Department of Fuel, Minerals and Metallurgical Engineering Tech_new...• Principles of Extractive...

Course Structure

M. Tech. Fuel, Minerals and Metallurgical Engineering

ANNEXURE – I

Department of Fuel, Minerals and Metallurgical

Engineering Indian Institute of Technology (ISM) Dhanbad

Dhanbad, Jharkhand, India

SEMESTER - 1

Course No. Course Name L T P C

DC1 Coal and Mineral Processing 3 0 0 9

DC2 Transport Phenomena 3 0 0 9

DC3 Numerical methods & Computer

Applications 3 0 0 9

DC4 Unit operations in Extractive

Metallurgy 3 0 0 9

DC5 Fuel Technology 3 0 0 9

DP1 Coal and Mineral Processing Practical 0 0 3 3

DP2 Extractive Metallurgy Practical 0 0 2 2

Total 15 0 5 50

SEMESTER - 2


DE1 Department Elective 1 3 0 0 9



OE1 Open Elective 1 3 0 0 9


DP3 Materials Characterization Practical 0 0 3 3

DP4 Fuel Technology Practical 0 0 2 2

Total 15 0 5 50

SEMESTER - 3


DC6 Thesis Unit 1 0 0 0 9




Total 0 0 0 36

SEMESTER - 4






Total 6 0 0 36

Table 1. List of Department Core (DC): Theory Courses

Course No. Course

Code Course Name L T P C

DC1 FMC501 Coal and Mineral Processing 3 0 0 9

DC2 FMC502 Transport Phenomena 3 0 0 9

DC3 FMC503 Numerical methods & Computer

Applications 3 0 0 9

DC4 FMC504

Unit Operations in Extractive

Metallurgy 3 0 0 9

DC5 FMC506 Fuel Technology 3 0 0 9

Table 2. List of Department Core (DC): Practical Courses

Course No. Course


DP1 FMC551 Coal and Mineral Processing Practical 0 0 3 3

DP2 FMC552 Extractive Metallurgy Practical 0 0 2 2

DP3 FMC556 Materials Characterization Practical 0 0 3 3

DP4 FMC553 Fuel Technology Practical 0 0 2 2

Table 3. List of Department Electives (DE)

Course

Code Course Name L T P C Remark

FMD 522 Coal Preparation 3 0 0 9 Mineral

FMD 537 Plant Flowsheet Development &

Economics

3 0 0 9 Mineral

FMD 538 Processing and Dewatering of Fine

Particles

3 0 0 9 Mineral

FMD 539 Process Control Mineral

FMD 540 Size Enlargement Processes 3 0 0 9 Mineral

FMD 541 Processing Equipment Selection 3 0 0 9 Mineral

FMD 515 Thermochemical Conversion of Coal

and Biomass

3 0 0 9 Fuel

FMD 527 Combustion Engineering

3 0 0 9 Fuel

FMD 528 Power Plant Engineering 3 0 0 9 Fuel

FMD 530 Biofuels 3 0 0 9 Fuel

FMD 531 Alternate Energy Systems

3 0 0 9 Fuel

FMD 533 Energy Conservation Processes 3 0 0 9 Fuel

FMD 525 Iron and Steel Making 3 0 0 9 Metallurgy

FMD 516 Advanced Phase Transformation 3 0 0 9 Metallurgy

FMD 517 Mechanical Behaviour of Materials 3 0 0 9 Metallurgy

FMD 518 Joining of Materials 3 0 0 9 Metallurgy

FMD 519 Introduction to Computational Materials

Science 3 0 0 9 Metallurgy

FMD 520 Advanced Thermodynamics and

Kinetics 3 0 0 9 Metallurgy

FMD 534 Metal Forming Technology 3 0 0 9 Metallurgy

FMD 535 Powder Metallurgy 3 0 0 9 Metallurgy

FMD 536 Surface Engineering 3 0 0 9 Metallurgy

Table 4. List of Open Electives (OE) Offered by FMME Dept.

Course


FMO 542 Mineral Processing Economics 3 0 0 9

FMO 543 Waste Processing and Management 3 0 0 9

FMO 544 Clean Coal Technology 3 0 0 9

FMO546 Mechanochemistry in Nanoscience and Materials

Engineering 3 0 0 9

FMO547 Additive Manufacturing 3 0 0 9

FMO548 Analysis and Modelling of Welding 3 0 0 9

FMO549 Introduction to Integrated Computational Materials

Engineering 3 0 0 9

FMO 550 Cement Technology 3 0 0 9

Course

Type Course Code Name of Course L T P Credit

Core FMC 501 COAL AND MINERAL PROCESSING 3 0 0 9

Course Objective

To impart fundamental understanding of various unit operations in coal and mineral processing.

Learning Outcomes

At the end of the course, the students would have understanding of the various unit operations,

equipments and beneficiation techniques for processing of coal and minerals

COURSE CONTENTS

MODULE 1: Introduction [4]

Necessity, scope, importance of coal and mineral processing. Important definitions: ore, mineral,

gangue, concentrate, tailing, yield, recovery and ratio of concentration etc. Properties of different

minerals relevant to their processing.

MODULE 2: Properties of solids and their handling [10]

Particle size, shape, specific surface area, density, shape factor, screen analysis, different types of

screens – static and dynamic, screening surfaces and screen efficiency, factors influencing screen

efficiency. Standard screen series, estimation of average particle size, differential and cumulative

particle size analysis, sampling of coal and minerals. Fundamentals of size reduction, comminution

laws, different types of crushers and grinding mills, their features and application. Liberation of

minerals, degree of liberation.

MODULE-3: Fluid-Particle interaction [4]

Movements of solids in fluid, Laws of settling, free settling, hindered settling. Classification -

types of classifiers, their principles and operations.

MODULE-4: Gravity Separation [8]

Different types of gravity separation-Principles, units, applications of dense media, Jigs, flowing

film concentrators, cyclones.

MODULE-5: Magnetic and electro-static separation [5]

Magnetic and electro-static separation: Principles, different types of magnetic and electrical

separators, their features and applications.

MODULE-6: Froth Flotation & dewatering [8]

Flotation theory, double layer of solid-liquid interface, zeta potential. Physics and chemistry of

interfaces, surface energy, interfacial tension and its role in flotation. Flotation reagents and their

importance. Characteristics of minerals and reagents, flotation applications in coal and minerals.

Dewatering – Flocculation, Thickening, filtration and drying. Leaching and extraction.

Text Books:

• Mineral Processing Technology (B. A. Wills)

References:

• Introduction to Mineral Processing (Kelly and Spottiswood)

• Principles of Mineral Dressing (A. M. Gaudin)

• Coal Preparation (J. W. Leonard)

• The Coal Handbook: Towards Cleaner Production (D. Osborne)

• Coal preparation, Vol-1 and Vol-2, D. Osborne

Course


Core FMC 502 TRANSPORT PHENOMENA 3 0 0 9

Course Objective

The main objective of the course is to learn the properties of fluid and its transportation.

Learning Outcomes

At the end of the course, student will be able to understand the properties of fluid and its

transportation.

COURSE CONTENTS

MODULE-1: Introduction, Transport Processes, Dimensional Analysis. [4]

MODULE 2: Momentum Transfer: Steady and Unsteady Flows; Overall mass, energy and

momentum balance; Navier Stokes equation; Newton’s Law, Non-Newtonian Fluids; Laminar

flow in falling film, flow through conduits etc; Inviscid fluid flow, Viscous flow, Laminar and

Turbulent Boundary Layer Theory, Friction Factor; Flow past immersed objects, packed and

fluidized bed. [8]

MODULE 3: Mass Transfer: Steady state mass transfer and diffusion; molecular diffusion in

gases, liquids, biological gels and solids; Unsteady state mass transfer under different conditions,

mass transfer coefficient, diffusion through porous medium and capillaries; Boundary layer flow

and turbulence in mass transfer, Simultaneous heat, mass and momentum transfer. [8]

MODULE 4: Heat Transfer: Conduction: Steady State: One Dimensional – Composite wall and

cylinder; Multi-dimensional- Differential heat balance, shape factor, graphical and numerical

methods.

Unsteady State: Analytical solutions of one dimensional lumped heat capacity system, heat flow

in semi-infinite solid, convection boundary conditions, Heisler chart solutions.

Convection: Natural and forced convection, overall heat transfer coefficient, fouling factor, types

of heat exchanges.

Radiation: Physical mechanism, radiation properties, shape factor, heat exchange between non-

black bodies, infinite parallel planes, radiation shields, gas radiation. [10]

MODULE-5: Application of software (MatLab, CFD, FLUENT, ANSYS, etc.) in Transport

Phenomena. [9]

Text Book:

• G.H. Geiger and D.R. Poirier, TMS, Transport Phenomena in Metallurgy, Addison-

Wesley, 1973

References:

• R. Byron Bird, Warren E. Stewart, Edwin N. Lightfoot., Transport Phenomena 2nd

Edition, John Wile and sons Pvt Ltd.

Course


Core FMC 503 NUMERICAL METHODS &

COMPUTER APPLICATIONS

3 0 0 9

Course Objective

The main aim of the course is to introduce the students to solve various mathematical problems using

numerical analysis with the help of MATLAB programming

Learning Outcomes

At the end of this course students will be able to use MATLAB for various modelling and simulations

problems in engineering applications.

COURSE CONTENTS

MODULE-1: Basics of MATLAB programming, Array operations in MATLAB, Loops and

execution control, working with files: Scripts and Functions, Plotting and program output, creating

plots I Matlab. Matlab’s built in functions and User defined functions. [5]

MODULE 2: Defining errors and precision in numerical methods, Truncation and round-off

errors, Error propagation, Global and local truncation errors. Vectors and Matrix operations in

Matlab. [4]

MODULE-3: Linear algebra in MATLAB, Gauss Elimination, LU decomposition and partial

pivoting, Iterative methods: Gauss Siedel, Special Matrices: Tri-diagonal matrix algorithm.

