening, Jominy end-quench test, tempering, martempering and austempering, quenching, surface hardening, case hardening, nitriding.
5 Hours

Module 4: Defects in crystals: Point, line, planar defects, Hume-Rothery rules for solid solution, enthalpy of vacancy formation in crystal (?Hf) dislocation: edge and screw, characteristics of dislocations, mixed dislocations, slip in FCC, BCC crystals, non-basal slip, partials dislocations, stacking faults, influence of partials dislocations and stacking fault energy on deformation, interaction of dislocations, Lomer-Cottrell barrier, types of dislocation motion: glide, climb, cross-slip, jogs and kinks, Peierls Nabarro stress, slip system in crystals, resolved shear stress.
6 Hours

Module 5: Strengthening mechanisms: Grain Size Hardening (Hall-Petch Relationship), Solid Solution Hardening: elastic interaction, modulus interaction, stacking fault interaction, electrical (valence) interaction, short-range order interaction, long-range order interaction Precipitation and Dispersion hardening, Freidel cutting and Orowan looping mechanism, coherent, incoherent, and semi-coherent precipitates, G-P zone, and age hardening response of Al-Cu alloys, precipitation hardening
4 Hours
Module 6: Ironmaking & Steelmaking (Blast Furnace Operation): Fundamental of steel metallurgy, production of Pig iron in blast furnace (BF), raw materials, BF operation: role of Hopper, Stack, Bosh, Hearth, Tuyere & Bustle pipe, Mantles & Column, temperature & reactions in BF, mass and heat balance in BF, complex gas mixture, chemical equilibrium, Ellingham diagram, Activity in concentrated and dilute solution, Rauolt’s law, and Henry’s law, weight percent standard state, solute-solute interaction, determination of self-interaction coefficient, gases in liquid metal: Sievert’s law, secondary steelmaking, BOF, Open hearth process, DRI based steelmaking, EAF, decarburization/desulphurization, AOD/VOD, degassing, role of RH degasser.
7 Hours

Course Objectives

Course Outcomes

CO1: Students will gain knowledge on materials deformation behavior, role of point, line defects toward failure of metals, various strengthening mechanisms, role of solute and dispersed precipitates, Peierls-Nabarro stress for polycrystal, critical resolved shear stress for single crystal, Fe-Fe3C phase diagrams, role of TTT/CCT diagrams and their implication toward the formation of austenite, ferrite, cementite, martensite phase(s) for eutectic, and hypo/hyper eutectic system, various heat treatment strategies of steel including normalizing, annealing, spheroidizing, tempering, etc. and extractive metallurgy of copper, zinc, aluminum, etc. <br /> <br />CO2: Apply the theoretical knowledge imparted during the course to conduct independent research and developmental work related to alloy development, physical metallurgy, mechanical metallurgy, suitable heat treatment, microstructure-property relationships, the corrosion behavior of metals/alloy, etc. <br /> <br />CO3: Able to independently/gruop solve numerical problems and case studies related to dislocations, resolved shear stress, Peierls-Nabarro stress, strengthening phenomena, CCT, TTT diagrams, hypo/hypereutectic Fe-Fe3C diagrams, Lever rule, etc.

Essential Reading

Supplementary Reading

Journal and Conferences