Syllabus

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

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

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

Defects in crystals: Point, line, planar defects, Hume-Rothery rules for solid solution, enthalpy of vacancy formation in crystal (delta 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

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

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

To provide undergraduate ceramic engineering students and students from the cluster with a fundamental understanding of key metallurgical phenomena.

To develop in-depth knowledge of metallurgical phenomena and the physical behavior of metals and alloys, including material deformation, strengthening mechanisms, Fe–Fe3C phase diagrams, heat treatment processes, and TTT/CCT diagrams.

To structure the course in a manner that supports students aspiring for higher studies by enhancing their analytical skills, broadening their knowledge base, and preparing them for the Graduate Aptitude Test in Engineering (GATE).

Students will develop a comprehensive understanding of material deformation behavior, including the role of point and line defects in the failure of metals. They will study various strengthening mechanisms, the effects of solute atoms and dispersed precipitates, and concepts such as Peierls–Nabarro stress in polycrystals and critical resolved shear stress in single crystals. The course also covers Fe–Fe3C phase diagrams, TTT/CCT diagrams, and their implications for the formation of phases such as austenite, ferrite, cementite, and martensite in eutectic and hypo-/hyper-eutectic systems. Additionally, students will learn different heat treatment processes (normalizing, annealing, spheroidizing, tempering, etc.) and the fundamentals of extractive metallurgy of metals like copper, zinc, and aluminum.

Students will be able to apply theoretical concepts gained during the course to undertake independent research and development work in areas such as alloy design, physical and mechanical metallurgy, appropriate heat treatment processes, microstructure–property relationships, and the corrosion behavior of metals and alloys.

Students will be able to independently and collaboratively solve numerical problems and analyze case studies related to dislocations, resolved shear stress, Peierls–Nabarro stress, strengthening mechanisms, CCT and TTT diagrams, hypo-/hyper-eutectic Fe–Fe3C systems, and the Lever Rule.

A. Ghosh and A. Chatterjee,, Ironmaking and Steelmaking Theory and Practice, Prentice-Hall of India Private Limited , 2008

A. Ghose and H. S. Ray,, Principles of Extractive Metallurgy, Wiley Eastern , 1981

W.G. Davenport, M. King, M. Schlesinger, A.K. Biswas, Extractive Metallurgy of Copper, Pergamon Press, 5th ed. (2011) , 2011

R.J. Sinclair, The Extractive Metallurgy of Zinc, AusIMM , 2005