Nonlinear equations in single variable, MATLAB function fzero in single variable, Fixed-point

iteration in single variable, Newton-Raphson in single variable, MATLAB functions for single and

multiple variables, Newton-Raphson in multiple variables. [4]

MODULE-4: Numerical Differentiation in single variable, Numerical differentiation of Higher

derivatives, Differentiation in multiple variables, Newton-Cotes integration formulae, Multi-step

application of Trapezoidal rule, MATLAB functions for integration. [4]

MODULE-5: Introduction, Linear least squares regression. Functional and nonlinear regression,

Interpolation in MATLAB using different functions. [4]

MODULE-6: Introduction to ODEs; Implicit and explicit Euler’s methods, Second-Order Runge-

Kutta Methods, MATLAB ode45 algorithm in single variable, Higher order Runge-Kutta

methods, Error analysis of Runge-Kutta method. Solution of ODE using Matlab. [6]

MODULE-7: Different types of Partial differential equations. Numerical solution of PDE using

Matlab. [4]

MODULE-8: Polynomial curve fitting. Curve fitting using Matlab and other techniques.

Mathematical computations and statistical analysis. [4]

MODULE-9: Applications of numerical methods in solving various mathematical equations of

Fuel and Mineral Engineering. Introduction to FEM, DEM, CFD software. [4]

Text Book:

• Pallab Ghosh, Numerical, Symbolic and Statistical Computing for Chemical Engineers

Using MATLAB, Prentice Hall, 2018.

Reference Books:

• W. Y. Yang, W. Cao, T. Chung, S. Chung and J. Morris, Applied Numerical Methods

Using MATLAB, John Wiley, 2005

• Constantinides and N. Mostoufi, Numerical Methods for Chemical Engineers with

MATLAB Applications, Prentice Hall, 1999.

Course


Core FMC 504 UNIT OPERATIONS IN EXTRACTIVE

METALLURGY

3 0 0 9

Course Objective

The objective of this course work is to provide knowledge of various metal extraction process.

Learning Outcomes

At the end of the course the students will be able to learn various metal extraction processes, industrial

practices, etc.

COURSE CONTENT:

MODULE-1: Pyro-metallurgy: Principles of pyro-metallurgy, Unit operations in pyro-

metallurgy, Calcination, Roasting, Smelting, Converting and Fire-refining. [8]

MODULE-2: Hydrometallurgy: Principles of hydro-metallurgy, Leaching, Solvent-extraction,

Iron Exchange, Cementation. [6]

MODULE-3: Electro-Metallurgy: Principles of electrolysis, Electro-winning and Electro

refining. [8]

MODULE-4: Extraction Processes of major Non-ferrous metals: Aluminium, Copper, Nickel,

Zinc, Lead, Titanium, Magnesium, Uranium, Gold and Silver. Including material preparation and

refining etc. Properties and uses of metals and their alloys for industrial applications. [11]

MODULE-5: Iron and Steel making principles. Integration of above processes. Heat, mass and

overall energy balance in metallurgical operations. [6]

Text Books:

• First Course in Iron and Steel Making by Dipak Mazumdar

• Ahindra Ghosh, Amit Chatterjee, Iron Making and Steelmaking: Theory and Practice,

PHI Learning Pvt. Ltd., 2008

References:

• Principles of Extractive Metallurgy by A Ghosh and H S Ray

• Extraction of nonferrous Metal by H. S. Ray, R. Sridhar and K.P. Abraham

• H.S. Ray, R. Shreedhar and K.P. Abraham- Extraction of non-ferrous metals- affiliated

East West press pvt. Ltd, Oscar Publications, New Delhi,2011.

• S. Venkatachalam, Hydrometallurgy, Narosa Publishing House, 1998

• Engineering in process metallurgy, R.I.L. GUTHRIE

• R D Pehlke, Unit Processes in Extractive Metallurgy- American Elsevier

pub.Co.,Mishigan, 1973.

Course


Core FMC 506 FUEL TECHNOLOGY 3 0 0 9

Course Objective

The main aim of the course is to give an introduction to the different types of fossil fuels. The emphasis

of the course will be on the characterizations and utilizations of solid fuels, basics of liquid and

gaseous fuels.

Learning Outcomes

At the end of this course students should able to analyze quality of fuels based on its properties and

possible utilizations.

COURSE CONTENTS

Module 1: Introduction: Introduction to energy resources, Indian perspective, Origin and

formation of coal: Different theories on coal formation, Coal, metamorphism, Rank of coal,

classification of coal. [5]

Module 2: Properties of coal: Size analysis, Proximate analysis, Ultimate analysis, coal

petrography Gross calorific value, Net calorific value, Free Swelling Index, Caking Index, Roga

Index, LTGK, Dilatometric properties. Estimation of total moisture. Determination of HGI.

Porosity, density, electrical conductivity, specific heat, thermal conductivity, hardness. [8]

Module 3: Coal Utilization: Introduction to coal carbonization, Impact of coal constituents on

coal carbonization, Behavior of coal at an elevated temperature, Pre carbonization techniques- Top

charging, Stamp charging, Blending, Briquetting, Formed coke, Dry and wet quenching of coke.

Types of Carbonization- Low Temperature Carbonization and High Temperature Carbonization,

Types of Ovens- Recovery and Non- recovery coke ovens, Flue arrangements. By- products

recovery processes, methods of conservation of coking coal. Physical and Chemical properties of

coke: Shatter index, Micum index, Coke reactivity index, Coke strength after reaction.

Fundamentals of coal combustion, combustion stoichiometry. Fundamentals of coal gasification,

producer gas, water gas. Chemicals and fertilizers from coal. [8]

Module 4: Liquid Fuel: Introduction to crude oil and petroleum products. Characterization of

liquid fuels. [4]

Module 5: Gaseous fuels: Natural gas, LPG, SNG their characteristics, rich gases such as SNG.

Formation of natural gas, gas reservoir, properties of natural gas, Natural gas dehydration,

sweetening, and different products obtained from natural gas. Utilization of Natural gas, LPG in

different industrial applications. Purification of fuel gases. [4]

Module 6: Biomass: Utilization of biomass as fuel. Proximate analysis, GCV, ultimate analysis

of common biofuels. Production of biochar, bio oils for various industrial applications. [6]

Module 7: Utilization of various waste materials as fuel. Introduction to Fuel cell. [4]

Text Book:

1. Fuels and Combustion: Samir Sarkar, University Press (India) Pvt Limited, India.

Reference Books:

1. Elements of Fuels, Furnaces and Refractories: O P Gupta, Khanna Publishers, India

2. Fuels, Furnaces and Refractories: R C Gupta, PHI Learning Private Limited, India

Course


DP FMC 551 COAL AND MINERAL PROCESSING

PRACTICAL

0 0 3 3

List of Practicals

1. Sampling - Bulk and sub-sampling, accuracy

2. Crushing characteristics of Jaw crusher, Roll crusher

3. Sieve and sub-sieve size analysis

4. Effect of different parameters on Ball mill grinding

5. Beneficiation using Mozley mineral separator

6. Beneficiation using Jig

7. Estimation of magnetics content by Davis tube magnetic separator

8. Beneficiation of copper ores using froth flotation

9. Beneficiation of lead-zinc ores using froth flotation

10. Beneficiation using Dry and wet high intensity magnetic separator

11. Beneficiation using Wilfley Table

Course


DP FMC 552 EXTRACTIVE METALLURGY

PRACTICAL

0 0 2 2

List of Practicals

1. Estimation of Fe, SiO2, Al2O3 for a given iron ore

2. Effect of moisture on iron ore green pellet using disc pelletiser

3. Effect of rotation speed and angle of inclination of disc on green pellets production

4. Effect of moisture on iron ore green pellet using drum pelletiser

5. Effect of bentonite on iron ore green pellet using drum pelletiser

6. Roasting of sulphide ore

7. Calcination of limestone

8. Roasting of iron ore

9. Leaching of sulphide ore/ concentrate

10. Cementation

11. Carbothermic reduction process

Course


DP FMC 556 Materials Characterization Practical 0 0 3 3

List of Practicals

1) Characterization of mild steel using optical microscope

2) Characterization of Aluminium alloy using optical microscope

3) Identification of ferrite and martensite using colour tint etching

4) Microhardness measurement of steel and Aluminium alloy

5) Thermal characterization using DSC and TGA

6) Identification of BCC and FCC samples using XRD

7) Identification of phase composition using SEM EDS

8) Demonstration of TEM and XRF

9) Tensile testing of steel sample

10) Impact testing of steel sample

11) Demonstration of EPMA

Course


DP FMC553 FUEL TECHNOLOGY PRACTICAL 0 0 2 2

1. Ultimate Analysis of coal

2. FSI Analysis of coal

3. Determination of Caking Index of coal

4. Determination of LTGK of coal

5. Determination of Flash Point and Fire point of Liquid Fuel

6. Determination of Viscosity of petroleum oils.

7. Determination of Aniline Point of diesel oil.

8. Determination of Penetration Index of Bitumen & Wax.

9. Determination of Cloud and Pour Point of diesel oil

10. ASTM Distillation of crude oil and petroleum products.

11. Determination of Smoke point of kerosene oil.

List of Department Electives

Course


DE FMD 522 COAL PREPARATION 3 0 0 9

Course Objective

• To learn the characteristics of coal relevant to its preparation

• To identify the different unit operations used for the preparation of coal for its utilization in

thermal power plants and coke ovens

Learning Outcomes

At the end of the course, the students would be able to

• Understand the cleaning of coarse coal and fine coal.

• Carry out the performance analysis of coal beneficiation equipment

• Get orientation of industrial coal preparation flowsheets.

COURSE CONTENTS

MODULE 1: INTRODUCTION & COAL WASHABILITY [10]

Coal formation, coal geology, types of coal and coal properties. Proximate analysis, HGI, GCV.

