Aluminium based Alloys and Metal Matrix Composites

By Prof. Ranjit Bauri   |   IIT Madras
Learners enrolled: 584
About the course: Aluminium and its alloys are one of the most important classes of engineering materials which are used in many applications starting from household to aircrafts. Given the wide range of applications of Al alloys the property requirements are also quite diverse. Therefore, understanding the structure-property correlation i.e. the Physical metallurgy of Al alloys is very important.

Composites on the other hand supplement many of the properties needed in a particular application.
This course will cover the aluminium alloys and their composites in the entirety. The objective is to learn about Al alloys and composites with an emphasis on the physical metallurgy and the structure-property correlation. It is expected that at the end of the course students will develop a clear understanding on Al alloys, Physical metallurgy and Metal matrix composites.

PRE-REQUISITES: Basics of Materials Science & Engineering

INDUSTRY SUPPORT: TVS motors, Rane Group, Ashok Leyland, Mahindra and All other major automotive manufacturers
Course Status : Completed
Course Type : Elective
Duration : 12 weeks
Category :
  • Metallurgy and Material science & Mining Engineering
Credit Points : 3
Level : Undergraduate/Postgraduate
Start Date : 25 Jul 2022
End Date : 14 Oct 2022
Enrollment Ends : 08 Aug 2022
Exam Date : 30 Oct 2022 IST

Note: This exam date is subjected to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Introduction, Pure Aluminium, Extraction of Aluminium, Removal of impurities, Alloy Designations, Cast Alloys, Al-Si alloys, Modification of Al-Si alloys
Week 2: Modifying Al-Si alloys, Alloy designations, Solid solution strengthening, Mechanisms of Solid solution strengthening. Buildup of solute atmosphere, Yield point phenomena, Strain aging, Cottrel-Bilby theory of strain aging.
Week 3: Portevin–Le Chatelier (PLC) effect, Dynamic Strain Aging (DSA), Penning theory of DSA, Precipitation hardening – Introduction.
Week 4: Precipitation hardening, T-T-T diagram of precipitation, Alloy tempers, GP zones, Natural Aging. Mechanisms of Precipitation hardening, Precipitation hardenable Alloys, Precipitation sequence.
Week 5: Properties of 7XXX series alloys; Precipitation sequence in 8XXX series alloys, Order strengthening in Al-Li alloys, Strain Hardening. Recovery & Recrystallization.
Week 6: Nucleation and Growth in Recrystallization, Dynamic Recrystallization, DDRX, CDRX, GDRX.
Week 7: Grain refinement strengthening, Grain refinement methods, Homogeneous and Heterogeneous Nucleation, Grain refinement by Melt inoculation.
Week 8: Mechanisms of grain refinement by melt inoculation, Fading & Poisoning, Grain refinement by melt vibration, Severe Plastic Deformation (SPD), Dynamic recrystallization in SPD.
Week 9: Metal Matrix Composites (MMC): Definition of composite, Processing of MMCs: Liquid state processing, Stir casting, Melt infiltration. Spray deposition, Solid state and Vapor state processing, Spray deposition, CVD and PVD. Insitu Composites. Particle bonding and distribution in MMCs.
Week 10: Properties of Metal Matrix Composites, Rule of mixtures, Strengthening Mechanisms in MMCs.
Week 11: Fracture Behavior of composites, Ductile Fracture of Metals, Fracture Behavior of Discontinuously Reinforced Composites.
Week 12: Fatigue, Fatigue Behavior of MMCs

Books and references

1.  Frank King, Aluminum and its Alloys, Ellis Horwood Publishers, 1987.
2. John E. Hatch, Aluminum – Properties and Physical Metallurgy, ASM, 3rd ed. (1988).
4. Subra Suresh, A. Mortensen, A Needleman, Fundamentals of Metal Matrix Composites, Butterworth-Heinemann, 1993.
4. T. W. Clyne, P. J. Withers, An Introduction to Metal Matrix Composites, Cambridge University Press, 1993.
5. Ranjit Bauri, Devinder Yadav, Metal Matrix Composites by Friction stir processing, Butterworth-Heinemann, 2018.

Instructor bio

Prof. Ranjit Bauri

IIT Madras
Dr. Ranjit Bauri is a Professor in the Dept. of Metallurgical and Materials Engineering, IIT Madras. He has more than a decade of experience in teaching and research. The broad areas of his expertise include Powder Metallurgy, Ceramics, Composite materials, Energy Materials, Aluminum alloys, Friction stir welding and processing, and Microscopy.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 30 October 2022 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.


Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Madras. It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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