Elementary Principles of Metallurgy | - Introduction to metallurgy - ores/ ore dressing
- Methods of sampling
- Communication
- Screening and classification
- Minerals of commercially important metals
- Principles and processes of pyro, hydro, and electrometallurgy
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Fuels, Refractories, and Pyrometry | - Classification of solid, liquid, and gaseous fuels
- Testing and properties of important fuels
- Manufacture and selection of refractories
- Principles and operation of important pyrometers
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Metallurgical Thermodynamics | - Introduction and applications of thermodynamics
- First law of thermodynamics
- Thermochemistry
- Second law of thermodynamics
- Ellingham diagrams
- Fugacity/activity/ equilibrium constant
- Phase equilibria
- Solutions
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Physical Metallurgy | - Structure of metals and alloys
- Solidification
- Diffusion
- Binary thermal equilibrium diagrams
- Iron-carbon diagram
- Important non-ferrous binary alloy systems
- Microscopic and macroscopic examination of metals and alloys
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Heat Treatment Technology | - Heat treatment of plain carbon steels
- Annealing/ normalizing/ hardening/ tempering of steels
- TTT diagrams
- Hardenability
- Grain size, quenching media
- Alloy steel and the effect of alloying elements on plain carbon steel
- Stainless steels/ tool steels
- Case hardening techniques
- Special heat treatment techniques: austempering/ martempering/sub-zero treatment
- Heat treatment of non-ferrous metals and alloys
- Age hardening
- Heat treatment furnaces and atmospheres
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Ferrous Extractive Metallurgy | - Iron ores and preparation of iron ores
- Blast furnace plant and equipment
- Blast furnace reactions
- Irregularities and recent trends
- Sponge iron and methods of production
- Ferroalloys, types and applications
- Steel making by Bessemer, LD, Kaldo, Open Hearth, & Electric Furnaces
- New techniques in steel-making
- Vacuum treatment of liquid steel
- Ingot defects
- Continuous casting
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Non-Ferrous Extractive Metallurgy | - Extraction of copper
- Pyro and hydrometallurgical methods and refining
- Aluminium
- Extraction /Anode effect/ refining
- Zinc and lead
- Pyro and hydrometallurgical extraction and refining
- Extraction of magnesium by Dows and pidgeon processes
- Extraction of titanium by Kroll’s process
- Refining by Van Arkell’s process
- Extraction of thorium and zirconium
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Material Testing | - Tension test
- Stress-strain relationship
- Necking phenomenon - ductile & brittle fracture
- Griffith’s theory of brittle fracture
- Hardness tests (principles & types)
- Impact testing (notched bar impact tests)
- Transition temperature
- Fatigues, stress cycles, S-N diagram, factors affecting fatigue
- Creep testing - creep curve
- Stress (rupture test)
- Non-destructive testing (principles/ methods/ applications of liquid penetrant)
- Radiography
- Ultrasonic magnetic particle
- Eddy current test
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Mechanical Metallurgy | - Plastic deformation of metals
- Lattice defects
- Slip and twinning
- CRSS
- Strengthening mechanism
- Strain hardening
- Hot and cold working
- Recovery, recrystallization, and grain growth
- Metal forming processes
- Rolling/ forging/ extrusion/ sheet metal forming processes and defects
- Powder metallurgy
- Methods of power production
- Characterization/ compaction/ sintering/ applications of powder metallurgy
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Foundry Technology | - Types of foundries
- Basic steps in casting
- Patterns: types/ materials/ pattern allowances
- Molding stands: properties/ testing
- Moulding processes and equipment
- Sand casting/ die casting/shell moulding/centrifugal casting/ investment casting and CO2 processes
- Cores - types of cores & properties/ pouring and feeding of casting
- Cast irons - types/ melting of cast irons
- Grey/ SG/ Malleable iron
- Aluminium/ copper/ steel foundry practices
- Defects in casting
- Cleaning and salvage of casting
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Welding Technology | - Basic concepts of welding
- Principles and processes of various welding techniques, such as oxy-acetylene
- Arc welding
- Inert gas welding (TIG and MIG)
- Special welding processes
- Plasma, resistance, electro slag, electron beam, thermit, and laser
- Soldering and brazing
- Weldability & factors affecting it
- Heat-affected zone
- Microstructure
- Post-weld treatments
- Welding defects
- Inspection andtesting
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