Necessity, scope and application of coal preparation. Sink - Float tests and washability studies.

MODULE-2: CRUSHING AND SCREENING OF COAL [9]

Crushers for coal. Rotary breaker, Roll crushers, Impact group of crushers, Sizers, etc. Pulveriser,

Ball mill, Screening. Impact of Particle size distribution on coal washing. Industrial screens.

Performance evaluation of crusher, mills and screens. Overview of coal handling circuit in coal

washeries.

MODULE-3: GRAVITY SEPARATION OF COAL [10]

Jigging, Dense medium separation, Dense media bath, Dense media cyclone. Dry beneficiation of

coal. Choice between the washers. Performance evaluation: Partition curve, misplacement,

probable error in separation, imperfection, yield reduction factor, organic efficiency.

MODULE-4: FINE COAL CLEANING & DEWATERING [7]

Fine coal cleaning using Spirals, water only cyclones, froth flotation. Dewatering - Centrifuges,

thickeners, cyclones and filters.

MODULE-5: COAL PREPARATION PRACTICES [3]

Typical flowsheets for preparation of metallurgical (coking) and thermal (non-coking) coal.

Text Book:

• Coal Processing Technology (D. G. Osborne)

References:

• Coal Preparation (J. W. Leonard)

• The Coal Handbook: Towards Cleaner Production (D. Osborne)

• The Principles of Coal Preparation (G. J. Sanders)

Course


DE FMD 537 PLANT FLOWSHEET

DEVELOPMENT & ECONOMICS

3 0 0 9

Course Objective

To give concept of overall economics of coal and mineral processing plants along with methodologies

for equipment selection and sizing for development of flowsheets

Learning Outcomes

Upon successful completion of this course, students will:

• be able to understand plant economics that will help in designing the plant.

• be able to selection equipment for size reduction, size separation and beneficiation of coal and

minerals

be able to develop the flowsheet for coal and minerals along with material balance

COURSE CONTENTS

Economics of mineral projects: Typical cost components in a mineral project: Capital costs,

operating costs (fixed and variable costs). Key financial aspects to evaluate feasibility of project

- cost curve, profitability, Net Present Value, IRR and depreciation accounting [6]

Social and environmental assessment: Aspects for sustainable development of mineral

industry: environment, social, resource conservation, community health, Life cycle assessment,

environmental audit, R-R-R approach for sustainability etc. [4]

Design and development of crushing circuit: Jaw, cone, roll Crusher and screen sizing and

selection, mass balance and crushing circuit development with specific case studies [5]

Design and development of grinding circuit: Grinding mill selection along with grinding

media, wear rate etc. and hydrocyclone/classifier selection, material balance, water balance, with

grinding circuit design and development [6]

Design and development of coal preparation plant flowsheets: Washer selection,

development of plant flowsheets for thermal and metallurgical coals on single and composite

(blended) feed basis including mass, water and ash balancing with special focus on separation

circuit. [7]

Design and development of mineral process plant flowsheets: Development of plant

flowsheets for mineral processing plants including iron, sulphide ore, mass, water and grade

balancing with special focus on separation circuit. [7]

Other plant flowsheets - Flowsheet development for beach sand, rock phosphate, limestone,

graphite, uranium ore etc. [4]

Text Books:

• K. K. Chatterjee , An Introduction to Mineral Economics, New Age International

• A L Mular, R B Bhapu, Mineral Processing Plant Design, 2nd Edition, SME

• J W Leonard, Coal Preparation” 3rd/ 4th/ 5th Edition, SME

Reference Books:

• Subhash C. Ray, Indra N. Sinha, Mine and Mineral Economics, Prentice Hall

• D G Osborne, The coal handbook – Vol. 1, Woodhead Publishing, 2013

• A L Mular, D J Barratt, D N Halbe, Mineral Processing Plant Design, Practice and

Control, SME

• Metso Minerals, Basics in Mineral Processing, Metso Minerals, Metso Minerals, E book

Course


DE FMD 538 PROCESSING AND DEWATERING

OF FINE PARTICLES

3 0 0 9

Course Objective

To give idea of various mineral processing techniques at fine particle size and idea of dewatering

technology.

Learning Outcomes


• be able to acquire the knowledge about the processing of particles at fine size range.

be able to dewater the wet materials generated from mineral processing plants.

COURSE CONTENTS

Introduction: Fundamentals of fine particle processing [3]

Froth Flotation: Flotation theory, flotation reagents, laboratory flotation tests. Types of flotation:

emulsion flotation, carrier flotation, selective flotation, floc-flotation, skin flotation, reverse

flotation, electro flotation. Flotation machine features and functions. Design, selection and sizing.

Conventional and modern flotation machines - Column flotation, Jameson Cell etc [15]

Oil agglomeration: Principles, process equipment, practices, reagents and application [4]

Fluidization: Principles, process equipment and practices Applications of fluidisation [2]

Flocculation and selective flocculation: Principles, process equipment, practices, reagents, and

their selection [4]

Thickening and filtration: Thickening fundamentals, basic machine features, different types of

thickeners – conventional thickener, high rate thickener, lamella thickener, deep cone thickener,

paste thickening technology etc. Filtration principles, constant rate and constant pressure filtration,

filters – vacuum drum filter, vacuum disc filter, filter press, horizontal belt filter. Design, selection

and sizing of thickeners and filters [9]

Drying: Principles and methods [2]

Text Book:

• Mineral Processing Design and Operation: An Introduction (A. Gupta and D.S. Yan)

References:



Course


DE FMD 539 PROCESS CONTROL 3 0 0 9

Course Objective

To give concept of various control instruments, process control and plant layout.

Learning Outcomes


• have a broad understanding of fundamentals aspects of development of plant control strategy.

• have a good understanding of various instruments used in industrial operations.

have good knowledge on operation and control of mineral processing equipment and plants.

COURSE CONTENTS

MODULE-1: Introduction- Need of process control, technical and economic benefits.

Fundamental Aspects-Recognition of dynamic nature of control operation; identification of

controllable and non-controllable operating variables; defining control objectives; identification

of process and plant constraints. [6]

MODULE-2: Types of Control Actions: Feed Forward and feedback control; construction of a

feedback controller; proportional action, integral action and derivative action; tuning of feedback

controllers; multiple input control; ratio control and cascade control. [6]

MODULE-3: Instrumentation for measurement: On-line particle size distribution,

Metallurgical grade analysis and coal analysis; pulp density, pulp level, froth level, slurry flow

rate, ball mill load and other required measurements. [8]

MODULE-4: Control of plant operations: Crushing circuit, grinding circuit, flotation circuit,

dewatering and other allied operations. PLC and DCS control systems. Expert systems for plant

control. Example of some actual implementation of control systems in an operating plant and the

control strategies used. [13]

MODULE-5: Plant Layout: Introduction of Plot Plan, Contour, Concept of levels, Floors,

Location of equipment, etc. Design of Plant layout, Building Layout, Equipment Layout. Input

details required to design a plant layout. Major points considered while designing a plant layout.

Layout design of plant buildings - crushing, grinding, flotation, dewatering, etc. Introduction of

piping layout. Role of civil and structural inputs in layout design. [6]

Text Book:

• Mineral Processing Technology (B. A. Wills)

References:



Course


DE FMD 540 SIZE ENLARGEMENT PROCESSES 3 0 0 9

Course Objective

The main aim of the course is to give fundamental concepts of size enlargement process.

Learning Outcomes

At the end of the course student will be conversant with the effective utilization of ore fine in blast

furnace and other applications.

COURSE CONTENTS

MODULE-1: Introduction to different size enlargement processes, necessity and scope of size

enlargement. Agglomeration: Fundamental forces of cohesion between particles, surface tension,

forces between micro assemblies, pore size distribution, pelletization, sintering and other

agglomeration methods – principles, mechanisms, use of additives, effect of induration and

assessment of quality of agglomerates, Blaine index. [8]

MODULE-2: Pelletization - Raw material preparation, Characteristics of raw materials for

pelletization, additives, binders etc. Green-ball formation, effect of process parameters on size

and strength of green-pellets, testing of Green-balls. Drying and firing of Green Balls, testing of

indurate pellets like Tumbler-test, Reducibility, Swelling index, Reduction Degradation Index,

Compressive strength etc. [10]

MODULE-3: Pelletization Equipment - Operation of Disc and Drum-Pelletizers, Different types

of pellet-firing system, Shaft-furnace, Grate-system and Grate Kiln System. Uses of pellets for

Blast Furnace and Direct Reduction Iron-making. [5]

MODULE-4: Sintering- various raw materials used for production of sinter. Preparation of fuel

mix and flux and their effect on the process of sintering. Calculation of charge-components for

producing desired quality of sinter to be used in Blast-Furnace for Iron making.

[5]

MODULE-5: Proportioning of Raw-materials, Primary and secondary mixing together with

Moistening, Sintering-Mineralogy, its effect on strength of sinter, Productivity of sintering

moisture, Control of various parameters for improving quality of product. [7]

MODULE-6: Briquetting, oil agglomeration, flocculation – Fundamentals, operating process,

design parameters and applications. [4]

Text Books:




References:

• An Introduction to Modern Steel Making- R.H. Tupkary, Khanna publishers

• Pelletizing of Iron ores – Kurt Meyer, Springer-Verlag 10980

Course


DE FMD 541 PROCESS EQUIPMENT SELECTION 3 0 0 9

Course Objective

The objective of this course is to give the concept of equipment selection.

Learning Outcomes

At the end of the course student will be able to select an equipment for a particular process.

COURSE CONTENTS

MODULE-1: Introduction, mass balance, water balance, grade balance and throughput

calculations for process unit operation. [3]

MODULE-2: Selection and sizing of crushers and screens. [7]

MODULE-3: Selection of grinding mills. [7]

MODULE-4: Estimation of number and size of flotation cells. [4]

MODULE-5: Selection of hydrocyclone, classifiers.

