PES INSTITUTE OF TECHNOLOGY

Bangalore South Campus

DEPARTMENT OF MECHANICAL ENGINEERING

LESSON PLAN

Faculty name : Venkata Reddy

Subject name : Materials Science & Metallurgy
Subject code : 10ME32
Total No. of Lecture hrs: 52 No. of Lecture hrs/week: 04

% of Portions
Class # Unit Topics to be covered covered

Part A
Structure of crystalline solids. Fundamental concepts of Unit cell space
lattice, Bravais Lattices, Unit cells for cubic structures and HCP. Study
of stacking of layers of atoms in cubic structure and HCP, calculations of
1-7 Unit 1
radius, co-ordination No. and Atomic Packing Factor for different cubic 13.5 %
structures, Crystal imperfections point, line, surface & volume defcts,
Diffusion diffusion mechanism, Ficks laws of diffusion
Concepts of stress and strain, tensile properties, true stress & true strain,
8 - 13 Unit 2 Hardness Rockwell, Vickers & Brinnel Hardness testing, Plastic 25 %
deformation - slip and twinning
Fracture types, shapes in cup & cone fracture, Griffiths criterian, Fatigue
Fatigue tests, S-N curves, Factors affecting fatigue life and protection 38.5 %
14 - 20 Unit 3
methods. The creep curves, mechanism of creep, creep resistant
materials
Solid solutions, Types, Rules governing formation of solid solutions,
Phase diagrams Basic terms, phase rule, cooling curves, construction of 50 %
21 - 26 Unit 4
Phase diagrams, interpretation of equilibrium diagrams, Types of Phase
diagrams, Lever rule
Part B
Iron carbon equilibrium diagram, phases in the Fe-C system, Invariant
reactions, critical temperatures, Microstructures of slowly cooled steels,
effect of alloying elements on the Fe-C diagram, ferrite and austenite 63.5 %
27 - 33 Unit 5
stabilizers. The TTT diagram, drawing of TTT diagram, TTT diagram for
hypo & hyper eutectoid steels, effect of alloying elements on CCT
diagram
Annealing and its types, normalizing, hardening, tempering,
martempering, austempering, hardenability, surface hardening like 75 %
34 - 39 Unit 6
carburizing, cyaniding, nitriding, and induction hardening, Hardenability
Jominy End Quench test, Age hardening Aluminium and Copper alloys
Engineering alloys Properties, composition and uses of low Carbon,
mild medium and high carbon steels, Steel designation AISI and SAE
40 - 46 Unit 7 designation; Cats Irons gray CI, White CI, Malleable CI & SG CI; 88 %
Microstructures of CI. The light alloys Al, Mg and Ti alloys; Copper and
its alloys, Brasses & Bronzes
Corrosion & its prevention, Galvanic cell; The electrode potentials,
Polarization and Passivation; General methods of corrosion prevention,
47 - 52 Unit 8
Cathodic protection; Coatings, Corrosion prevention by alloying; Stress 100 %
corrosion cracking

Text Books:
 1. Materials Science and Engineering An introduction; William D Callister Jr; Wiley India Pvt. Ltd., 6 th
Edition, 2006, New Delhi

2. Essentials of Materials for Science and Engineering, 4th edition Donald R Askeland and Pradeep, P.
Phule, Thomson Engineering (2006)

Reference Books:

1. Introduction to Material Science for Engineering 6th Edition, James F Shackel, Ford Pearson, Prentice
Hall, New Jersey, 2006

