Mechanical diploma technician works in the metal working industry. To meet current and future metal demands it is essential to get material knowledge. Materials like ferrous and non-ferrous metals, polymer, ceramics and composites are widely used in a variety of engineering applications. This course deals with these materials along with advanced materials, their metallurgical considerations, heat treatment processes, structure property relationship and applications. This course will enable diploma engineering students to identify a variety of material and their selection for various applications which is used in connection with smelting, welding, machining, bending, extruding, tapping, soldering, casting, pumping, structural work, crushing, and other industrial processes.
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Unit – I Basics of Engineering Materials [14 Marks] 1.1 Classification of engineering materials 1.2 Crystal structure, Unit cell and space lattice 1.3 Microstructure, types of microscopes 1.4 Sample preparation, etching process, types of etchants. 1.5 Properties of metals Physical Properties, Mechanical Properties. 1.6 Concept of phase, pure metal, alloy and solid solutions. 1.7 Iron Carbon Equilibrium diagram various phases. Critical temperatures and significance. Reactions on Iron carbon equilibrium diagram 1.8 Hardness testing procedure on Brinell and Rockwell tester.
Unit – II Steel & Cast Iron [16 Marks] 2.1 Broad Classification of steels. i. Plain carbon steels: Definition, Types and Properties, Compositions and applications of low, medium and high carbon steels. ii. Alloy Steels: Definition and Effects of alloying elements on properties of alloy steels. iii. . Tool steels: Cold work tool steels. Hot work tool steels, High speed steels (HSS) iv.Stainless Steels: Types and Applications v. Spring Steels:Composition and Applications. vi. Specifications of steels and their equivalents. 2.2 Steels for following components: Shafts, axles, Nuts, bolts, Levers, crank shafts, camshafts, Shear blades, agricultural equipment, household utensils, machine tool beds, car bodies, Antifriction bearings and Gears. 2.3 Types of cast irons as white. Gray, nodular, malleable 2.4 Specifications of cast iron. 2.5 Selection of appropriate cast iron for engineering applications. 2.6 Designation and coding (as per BIS, ASME, EN, DIN,TIS) of cast iron, plain and alloy steel. 2.7 Use of iron and steel in ancient India; Munda, Tikshna and Kanta types of iron and steels (IKS)
Unit – III Non Ferrous Materials & Powder Metallurgy [14 Marks] 3.1 Copper and its alloys – brasses, bronzes Chemical compositions, properties and Applications. 3.2 Use of copper in ancient India and its mention in Rigveda(IKS) 3.3 Aluminum alloys -Y-alloy, Hindalium, duralium with their composition and Applications. 3.4 Bearing materials like white metals (Sn based),aluminum, bronzes. Porous, Self -lubricating bearings. 3.5 Powder Metallurgy: Introduction, Advantages, limitations and applications. Preparation of Metal Powders, Basic Steps for Powder Metallurgy.
Unit – IV Non Metallic Materials & Advanced Materials [14 Marks] 4.1 Polymeric Materials i. Polymers:- types, characteristics, ii. Properties and uses of Thermoplastics, Thermosetting Plastics and Rubbers. iii.Thermoplastic and Thermosetting Plastic materials 4.2 Characteristics and uses of ABS, Acrylics. Nylons and Vinyls, Epoxides, Melamines and Bakelites 4.3 Rubbers: Neoprene, Butadiene, Buna and Silicons -Properties and applications. 4.4 Ceramics -types of ceramics, properties and applications of glasses and refractories 4.5 Composite Materials – properties and applications of Laminated and Fiber reinforced materials 4.6 Advanced Engineering Materials: Properties and applications of Nanomaterials and smart materials & Biomedical materials.
Unit – V Heat Treatment processes [12 Marks] 5.1 Overview of heat treatment. 5.2 Annealing: Purposes of annealing, Annealing temperature range, Types and applications. 5.3 Normalizing: Purposes of Normalizing, temperature range. Broad applications of Normalizing. 5.4 Hardening: Purposes of hardening, Hardening temperature range, applications 5.5 Tempering: Purpose of tempering Types of tempering and its applications 5.6 Case hardening methods like Carburizing, Nitriding, and Cyaniding. 5.7 Heat treatment Furnaces – Muffle, Box type.