[4]

MODULE-6: Outline of selection of gravity, magnetic and electrostatic separators. [6]

MODULE-7: General outline of selection of water pump, slurry pump, froth pump, sump pump.

Application of DE system, DS system. Blower, Compressor, etc, in mineral processing plants.

Safety and statutory obligations in mineral processing plant design. [8]

Text Book:

• Mineral processing plant design – Mullar and Bhappu.

References:

• A.Gupta and D.S.Yan: Introduction to Mineral Processing Design and Operation.

• E. G. Kelly, D. J. Spottiswood: Introduction to Mineral Processing.

Course


DE FMD 515 THERMOCHEMICAL

CONVERSION OF COAL AND

BIOMASS

3 0 0 9

Course Objective

The main aim of the course is to give detailed information about utilisation potential of Biomass and

Coal, their Conversion technologies, application and challenges in industry.

Learning Outcomes

At the end of this course students will know about conversion technologies of coal and biomass and

their application to various industries.

COURSE CONTENTS

Module 1: Introduction to Bio energy; Biomass harvesting; Availability; Refuse Derived Fuel;

Classification of biomass feedstock: First, second and third generation bio fuels. Classification

of coal, Assessment of coal and biomass for thermochemical conversion processes.

[6]

Module II: Characterization of feedstocks; Physico-chemical properties, Ultimate and

Proximate analysis, Compositional analysis, Calorific value; Thermal analysis of organic and

inorganic composition of Coal and Biomass by Thermogravimetric Analysis (TGA),

Derivative Thermogravimetry (DTG), Differential Scanning Calorimetry (DSC), differential

thermal analysis (DTA), Ash Fusion Temperature. [10]

Module III: Biomass compaction (briquetting and pelletisation); Biofuel quality upgradation;

Coal and Biomass blends; Fuel and emission quality norms.

Thermochemical Processes (combustion, gasification, pyrolysis, partial oxidation, auto-

thermal reforming). Technologies for production of bio-fuels like bio-char, synthesis gas, bio-

hydrogen, ethanol, butanol, biogas, methanol, dimethyl ether and paraffinic fuels etc.

[11]

Module IV: Biomass fuelled combustion devices for cooking and heating applications.

Utilization of biomass in external combustion engines including steam turbine power plant and

Gas turbine, Integrated Gasification Combined Cycle (IGCC); soil ameliorant, waste water

treatment, Carbon sequestration, reducing agent for metallurgical purpose. [6]

Module V: Case studies for setting up biomass based smallpower plant (~ 1MW) capacity for

rural electrification, Briquette making plants, Gasification industries, analysis of carbon neutral

and carbon credit. [6]

Text Book:

1. Jay J. C., Biomass to Renewable Energy Processes, Taylor and Francis, CRC Press, 2018

2. Konur O., Bioenergy and Biofuels, Taylor and Francis, CRC Press, 2018

3. Coal Gasification and Its Applications, David Bell Brian Towler Maohong Fan, 1st Edition

November 2010

4. Mukunda, H. S., Understanding Clean Energy and Fuels from Biomass, Wiley India, 2011

Reference Book:

1. Biomass Gasification, Pyrolysis and Torrefaction Practical Design and TheoryBook • Third

Edition • 2018

2. G.Tchobanoglous, H.Theisen, S.V.Tchobanoglous, G.Theisen, H.V.Samuel, Integrated

Solid Waste management: Engineering Principles and Management issues, New York,

McGraw Hill, 1993.

Course


DE FMD 527 COMBUSTION ENGINEERING 3 0 0 9

Course Objective

The main objective of the course is to give basic idea of combustion processes, their control and

various types of industrial combustion units.

Learning Outcomes

At the end of this course students will be able to analyze different types of combustion processes

and mechanism to be adopted to control combustion process and associated pollution.

COURSE CONTENTS

Module 1: Heat Transfer Fundamentals: Basics of heat transfer by conduction, convection,

radiation, heat exchanges, unsteady state heat transfer, heat transfer in laminar, turbulent fluid

medium. [10]

Module 2: Combustion Fundamentals: Introduction, Energy Sources, Combustion

stoichiometry and thermo-chemical calculations, necessity of flue gas composition analysis

and methods of flue gas analysis. Reaction kinetics, activation energy, Rate of heat release.[8]

Module 3: Theoretical Models: Theoretical models of coal combustion. Shrinking core

model, coal de-volatilization, Thermogravimetric analysis, non-isothermal and isothermal

combustion of coal, burning temperatures models and profiles. DTG, DSC, DTA analysis of

coal. [8]

Module 4: Influence of Fuel properties: Effects of fuel properties on combustion process and

flue gas composition. [6]

Module 5: Industrial combustion Processes: Fundamentals and operations of Boiler,

Furnace, Oil & Gas Burner, Cement Kiln, Grate firing, FBC, Pulverized firing. Heat and mass

balance for industrial combustion units. Design calculations for various combustion units: Blast

furnace, FBC boiler, pulverized boiler, cement kiln etc. [7]

Text Book:

• An Introduction to Combustion: Concepts and Applications, Stephen Turns, Mcgraw

Hill

Reference Books:

• Fundamentals of Combustion: D P Mishra, PHI Learning Private Limited, India

• Fuels and Combustion: Samir Sarkar, University Press (India) Pvt Limited, India.

Course


DE FMD 528 POWER PLANT ENGINEERING 3 0 0 9

Course Objective

The main aim of the course is to give detailed information about operations of different types of

thermal power plants operations.

Learning Outcomes

At the end of the course student will get detailed knowledge of thermal power plants.

COURSE CONTENTS

Module 1: Introduction to modern power plants, electricity generation, transmission, power

grid system. Electricity consumption pattern and importance of power grid for capacity

estimation. [5]

Module 2: Types of power plant, General layout of modern power plant, site selection, and

material requirement. [4]

Module 3: Coal handling system, storage and feeding system, combustion equipment for steam

boilers, ash-handling system. [5]

Module 4: Power Plant Cycles: Rankine, Reheat, Regenerative, Otto, Diesel, Dual

Combustion, Gas turbine [14]

Module 5: Types of boiler: Water tube, Fire tube, and High pressure. Feed and cooling water

system, Boiler, condenser, cooling tower, process water recycle Heat balance, boiler and plant

efficiency. [5]

Module 6: Introduction to gas and other fuel based power plant systems. Wind energy based

power plants, solar thermal, geo thermal, hydro power plant, pumped storage hydro power

plants. [6]

Text Book:

• Power plant Engineering: P K Nag, Tata-Mcgraw Hill Publishing Company Limited,

India

Reference Books:

• Power plant Engineering: Manoj Kumar Gupta, PHI Learning Private Limited, India

• Green Power: The eco- friendly energy engineering; Nikolai V. Khartchenko

Course


DE FMD 530 BIOFUELS 3 0 0 9

Course Objective

The main aim of the course is to give detailed information about processing and utilization of biofuels.

Learning Outcomes

At the end of this course students will be able to analyze different types of biofuels processing and

characterizations.

COURSE CONTENTS

Module 1: Introduction and perspective of biofuels: Fossil versus renewable energy,

resources, economic impact of biofuels, Comparison of Bio-energy Sources, Bio-refinery,

biofuel production and applications, alternative energies, environmental impact of biofuel, Fuel

Ratings. [4]

Module 2: Harvesting Energy from Biochemical Reaction: Biochemical Pathways for

various metabolic process, chemical oxygen demand and biological oxygen demand

Biochemistry of Bioethanol production. Biomass preprocessing: drying, size reduction, and

densification. Ethanol production from sugar and starch feedstock ethanol production from

lignocellulosic feedstocks, fermentation process and types of fermenters. [6]

Module 3: Biofuel Feedstocks and production of biofuel: Various types of feedstocks, starch

feedstocks, sugar feedstocks, lignocellulosic feedstocks, plant oils and animal fats,

miscellaneous feedstocks. [6]

Module 4: Bioenergy from biomass as source of alternative energy: Wet milling of grain

for alcohol production, grain dry milling cooking for alcohol production, use of cellulosic feed

stocks for alcohol production chemistry of biodiesel production Biodeisel production by using

various microorganisms, algae and Transesterification process, Chemistry of biodiesel

production, oil Sources and production by plants and other sources, methods of biodiesel

production. [6]

Module 5: Biological Production of Hydrogen by various microorganisms: Photo

biological hydrogen production by using algae, Hydrogen Production by Fermentation various

metabolic process for hydrogen production, Bioreactor Design for Biofuel Production.

Fermentation process, various types of fermenters, bioreactor operation and design. [6]

Module 6: Microbial Fuel Cells and its role in energy production: Microbiology of methane

production, biomass sources for methane production, biogas composition and use, biochemical

basis of fuel cell design, Global warming and it's environmental impact. Introduction to global

warming, global warming factors, geo-chemical cycles, carbon nitrogen and hydrogen cycles

[6]

Module 7: Environmental impacts: Environmental impacts of biofuel production, Energy

balance and life-cycle analysis of biofuel production, Value-added processing of biofuel

residues and co-products. [5]

Text Book:

• Vaughn C. Nelson, Kenneth L. Starcher, Introduction to Bioenergy (Energy and the

Environment).

Reference Books:

• Anju Dahiya, Bioenergy: Biomass to Biofuels.

• Yebo Li, Samir Kumar Khanal, Bioenergy: Principles and Applications, Wiley, 2016

• Biotol Series, Vch Ellis Horwood, Butterworth-Heinemann, Product Recovery In

Bioprocess Technology, Elsevier.

Course


DE FMD 531 ALTERNATIVE ENERGY SYSTEMS 3 0 0 9

Course Objective

The main aim of the course is to introduce students about non-conventional energy systems, power

productions from non-fossil fuel sources.