2. Foundations of materials science and engineering Smith, 3rd ed. McGraw hill 1997

3. Physical Metallurgy Principles and Practices by V. Raghavan, PHI,2nd Edition, 2006, New Delhi

QUESTION BANK
PART A
Unit 1
1. Describe with neat sketches the arrangement of atoms in BCC, FCC and HCP crystals with examples.
2. Define coordination number of packing efficiency.
3. Distinguish between a crystal and a non-crystal.
4. Define a space lattice and unit cell.
5. What is dislocation. Explain different types and their formation.
6. Explain the mechanism of deformation by means of an edge dislocation.
7. What are vacancies. How are they formed and explain the formation of Schottky and Frenkel defects.
8. What is burgers vector.
9. Explain Frank Read source for the generation of dislocations.
10. Show that FCC structure is always more close packed than BCC.
11. Explain the term Atomic packing factor. Calculate packing efficiency for FCC and BCC.
12. Determine the following for BCC and FCC (i) lattice constant (ii) APF *
13. Classify crystal imperfections in the order of their geometry*
14. Aluminum of lattice parameter of 0.405 nm has FCC crystal structure. Calculate its atomic radius [Answer
: 0.1432 nm]
15. What is diffusion? Explain different types and mechanism of diffusion.*
16. Write Fick's laws of diffusion and illustrate with examples.
17. What are the factors affecting diffusion. Explain any three factors.
18. At 900 C, what is the time required to carburise a steel with an initial concentration of 0.2% C to 1.0% C at
a depth of 0.2mm. Assume a constant surface concentration of 1.4% C due to carburising atmosphere.
[Ans.: 14980 seconds]
Unit 2
1. List and define important properties determined in a tensile test.
2. Derive an expression for the true stress and True strain of a material in terms of engineering stress and
engineering strain.
3. Discuss yield point phenomenon in steels. Discuss Bauschinger effect.
4. A low carbon steel is subjected to a tensile load of 7000 kg. Assuming no change in volume during
extension, determine Engineering stress, Engineering strain, True strain and True stress. The initial dia. of
rod is 13 mm and the specimen under load is 12 mm. [Answer: Engineering strain = 0.1736;
Engineering stress = 517 MPa ; True strain = 0.16; True stress= 608 MPa]
5. Explain off-set Yield strength
6. Explain the properties applicable to non-linear elastic materials
7. Explain different varieties of stress strain curves that can result from tensile test of engineering materials
8. Distinguish between upper and lower yield point, Resilience and toughness, Proportional limit and elastic
limit.
9. On a stress-strain diagram, for a load beyond yield strength that is suddenly removed, show the elastic and
plastic strain.*
10. Draw stress-strain curve for a ductile material and explain the salient features. Define 0.2% proof stress.
11. Compare the stress-strain curve for a ductile and brittle material and discuss the importance of gauge length
in a tensile test. *
12. Compare engineering stress-strain curve and true stress-true strain curve for a ductile material.
13. Discuss on a) effect of grain size on strength*
14. Explain Hardness test methods by Rockwel, Vickers & Brinnel
15. Explain Scmids law or Explain critical resolved shear stress*
16. Explain clearly the twining mechanism using a neat sketch.*
17. Write a note on slip and twining.
18. Distinguish between slip and twinning
Unit 3
1. Briefly explain different modes of Fracture
2. Distinguish between Ductile and Brittle fracture
3. Explain Griffith theory of Brittle fracture
4. Briefly explain Linear Elastic Fracture Mechanics
5. The critical stress intensity factor (Fracture Toughness K IC, of a material used for a component is 26 MPa
m. What is the applied stress that will cause fracture if the component contains an internal crack of length
is 1.72 mm. Assume the geometric constant is 1. [Answer : 353 MPa]
6. Draw a typical curve for a metal under constant load and constant temperature at relatively medium
temperatures
7. Priefly explain the important properties related to creep
8. Define the term creep. Illustrate the phenomenon citing an example
9. Explain different types of fatigue loading with examples
10. Explain experimental method of obtaining S-N curve for a metallic material.
11. Briefly explain the mechanism of Fatigue
12. What are the factors that influence Fatigue life
Unit 4
1. What is lever rule? Discuss its applications. *
2. What is Gibbs phase rule. Clearly explain with examples.*
3. Define eutectic. Draw an eutectic phase diagram. What do liquidus and soilidus curve represent.
4. With the help of cooling curves explain the solidification of (i) pure metal, (ii) Binary eutectic alloy *
5. With equations & illustrations explain following invariant phase reactions : a) eutectic, b) eutectoid, c)
peritectic and d) peritectoid reaction
6. Explain Hume-Rothery rules for solid solutions
7. Enumerate on intermediate phases
8. How do you construct phase diagram experimentally.
9. Two metals A and B are used to form an alloy containing 75% A and 25% B. A melts at 650 oC. When
alloyed together, A and B do not form any compound or intermediate phase. The solid solubility of metal A
in B and of B in a are negligible. The metal pair forms an eutectic at 40% A and 60% B which solidifies at
300oC. Assume the liquidus and solidus lines to be straight. Draw the phase diagram for the alloy series and
find (i) The temperatures at which the alloy starts and completes solidification. (ii) The percentage of
eutectic in the alloy at room temperature.
PART B
Unit 5
1. Write a neat sketch of iron carbon equilibrium diagram and label the areas and explain the solidification of
hyper eutectoid steels. *
2. Distinguish between annealing, normalizing, hardening and tempering. *
3. Distinguish between pearlite, Bainite, and martensite.
4. Describe the construction of a heat treatment furnace. Write a note on temperature measurement.
5. Explain invariant reactions encountered in equilibrium diagram and show all details on it. Explain the
cooling of (a) Fe - 0.6% c steel (b) Fe - 1.2% c steel (c) Fe - 3.6% c alloy
6. With a neat sketch explain T-T-T diagram. Indicate its use to a mechanical engineer in practice.
7. With a neat sketch explain C-C-T diagram. Indicate its use to a mechanical engineer in practice.
8. Estimate the amount of pro-eutectoid cementite, eutectoid cementite, pearlite and eutectoid ferrite in 1.2%
carbon steel. [Answer : Pro-eutectoid ferrite = 0.41 ; Eutectoid ferrite = 0.52 ; Eutectoid cementite =
0.07 ; Pearlite = 0.59]
Unit 6

