Materials and Manufacturing Processes

Section I: ENGINEERING MATERIALS

       I.          Materials

1.     Introduction

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

     II.          Mechanical Behaviour of materials

1.     Introduction

2.     Scope

3.     Destructible tests

Ø  Compression

Ø  Hardness

Ø  Creep

Ø  Impact

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

Section II: CONVENTIONAL MANUFACTURING

2.     Scope

3.     Fundamentals of Casting

4.     Sand Mould Casting Processes

Ø  Mould Making

Ø  Core making

5.     Metal mould Casting Processes

Ø  Slush Casting

Ø  Centrifugal Casting

Ø  Continuous Casting

7.     Plaster mould casting

8.     Ceramic mould casting

9.     Design of Casting

  IV.          Forming

1.     Introduction

2.     Scope

4.     Types of Forming

Ø  Bulk Forming

·       Rolling

·       Extrusion

·       Drawing

·       Forging

·       Shearing

·       Bending

·       Deep drawing

·       Embossing

    V.          Welding

1.     Introduction

2.     Scope

3.     Welding Processes

·       Oxy-acetylene Welding

·       Air acetylene Welding

Ø  Arc Welding

·       Arc welding with consumable electrodes

v Metal inert gas welding

v Submerged arc welding

·       Arc welding with non consumable electrodes

v Gas tungsten arc welding

v Plasma arc welding

Ø  Resistance Welding

Ø  Friction welding

Ø  Cold welding

Ø  Soldering

Ø  Mechanical Fastener joining

Section III: CONVENTIONAL MACHINING

2.     Scope

3.     Mechanics of Metal Cutting

4.     Machines involved

Ø  Milling Machine

Ø  Drilling Machine

Ø  Turning

Ø  Milling

Ø  Boring

Ø  Drilling

Ø  Reaming

Ø  Planning and Shaping

Ø  Sawing

Ø  Filing

Ø  Broaching