Learning Outcomes

At the end of the course student will get overview of various alternate energy options available in

earth

COURSE CONTENTS

Module 1: Thermal System: Solar energy and Spectral Distribution, Sun Tracking, Heat

Transfer for Solar Energy, Solar Energy Collection, Parabolic Trough, Central Receiver,

Parabolic Dish, Solar thermal Power Plant, Flat Plate Solar collectors, Solar air heaters and

their applications, Photovoltaic conversion, Solar cell, Storage of Solar energy, Solar ponds.

Solar Thermal Power Plants. [6]

Module 2: Solar Photovoltaic Power System: The photovoltaic cell, Module and Array,

Equivalent Electrical Circuit, Open Circuit Voltage and Short Circuit Current, Array Design,

Sun Intensity, Sun Angle, Shadow Effect, Temperature Effect, Effect of Climate, Electrical

Load Matching, Sun Tracking, Peak Power Point Operation, PV System Components [6]

Module 3: Nuclear Energy: Fission and Fusion, Lawson’s criteria for fusion, impacts of.

byproducts on environment, Geothermal and Hydel energy. Fissile and Fissionable materials,

Heavy water, Theory of reactors. [6]

Module 4: Bio-energy: Bio diesel, anaerobic reactors, gas composition and yield etc. Biomass

for industrial applications. [6]

Module 5: Wind energy: Speed and Power Relations, Power Extracted from the Wind, Rotor

Swept Area, Air Density, Global Wind Patterns, Wind Speed Distribution. [4]

Module 6: Wind Power System: System Components, Tower, Turbine Blades, Yaw Control,

Speed Control, Turbine Rating, Electrical Load Matching, Variable-Speed Operation, System

Design Features, Number of Blades, Rotor Upwind or Downwind, Horizontal Axis Versus

Vertical Axis, Spacing of the Towers, Maximum Power Operation, Constant Tip-Speed Ratio

Scheme, Peak Power Tracking Scheme, System Control Requirements, Speed Control, Rate

Control, Environmental Aspects, Audible Noise, Electromagnetic Interference (EMI). [5]

Module 7: Tidal Energy, Hydro-power plants, Fuel cell. [6]

Text Book:

• D. P. Kothari, K. C. Singal and Rakesh Ranjan, Renewable Energy Sources and

Emerging Technologies 2nd Edition, PHI India.

Reference Books:

• Wind and Solar Power Systems: Mukund R. Patel, CRC Press, London.

• 2. B. H. Khan, Non-conventional energy resources, McGraw Hill, New Delhi.

• C. S. Solanki, Renewable energy Technology, Prentice Hall Publication, 2008.

• S. P. Sukhatme, Solar Energy, Tata McGraw Hill, New Delhi, 1996.

• W. C. Turner, Energy management handbook, Wiley Press, 1982

Course


DE FMD 533 ENERGY CONSERVATION

PROCESSES

3 0 0 9

Course Objective

The main aim of the course is to give detailed information about various energy conservation methods

and their significance in plant operations.

Learning Outcomes

At the end of the course student will be able to identify wastage of energy from various units and

ways to minimize them.

COURSE CONTENTS

Module 1: Introduction, definition, Need for Energy management, general principles of

Energy management, planning for energy management, Energy Basics for Energy manager,

starting of Energy management program, world Energy Utilization. [4]

Module 2: High temperature recovery systems, ceramic radiant tubes, boilers. Energy efficient

utilization system. Thermal insulation, pipe line insulation, insulation materials. Insulation on

thermal system and its effect on economics. [8]

Module 3: Heat exchangers for waste heat recovery. Heat pipes, liquid coupled and gas

coupled indirect heat exchangers. Rotating regenerators, plate heat exchangers, economizers,

recuperators, waste heat boilers, heat pumps, performance and application of waste heat

recovery system. Design of waste heat recovery systems. Ideal heat pump cycles. [10]

Module 4: Energy conservation in thermal power plant, coke ovens, Fertilizer, chloro-alkali

industry etc. [6]

Module 5: Factors influencing the efficiency of energy conservation systems. Efficient heat

distribution & utilization. Reduction & recovery of excess energy. Performance and application

of waste heat recovery system. Industrial wastes as sources of energy. Capital and operational

cost for different alternatives on economics sensitivity analysis. [7]

Module 6: Introduction to Energy storage. Fundamentals of Battery used for energy storage.

[4]

Text Book:

• Energy management principle- Applications, benefits, savings by craig B.Smith

Pergamon press.

Reference Books:

• Guide to energy management, Barney.L capehart, Wayne C Tar ner, William J

Kennedy

• Energy Efficiency in Electrical Utilities : Guide Book National Certification

Examination for Energy Manager and Energy Auditors , Bureau of Energy Efficiency,

New Delhi

Course


DE FMD 525 IRON AND STEEL MAKING 3 0 0 9

Course Objective

The objective of this course is to provide the principle of extraction of metal from its ores.

Learning Outcomes

At the end of the course student will be able to learn raw material preparation for extraction of iron

making and steel making.

COURSE CONTENTS

MODULE-1: Raw-Materials: Iron ore quality w.r.t. size, chemistry and other properties,

Types of fluxes used and the importance of coke-quality for iron making. Requirement of Raw-

materials per tonne of Liquid Iron Production. [5]

MODULE-2: Sintering and pelletization of Iron-ore fines and usage of Sinter/ Pellets, Iron

bearing burden and its importance. [6]

MODULE-3: Production of Pig Iron: Construction of Blast-Furnace, use of refractories,

Cooling of various plants. B.F aerodynamics, various reactions taking place in different zones,

Composition of slag and its effects on the quality of metal produced. [9]

MODULE-4: The parameters affecting the productivity of Blast-Furnace. Irregularities' in

blast furnaces, de-sulphurization and de-phosphorization of Pig-Iron. [5]

MODULE-5: D.R Processes: Raw material preparation. Quality requirement and consumption

norms Different methods of Sponge Iron Production. Scope of the process under Indian

condition. S-R Processes: Production of liquid iron by SR process – such as COREX,

ROMELT, Mini Blast - Furnaces and Electric Furnaces. [8]

MODULE-6: Steel making: Principles of steel making, Different methods used such as L.D.

Converter and Electric Furnaces. De-oxidization of steel, uses of different types of de-oxidizers

and alloys for different purposes. [6]

Text Books:




References:

• An Introduction to Modern Steel Making, R.H. Tupkary, Khanna publishers

• J. D. Gilchrist- Extractive metallurgy- Pergamon Press, 1989.

• W. G. Davenport, M. King, M. Schlesinger, A. K. Bishwas and - Extractive metallurgy

of Copper,4th ed., Pergamon Press,2002.

Course


DE FMD 516 ADVANCED PHASE

TRANSFORMATION

3 0 0 9

Course Objective

The objective of this course is to equip students with the fundamental theories of Phase

Transformation in Metals and Alloys, underlying principles governing various new development in

the metallurgical field.

Learning Outcomes

At the end of this course students will be familiar with various types of phase transformation, their

applications and analysis

COURSE CONTENTS

Module 1: Thermodynamics and Phase diagrams: Equilibrium, Single Component

Systems, Binary Solutions, Equilibrium in Heterogeneous Systems, Binary Phase Diagrams,

Influence of Interfaces, Ternary Diagrams, Kinetics of Phase Transformation. [6]

Module 2: Diffusion: Atomic Mechanisms of Diffusion, Interstitial Diffusion, Substitutional

Diffusion, Concept of Atomic Mobility, High Diffusivity Paths, Case Studies. [4]

Module 3: Crystal Interfaces and Microstructures: Interfacial Free Energy, Solid –Vapour

Interfaces, Boundaries in Single Phase Solids, Interphase Interfaces in solids, Mobility and

Migration of Boundaries. [5]

Module 4: Solidification: Nucleation in Pure Metals, Growth in Pure Solid, Alloy

Solidification, Solidifications of Ingots and Castings, Solidification of Fusion Welds, Case

Studies. [5]

Module 5: Diffusional Transformation in Solids: Homogeneous Nucleation,

Heterogeneous Nucleation, Precipitate Growth, Overall Transformation Kinetics,

Transformation Diagrams, Precipitation in Age Hardening Alloys, Precipitation of Ferrite

from Austenite, Cellular Precipitation, Eutectoid Transformation, Massive Transformation,

Ordering Transformation, Case Studies. [10]

Module 6: Diffusionless Transformations: Characteristics of Diffusionless

Transformations, Martensite Crystallography, Martensitic transformation: Nucleation &

Growth, Tempering of Martensite, Case Studies. [9]

References:

• David A Porter, Kenneth E Easterling, Phase Transformations in Metals and Alloys,

CRC Press

• Robert E. Reed Hill, Reza Abbaschian, Physical Metallurgy Principles, Van Nostrand

New York

• F. J. Humphreys, M. Hatherly, Recrystallization and Related Annealing Phenomena,

Elsevier

Course


DE FMD 517 MECHANICAL BEHAVIOUR OF

MATERIALS

3 0 0 9

Course Objective

The main objective of the course is to understand the mechanical properties of materials and its basic

principles

Learning Outcomes

On completion of this course, students will be able to solve problems related to mechanical property

of material and identify the suitable material

COURSE CONTENTS

Introduction: Basic assumptions in strength of materials approach, stress and strain relations,

elastic behavior, tensile testing, hardness testing [5]

Elements of plasticity: Flow curve, strain hardening, strain rate, temperature dependence of

flow stress [5]

Plastic deformation: Slip in crystals, Theoretical strength of a perfect crystal, critical resolved

shear stress, properties of dislocations, dislocation motion, deformation by twinning [5]

Strengthening mechanisms: Grain boundary strengthening, Solid solution strengthening,

Precipitate hardening, Strain hardening [6]

Fracture: Types of fracture, fracture modes, Griffith theory of brittle fracture of material,

ductile fracture, notch effects, introduction to fracture mechanics, Impact test [6]

Fatigue: S-N curve, low cycle and high cycle fatigue, structural features, surface effects,

metallurgical variables, Fatigue test [6]