1. Define carburizing . what are methods used in Industry.

2. Define nitriding. What are its advantages compare with gas carburizing.
3. Explain (i) Grain structure of cast metal (ii) Volumetric shrinkage in casting *
4. Define heat treatment.
5. Describe the structure of pearlite.
6. What is martensite? How is it formed? What are Ms and Mf temperatures.
7. Distinguish between hypo and hyper eutectoid steel.
8. What is cast iron. How is it formed? Explain using Fe-c equilibrium diagram.
9. Define hardenability. How does it differ from hardness?
10. What steels are commonly used for nitriding?
11. Describe induction hardening.
12. Describe flame hardening.
13. Describe normalizing annealing and hardening process T-T-T diagram. Write a note on microstructure
formed in each process. *
14. Explain clearly precipitation hardening process. For which alloy this process is used. *
15. Draw an equilibrium diagram for an eutectic type non ferrous alloy. Show all the salient features in it and
explain.
16. Describe the process of pack carburizing. How the carbon content on the surface in increased. Describe the
heat treatment carried out after carburizing.
17. Define cyaniding and nitriding. Discuss their purposes and advantages.
18. Describe Jominy End quench test for the determination of hardenability of steels.

Unit 7
1. How are steels classified? Briefly discuss different types of classification and their uses.
2. What are differences between Brass and Bronze. Discuss different types of brasses used in industries.*
3. What is stainless steel? Why it has high corrosion resistance. Discuss different types of stainless steel used
in industries.
4. Write the applications of stainless steel, High carbon steel, Aluminium alloys, Copper base alloys.*
5. Name at least four important aluminium base alloys. Give their composition and applications.
6. Explain the classification & temper designation of Al alloys
7. Explain the classification of Steels as per AISI
8. Explain the various steps used in making a powder metallurgy component (Spur gear).
9. Compare the properties and applications of different types of cast irons?*
Unit 8
1. Explain corrosion mechanism, Polarization & Passivation
2. Enumerate on corrosion prevention
3. Explain Galvanic cell and corrosion types
* Indicates questions appeared in VTU examinations
*****