Materials and Manufacturing Processes

Section I: ENGINEERING MATERIALS

       I.          Materials

1.     Introduction

2.     Scope

3.     Ferrous Metals

Ø  Structure

Ø  Properties

Ø  Processes

·       Heat treatment process

·       Production

Ø  Application

4.     Non Ferrous Metals

Ø  Types

Ø  Properties

Ø  Applications

5.     Ceramic

6.     Graphite, Diamonds

7.     Composites

8.     Polymers

9.     Summary

     II.          Mechanical Behaviour of materials

1.     Introduction

2.     Scope

3.     Destructible tests

Ø  Tension

Ø  Compression

Ø  Hardness

Ø  Fatigue

Ø  Creep

Ø  Impact

4.     Non destructible tests

Ø  Visual inspection

Ø  Radiography

Ø  Ultrasonic inspection

Ø  Magnetic Particles

Ø  Eddy current testing

Ø  Liquid (Dye) Penetration method

Ø  Acoustic method

5.     Failure characteristics in materials

Ø  Definition

Ø  Failure types

·       Ductile failure

·       Brittle failure

Ø  Plastic deformation responses

·       Residual stresses

·       Heat and Temperature responses

6.     Summary

Section II: CONVENTIONAL MANUFACTURING

   III.          Casting

1.     Introduction

2.     Scope

3.     Fundamentals of Casting

4.     Sand Mould Casting Processes

Ø  Pattern Making

Ø  Mould Making

Ø  Core making

Ø  Casting

5.     Metal mould Casting Processes

Ø  Slush Casting

Ø  Die Casting

Ø  Centrifugal Casting

Ø  Continuous Casting

6.     Investment Casting

7.     Plaster mould casting

8.     Ceramic mould casting

9.     Design of Casting

10.  Summary

  IV.          Forming

1.     Introduction

2.     Scope

3.     Hot working and Cold working

4.     Types of Forming

Ø  Bulk Forming

·       Rolling

·       Extrusion

·       Drawing

·       Forging

Ø  Sheet Metal Forming

·       Shearing

·       Bending

·       Spinning

·       Deep drawing

·       Embossing

5.     Summary

    V.          Welding

1.     Introduction

2.     Scope

3.     Welding Processes

Ø  Gas Welding

·       Oxy-acetylene Welding

·       Air acetylene Welding

·       Oxy hydrogen welding

Ø  Arc Welding

·       Arc welding with consumable electrodes

v Metal arc welding

v Metal inert gas welding

v Submerged arc welding

v Electro gas welding

·       Arc welding with non consumable electrodes

v Gas tungsten arc welding

v Carbon arc welding

v Plasma arc welding

Ø  Resistance Welding

Ø  Laser beam welding

Ø  Friction welding

Ø  Cold welding

Ø  Brazing

Ø  Soldering

Ø  Mechanical Fastener joining

4.     Summary

Section III: CONVENTIONAL MACHINING

  VI.          Machining

1.     Introduction

2.     Scope

3.     Mechanics of Metal Cutting

4.     Machines involved

Ø  Lathe Machine

Ø  Milling Machine

Ø  Drilling Machine

5.     Traditional Machining processes

Ø  Turning

Ø  Milling

Ø  Boring

Ø  Drilling

Ø  Reaming

Ø  Planning and Shaping

Ø  Sawing

Ø  Filing

Ø  Broaching