Creep: Creep mechanisms, creep curve, stress rupture test, structural changes, creep resistant

materials, superplasticity [6]

Mechanical behavior of non-metallic materials: Ceramics, glasses, polymers, composite

materials [3]

Text Books:

• Dieter, G. E., “Mechanical Metallurgy”, 3rd Ed., McGraw Hill Education India, 2010

• Courtney, T.H., “Mechanical Behavior of Materials”, 2nd Ed., McGraw Hill, 1990

• Meyers, M.A. and Chawla, K.K., “Mechanical Behavior of Materials”, Prentice Hall,

1999

• Hull, D. and Bacon, D.J., “Introduction to Dislocations”, 4th Ed., Butterworth-

Heinemann, 2001

• R.W. Hertzberg, Deformation and Fracture Mechanics of Engineering Materials, 4th

Ed., John Wiley, New York, 1996

• W.F. Hosford, Mechanical Behavior of Materials, Cambridge University Press, 2005

Course


DE FMD 518 JOINING OF MATERIALS 3 0 0 9

Course Objective

The main objective of the course is to understand various joining process used in industries for

metallic materials and their effect on microstructure and mechanical properties

Learning Outcomes

On completion of this course, students will be able to choose a particular joining process for

industrial application

COURSE CONTENTS

Fusion Welding Processes: Oxyacetylene Welding, Shielded Metal Arc Welding, Gas–

Tungsten Arc Welding, Plasma Arc Welding, Gas–Metal Arc Welding, Flux-Core Arc

Welding, Electron Beam Welding, Laser Beam Welding

[6]

Heat Flow in Welding: Heat Source, Analysis of Heat Flow in Welding, Effect of Welding

Parameters, Weld Thermal Simulator [6]

Residual Stresses, Distortion, and Fatigue [2]

Weld Metal Solidification: Epitaxial Growth at Fusion Boundary, Nonepitaxial Growth at

Fusion Boundary, Competitive Growth in Bulk Fusion Zone, Effect of Welding Parameters on

Grain Structure, Weld Metal Nucleation Mechanisms, Grain Structure Control, Solidification

Modes [8]

Weld Metal Chemical Inhomogeneities: Microsegregation, Banding, Macrosegregation in

Bulk Weld Metal [4]

Weld Metal Solidification Cracking: Metallurgical Factors, Mechanical Factors,

Characteristics, Cause, and Testing, Liquation Mechanisms, Hydrogen Cracking

[6]

Welding of Aluminium, Ni based alloys, Alloy steels [4]

Solid state welding joining process: Friction stir welding, Friction welding, Ultrasonic

welding [3]

Text books

• Sindo kou, “Welding metallurgy”, A John Wiley & Sons, Inc., Publication, Second

Edition

References

• John C. Lippold, “Welding Metallurgy and Weldability”, A John Wiley & Sons, Inc,

• John C. Lippold , Damian J. Kotecki, “Welding Metallurgy and Weldability of

Stainless Steels”, A John Wiley & Sons, Inc

Course


DE FMD 519 INTRODUCTION TO

COMPUTATIONAL MATERIALS

SCIENCE

3 0 0 9

Course Objective

The main objective of the course is to understand various computational techniques used in material

science in different length scales

Learning Outcomes

On completion of the course, students will be able to understand various computational methods that

can be used for material development and do some basic level coding

COURSE CONTENTS

Introduction to materials modeling and simulation, Scales in materials structure and

behavior, Simulation of finite systems, Periodic boundary conditions, Long-ranged potentials

[5]

Electronic structure methods, Quantum mechanics of multielectron systems, Wave

functions, Pseudopotentials, Use of density functional theory, Interatomic potentials, Pair

potentials, Determining parameters in potentials [5]

Molecular dynamics: molecular dynamics for atomic systems, Velocity rescaling,

Accelerated dynamics, Ensembles, Thermostat, Barostat, Time integration algorithms,

Interatomic potentials, Limitations of molecular dynamics [5]

Monte Carlo method: Ensemble averages, The Metropolis algorithm, The Ising model, Monte

Carlo for atomic systems, Time in a Monte Carlo simulation, Uses of the Monte Carlo method

in materials research, Kinetic Monte Carlo, Modeling Grain Growth [6]

Cellular automata: Basics of cellular automata, Lattice-gas methods, Relation to Monte

Carlo, Examples of cellular automata in materials research [5]

Phase field modelling: Conserved and non-conserved order parameters, Governing equations,

Free energy of an interface, Local free-energy functions, multi-phase field approach [6]

Multiscale modelling and examples in material research [4]

Finite element modelling, finite volume method, Introduction to software available in

different length scale simulations [3]

Text books

• Richard LeSar, “Introduction to Computational Materials Science” Materials Research

Society (MRS), Cambridge university press

References

• Dierk Raabe, “Computational Materials Science: The Simulation of Materials

Microstructures and Properties”, Wiley VCH

• June Gunn Lee, “Computational Materials Science: An Introduction”, CRC Press

Course


DE FMD 520 Advanced Thermodynamics and Kinetics 3 0 0 9

Course Objective

The main objective of the course is to understand the principles of thermodynamics and kinetics

Learning Outcomes

On completion of the course, students will be able to understand various metallurgical processes and

its fundamental thermodynamic and kinetics principles

COURSE CONTENTS

Simple and composite systems, stable equilibrium states. Adiabatic work interaction, heat

interaction, internal energy, First law [3]

Reversible processes, heat engines, Second law, Theorem of Clausius, entropy, combined

first and second law [4]

Legendre transforms, representations of the fundamental equation [2]

Equilibrium: extremum principles, membrane, phase and reaction equilibria. [3]

Single phase systems: Thermodynamic relations among variables [2]

Solutions, partial molal properties, solution models. Phase rule, unary, binary and ternary

phase diagrams. [4]

Thermodynamics of phase diagrams. Reacting systems, gas phase reactions, Ellingham

diagrams, Pourbaix diagrams. [5]

Thermodynamics of Phase Transformations: Melting and solidification, precipitation,

eutectoid, massive, spinodal, martensitic and order disorder transformations. First and second

order transitions. [7]

Ficks laws of diffusion, Diffusion mechanisms, Random walk model, Kirkendall effect,

Grain growth and coarsening, Analytical and numerical solutions, Diffusion in semi-infinite

and finite media, Concept of Johnson-Mehl equation [6]

Chemical Kinetics: Rate of reaction, Order of reactions, Homogeneous reactions,

Heterogeneous reactions, fluid-solid reactions, fluid-fluid reaction, Type of reactors [5]

Text Books:

Introduction to thermodynamics of materials, D R Gaskell, CRC Press; 5th edition

Thermodynamics and it's applications, Michael Modell and Robert C. Reid, Prentice hall,

Englewood cliffs, new jersey 1983

References

• H.B. Callen, Thermodynamics and an Introduction to Thermostatics, Jonh Wiley, New

York, 1985.

• R.T. DeHoff, Thermodynamics in Materials Science, McGraw-Hill, Singapore, 1993.

• O. Levenspiel, Chemical Reaction Engineering, 3rd edition, 2004

• P. Shewmon, Diffusion in Solids, Minerals, Metals & Materials Soc., 1989.

• R.W. Balluffi, S.M. Allen and W.C. Carter, Kinetics of Materials, John Wiley, 2003.

Course


DE FMD 534 METAL FORMING TECHNOLOGY 3 0 0 9

Course Objective

The main objective of the course is to understand various forming process used in industries for

metallic materials and their effect on microstructure and mechanical properties

Learning Outcomes

Students will be able to find the force, energy requirement etc. for a forming industry and also how

the forming process will affect the microstructure of the material

COURSE CONTENTS

Deforming system analysis. flow curves and their significance related to upsetting, forging,

rolling, extrusion, deep drawing, determination of flow curves, constitutive equations, role of

friction and temperature in metal forming, Concept of friction hill, concept of uniform work,

redundant work, frictional work, deformation efficiency, etc [10]

Extrusion: Hot and cold extrusion, analysis of extrusion using plasticity theory, extrusion

tooling, extrusion as a primary and secondary process, adiabatic and isothermal extrusion, heat

and velocity management in hot extrusion, defects in extrusion. [8]

Rolling: Analysis of rolling process, calculation of rolling loads, defects in rolling [5]

Forging: open and closed die forging, calculation of forging loads, defects in forging [5]

Wire, rod and tube drawing: analysis of loadscaoncept of drawability limits, defects in

drawing, Introduction to sheet metal forming [5]

Generation of processing map: instability criteria, strain rate sensitivity map, efficiency map,

application of FEM simulation for forming process optimization, numerical problems [6]

Text books

• Dieter G E., Mechanical Metallurgy, 3rd edition, McGraw Hill.

Reference Books:

• Hosford W F and Caddell W M., Metal Forming: Mechanics and Metallurgy, 4th

edition, New York: Cambridge University Press

• Henry S Valberg., Applied Metal Forming: Including FEM analysis, 1st edition, New

York: Cambridge University Press

Course


DE FMD 535 POWDER METALLURGY 3 0 0 9

Course Objective

To acquaint with a broad overview of powder metallurgy processes, and understand the recent

concepts in powder metallurgy and product design parameters

Learning Outcomes

• Conceptualize the powerful tool of powder metallurgy and directly apply to contemporary

products.

• Acquainted with various powder production techniques

• Processing parameters related to various fabrication techniques

Methods of characterization needed for evaluating the powder metallurgical products.

COURSE CONTENTS

Introduction to Powder Metallurgy, Definition [2]

Powder fabrication methods: Mechanical fabrication, electrolytic fabrication, chemical

fabrication, atomization. [8]

Microstructure control: Thermodynamics and kinetics of solidification, effect of fabrication

process parameters on microstructure. [6]

Powder Characterization: basis for particle size measurement, particle size and distribution,

dynamic light scattering, other methods of particle size measurement, surface area analysis [10]

Powder packing, Powder shaping, Consolidation, Compaction, sintering, characterization of

powder compacts. Cold Isostatic pressing, powder injection molding, slurry techniques, tape

casting, sintering, Full density processing, Finishing operations, Properties and Applications

[13]

Textbooks:

• Angelo, P.C. and Subramanian, R., “Powder metallurgy: science, technology and

applications”. PHI Learning Pvt. Ltd. 2008.

• Upadhyaya, A. and Upadhyaya, G.S., “Powder metallurgy: science, technology and

materials”. Universities Press. 2011.

Course


DE FMD 536 SURFACE ENGINEERING 3 0 0 9

Course Objective

To impart a comprehensive understanding on various aspects related with surface engineering of

metallic components for enhanced life.

Learning Outcomes

• Fundamental mechanisms of friction and wear, corrosion, fatigue etc

• Various surface protection techniques

• Recent trends in surface engineering

Methods of characterization needed for evaluating the metallurgical and mechanical properties and

performance of engineered surfaces.

COURSE CONTENTS

Introduction to surface dependent engineering properties, viz., Friction and wear, corrosion,

fatigue, etc.; surface-initiated engineering failures; surface degradation mechanisms;

importance and necessity of surface engineering; classification and scope of surface

engineering in metals, ceramics, polymers and composites, tailoring of surfaces of advanced

materials. Surface protection (Physical); surface modification (Chemical) techniques:

classification, principles, methods, and technology. Conventional surface engineering

methods: carburising, nitriding, cyaniding, diffusion coating, hot dipping, galvanizing etc. [13]

Electrochemistry and electro-deposition; scope and application of conventional surface

engineering techniques in engineering materials; advantages and limitations of conventional

processes. Recent trend in surface engineering: physical/chemical vapor deposition; thermal

spray coating; plasma assisted ion implantation etc [13]

Surface modification by directed energy beams like ion, electron and laser beams; energy

transfer, novelty of the directed energy beams assisted surface modification techniques.

Characterization (microstructural and compositional) and testing/evaluation of surface-

properties; structure-property correlation. Economics and energy considerations, designing of

surface engineering processes. [13]

Textbooks:

• J. R. Davis (Ed.): Surface Engineering for Corrosion and Wear Resistance, ASM

International, Materials Park, Ohio, 2001.

• K. G. Budinski (Ed.): Surface Engineering for Wear Resistance, Prentice Hall, New

Jersey 1988.

List of Open Electives

Course


OE FMO 542 MINERAL PROCESSING

ECONOMICS

3 0 0 9

Course Objective

To give knowledge of all aspects of the mineral industry and to assess Indian mineral reserves and

resources.

Learning Outcomes

This will enable students to get current information about the industry

COURSE CONTENTS

MODULE-1: Global scenario [6]

• World reserves of important minerals

• Different reserves classification systems e.g. UNFC, JORC

• India's position in global mineral industry

• Depletion of mineral resources and beneficiation prospects.

• Future potential of key minerals and factors driving their demand.

MODULE-2: Indian Mineral Industry [10]

• Mineral reserves in India and classification system adopted

• Contribution of minerals to Indian industrial and economic growth.

• Roles & responsibility of key Government organisations managing the mineral sector:

Ministry of Mines, Ministry of Coal, Indian Bureau of Mines, Coal Controller

Organisation, DGMS, state departments

• Major industrial revolutions and its impact on mineral industry.

• Domestic Demand and supply scenario of key minerals and metals.

• Policy framework in India - Mineral Sector Policies, Exploration Policies, Steel Policy,

MMDR and Rules framed thereunder, mineral auctions, etc.

• Future scenario and steps required to meet future requirements

MODULE 3: Economics of mineral projects [10]

• Typical cost components in a mineral project: Capital costs, operating costs (fixed and

variable costs)

• Key financial aspects to evaluate feasibility of project - cost curve, profitability, Net

Present Value, IRR

MODULE-4: Aspects for sustainable development of mineral industry: environment, social,

resource conservation, health, Life cycle assessment, etc. [6]

MODULE-5: Future technologies for mineral beneficiation. [7]

Text Book:

• An introduction to mineral economics by K K Chatterjee.

References:

• Mine and mineral economics by Subhash C. Ray and Indra N. Sinha.

• Ore geology, economic minerals and mineral economics by S K Tiwari

Course


OE FMO 543 WASTE PROCESSING AND

MANAGEMENT

3 0 0 9

Course Objective

To give knowledge of waste generation from processing plants, characterization and utilization.

Learning Outcomes

This will enable students to get information of plant waste and its utilization in various industries

COURSE CONTENTS

MODULE-1: Waste generation from processing plants, handling, storage and environmental

hazards. Characterization and utilization of solid wastes - red mud, steel plant waste, fly ash

waste, iron ore, copper, lead, zinc, coal tailings, etc. [8]

MODULE-2: Utilization of solid waste as building material, fertilizer, PVC products, paints,

pigments, cement industries, brick making, coating, chemical industries, filtration, purification,

etc. [10]

MODULE-3: Composition and properties of slags from BF, LD, EAF, Cupola, Slag produced

in Non-ferrous plants. Cements: type of slag, granulation treatment, transportation, grinding,

mixing & properties. Slag Wool: Type of slag, granulation, handling, compaction. Slag Blast:

properties & uses in Fertilizer industries, Composition, treatment & application, Slag grinding.

[11]

MODULE-4: Properties: Composition, size, shape, surface properties, refractoriness, density.

Applications: Building Brick – Binder selection, mixing, compaction, strengthening, Testing,

Equipments, economics. Insulation brick – Additives, compaction firing and testing. Soil

treatment – characteristic properties, uses, Pozolana – Properties & testing Road Making –

Properties & Testing, Horticultural Use, Effluent Treatment, Mine filling, Smelting, Other

uses. [10]

Text Book:

• Sustainable solid waste collection and management, By Ana Pires, Graça Martinho,

Susana Rodrigues, Maria Isabel Gomes

Course


OE FMO 544 CLEAN COAL TECHNOLOGY 3 0 0 9

Course Objective

The main aim of the course is to give fundamentals concept of efficient way of utilizing coal in

different applications with minimum environmental impact.

Learning Outcomes

At the end of the course student will be able to identify various techniques of utilizing coal for

cleaner environment.

COURSE CONTENTS

Module 1: Introduction to clean Fuel technology: Coal quality parameters for utilization in

thermal power plant, cement, steel and DRI plant. Pre-combustion cleaning, during combustion

cleaning, post-combustion cleaning, burning time, unburned carbon estimation and control.

Biological and chemical cleaning methods. [10]

Module 2: Emission control: Fly ash, SOx and NOx control strategies during combustion and

after combustion. Use of ESP, Cyclones, Filters and settling chambers. CO2 sequestration. [10]

Module 3: Coal gasification: Gasifying agents: oxygen, air, steam, reactions involved in

gasification. Effect of fuel properties on product, blending of fuels. Syn gas, Fuel gas. [8]

Module 4: Types of gasifiers: Fixed bed, moving bed, fluidized bed, entrained bed etc.

Product gas cleaning and energy utilization, removal of H2S, NH3, tar, suspended particulate

matter. [5]

Module 5: Other technologies: Underground coal gasification (UCG), Coal bed methane,

recovery of methane from CBM (Coal Bed Methane), CMM (Coal Mine Methane), AMM

(Abandoned Mine Methane), combined cycle power generation (IGCC), oxy-fuel combustion.

[6]

Text Book:

• Clean Coal Engineering Technology: Bruce G Miller, Elsevier Publications.

References:

• Fuels and Combustion: Samir Sarkar, University Press (India) Pvt Limited, India.

• The Chemistry and Technology of Coal: James G Speight, Marcel Dekker.

Course


OE FMO 550 CEMENT TECHNOLOGY 3 0 0 9

Course Objective

The aim of this course is to provide fundamental knowledge about cement manufacturing processes

and utilization of different types of fuels in cement manufacturing.

Learning Outcomes

After attending the course students will be able to understand cement manufacturing process and role

of various fuels in cement manufacturing.

COURSE CONTENTS

Module 1: Various processes of cement manufacture – dry, semi-dry and wet, overview of

various unit operations. Indian cement industry, the global scenario. [4]

Module 2: Phase composition of clinker minerals and cement, pozzolanic reaction, hydration

of cement, Raw mix proportioning, 2-, 3- and 4-component mixes, concepts of burn ability,

absorption and effect of coal ash Different zones in a cement kiln, preheaters and pre-

calcinators. [15]

Module 3: Coolers, burners, fuels, waste-derived fuels, Pet coke, refractory and refractory

practices. [8]

Module 4: Testing of cements for various properties. [4]

Module 5: Approaches to energy conservation, energy audits, co-generation of power,

Pollution control, noise abatement, concepts of LCA. EIA and EMP. [4]

Module 6: Quality control and plant layout of modern cement plants. [4]

Text Book:

• Chemistry of Cement and Concrete: F M Lea, Arnold, London

References:

• Cement Data Book: W. H Duda , Verlag G m Bh, Berlin, R. H. Bouge.

• Chemistry of Portland Cement, Reinhold, New York

Course


OE FMO 546 MECHANOCHEMISTRY IN

NANOSCIENCE AND MATERIALS

ENGINEERING

3 0 0 9

Course Objective

This multi-disciplinary course is designed for PG and final year UG students to develop an

understanding of

(a) fundamentals of mechanochemistry and mechanical activation of solids, and its

(b) applications encompassing minerals, metals and materials processing

Learning Outcomes

• Understanding of fundamentals of mechanical activations of solids and mechanochemistry

• Understanding of devices used for mechanical activation and judicious selection

• Understanding of techniques involved in bulk and surface characterisation of activated solids and

challenges

• Understanding of mechanically induced physicochemical changes and reactivity in a wide

spectrum of solids

Understanding of applications in diverse areas

COURSE CONTENTS

MODULE 1: (Fundamentals)

Introduction : Historical introduction to mechanochemistry and mechanical activation of

solids, definitions, mechanically induced vs. thermal transformations, theories and models in

mechanochemistry, fine grinding and mechanical activation, thermodynamics and crystal

chemistry perspectives, mechanochemistry and nanoscience, mechanical activation vis-à-vis

other non-equilibrium processing routes, applications at a glance [4]

Change in structure and chemical reactivity of solids due to deformation and fracture :

Macroscopic phenomena, structural changes associated with deformation and fracture;

relaxation of stored energy in activated solids, electrical and luminous phenomena triggered by

mechanical activation [4]

Fundamental of milling, devices and characterisation of activated solids : Milling mechanisms,

concepts of stress intensity, stress number and milling energy, high energy ball milling, milling

variables, role of medium (water/gases), grinding aids, kinetics of mechanical chemical

reactions; Devices for mechanical activation (planetary milling, attrition mills, eccentric

vibratory mills, jet mills, newer devices); characterisation (bulk and surface) of

activated/dispersed solids [5]

Mechano-chemical reactions: Homogeneous mechanochemical reactions, mechanochemical

dissociations and decompositions, solid-gas, solid-liquid and solid-solid mechanochemical

reactions, soft mechanochemistry, reactions combined with capillary condensation,

chemihesion and overlapping effects; inorganic (sulphides, oxides, oxyhydroxides, spinels,

silicates) vs. organic solids (polymers and macomoecules), mechanical activation of

amorphous materials [5]

MODULE 2: (Applications)

Mechanical alloying: Fundamental aspects, mixing in solid state, reactive ball milling,

composite materials, select examples of advanced alloys (quasi-crystals, high entropy alloys),

self-propagating high temperature synthesis, mechanically alloyed powders for surface

protective coatings [4]

Mineral Processing and extractive metallurgy: Mechanical activation of minerals (sulphides,

oxides, oxyhydroxides, carbonates, clay minerals), some examples from pyrometallurgy,

mechanical activation as a pre-treatment in leaching, leaching kinetics of activated minerals,

the concept of simultaneous milling and leaching, newer processes based on mechanical

activation (SMILE, ACTIVOX, MELT), micronisation of coal, using attrition milling for scale

up [5]

Environment and sustainability: Utilisation of wastes in building materials - mechanical

activation of fly ash and slags from ferrous and nonferrous metal production, improved

blended cements and geopolymers; red mud problem; CO2 sequestration; potash recovery

from clay minerals, utilisation of agro-wastes [5]

Mechanical activation of polymers and macromolecules: amorphisation, stress induced

transformation in drug molecules, drug solubility and its control, drug synthesis [3]

Advanced materials Examples related to Semiconductor materials, Hydrogen storage, Battery

materials, Permanent magnets) [4]

Text Books and References:

• Mechanochemistry in nanoscience and minerals engineering. Peter Baláž, Springer,

2008

• Mechanical Activation of Minerals by Grinding: Pulverizing and Morphology of

Particles. A.Z. Juhasz, L. Opoczky, Ellis Horwood Limited, New York, 1994

• Chemical Society Review (Theme Issue on Mechanochemistry), Volume 42, 2013

• Novel materials synthesis by mechanical alloying/milling, B. S. Murty and S.

Ranganathan, International Materials Reviews 1998 Vol.43 No.3 101

• High-energy ball milling Mechanochemical processing of nanopowders, Małgorzata

Sopicka-Lizer (Editor), CRC Press, 2010

• Mechanical alloying and milling, C. Suryanarayana, Progress in Materials Science 46

(2001) 1-184

• Mechanical Alloying Nanotechnology, Materials Science and Powder Metallurgy, M.

Sherif El-Eskandarany, Second Edition, Elsevier, 2015

• Macromolecular Mechanochemistry, Vol I and II, Cleopatra Vasiliu-Oprea and Florin

Dan, Cambridge International Science Publishing, 2006

• Lead lectures in ‘Frontiers in mechanochemistry and mechanical alloying’, Rakesh

Kumar, S. Srikanth and S.P. Mehrotra (Editors), NML and IMA Publication, 2011

+ several reviews and topic specific research papers

Course


OE FMO 547 ADDITIVE MANUFACTURING 3 0 0 9

Course Objective

To acquaint with the concept of AM, various AM technologies, selection of materials for AM,

modeling of AM processes, and their applications in various fields

Learning Outcomes

• Introduce various additive manufacturing technologies and their need.

• Materials science of AM technologies

• Recent trends in AM

• Commonly used mathematical models for AM technologies

Process selection planning and control for AM technologies

COURSE CONTENTS

Introduction to Additive Manufacturing: Fundamental Concepts, Classification of Additive

Manufacturing Processes, Additive Manufacturing Process Chain, Evolution of Additive

Manufacturing Processes, Advantages and Limitations of Additive Manufacturing [5]

Materials science for AM: Discussion on different materials used, multifunctional and graded

materials in AM, Role of solidification rate Evolution of non-equilibrium structure, Structure

property relationship, Grain structure and microstructure [10]

Additive Manufacturing Processes: Photopolymerization, Extrusion, Sheet Lamination, Binder

Jetting, Material Jetting, Directed Energy Deposition, and Powder-Bed Fusion Processes;

Solid-State Additive Manufacturing and Hybrid (Additive + Subtractive) Processes; Additive

Manufacturing of Common Engineering Metals [9]

Mathematical models for AM: Transport phenomena models- temperature, fluid flow and

composition, buoyancy driven tension driven free surface flow pool); Case studies: Numerical

Modeling of AM process, Powder bed melting based process, Droplet based printing process,

Residual stress, part fabrication time, cost, optimal orientation and optimal Defect in AM and

role of transport Simulations (choice of parameter, Model validation [10]

Process selection, planning, control for AM Selection of AM technologies using decision

methods, Additive manufacturing process plan: strategies and post processing. Monitoring and

control of defects, transformation [6]

Textbooks:

• Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies:

rapid prototyping to direct digital manufacturing Springer, 2010.

• Andreas Gebhardt, Understanding additive manufacturing: rapid prototyping, rapid

tooling, rapid manufacturing, Hanser Publishers, 2011.

• J.D. Majumdar and I. Manna, Laser-assisted fabrication of materials, Springer Series

in Material Science, e-ISBN: 978-3-642- 28359-8.

Course


OE FMO 548 ANALYSIS AND MODELLING OF

WELDING

3 0 0 9

Course Objective

The aim of this course is to provide fundamental knowledge about modelling of Fuzion welding

process and analysis

Learning Outcomes

After attending the course students will be able to understand the fundamentals of welding process

modelling in different length scales and numerical analysis of the process

COURSE CONTENTS

Introduction to welding processes, TIG welding, GMAW process, Submerged Arc Welding,

Laser welding, Electron beam welding, Heat sources, Heat removal, Thermal modelling (10)

Fluid flow modelling in welding, Fluid Flow in Arcs, Fluid Flow in Weld Pools, Zones in a

weldment, Keyhole mode of welding (4 )

Solute transfer modelling at macroscale and microscale, Solute segregation profile, Solute

Redistribution during Solidification, Solidification Modes and Constitutional Supercooling,

Microsegregation and Banding, Solidification Path (8)

Microstructure formation in welds, application of phase field modelling in welding, multi-

phase field modelling (5)

Analytical solution to weld thermal fields, Rosenthal, Adams, Rykalin, Hannerz models (4)

Numerical solutions to thermal field and fluid flow in welding (4)

Dissimilar welding, Application of FEM in welding (4)

Text books:

• Sindo kou , “welding metallurgy”, A John Wiley & Sons, Inc., Publication, Second

Edition

References

• John C. Lippold, “Welding Metallurgy and Weldability”, A John Wiley & Sons, Inc,

Course


OE FMO 549 INTRODUCTION TO INTEGRATED

COMPUTATIONAL MATERIALS

ENGINEERING

3 0 0 9

Course Objective

The aim of this course is to provide fundamental knowledge about ICME and its application in various

industries

Learning Outcomes

After attending the course students will be able to solve various industrial problems by using

computational, simulation and experimental techniques.

COURSE CONTENTS

Historical Development of ICME, ICME for Design, Design Optimization, Metamodeling

Approaches, Design with Uncertainty Analysis, ICME for Manufacturing, Open Architecture,

Modularity, Bridging the Scales, Data Modules, Standardization [4]

Prediction of Effective Properties, Homogenization of Materials with Periodic Microstructure,

Static Equilibrium of a Heterogeneous Material, Periodicity and Two-Scale Description, The

Asymptotic Homogenization Method, Homogenization of Materials with Random

Microstructure, Morphology Analysis and Definition of the RVE, Stochastic Homogenization,

Mechanical Properties of the Amorphous and Crystalline Phases, Virtual Material Testing

Tools for the Determination of Effective Properties, Program Environment for Virtual Testing

[15]

Data Integration, Standardized Postprocessing, Integrated Visualization, Data History

Tracking [4]

Application of ICME in Reheating, Welding, Hot Rolling [4]

Application of ICME in component development: Stainless Steel Bearing Housing, Piston Rod,

Gear, etc [4]

Importance of Physical simulation in ICME, physical simulation of manufacturing process

rolling, forging, welding, casting, additive manufacturing, etc. [4]

Future Directions, Platform Development, Application of Machine learning in ICME platform

[4]

Text books:

• Georg J. Schmitz, Ulrich Prahl, “Integrative Computational Materials Engineering:

Concepts and Applications of a Modular Simulation Platform”, A John Wiley & Sons,

Inc., Publication

References

• Mark F. Horstemeyer, “Integrated Computational Materials Engineering (ICME) for

Metals: Using Multiscale Modeling to Invigorate Engineering Design With Science”,

A John Wiley & Sons, Inc., Publication

• Richard LeSar, “Introduction to Computational Materials Science”, Materials Research

Society (MRS), Cambridge university press

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