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Materials Processing (Casting, Forming and Welding)

By Prof. Swarup Bag   |   IIT Guwahati
Learners enrolled: 1034   |  Exam registration: 219
ABOUT THE COURSE:
The progress of material processing is ever challenging with the development of new materials and their application in modern technologies. Materials processing effectively transforms the raw materials into useful products and largely decides the thermal, electrical, mechanical and other characteristic properties. The specific properties of materials, useful coating, thin film deposition, and integration of fibers mainly bring the functional properties of modern optical, electronic, and biomedical devices. Material processing technologies are mainly explained by heat transfer and material flow, diffusion, phase transformation and solidification that bridge the gap between manufacturing science and engineering. The syllabus is oriented to the conventional and advancement of the material processing technologies. The modules cover almost all the direction of material processing technologies and it is blended with fundamental development to the recent technologies. Audience will be able to develop fundamental understanding on different perspective and recent development in this field through the lectures and reinforce their knowledge by solving assignments. This course is presented in a lucid and simplified way to make it enjoyable to the beginners.

INTENDED AUDIENCE:
Second year onwards undergraduate students, post-graduate students having a background in Mechanical/Material Science/Metallurgical Engineering/ Production Engineering/Manufacturing Technology. The faculty of different institutes can attend this course as a part of FDP.
Summary
Course Status : Completed
Course Type : Core
Language for course content : English
Duration : 12 weeks
Category :
  • Mechanical Engineering
  • Metallurgy and Material science & Mining Engineering
  • Minor in Metallurgy
Credit Points : 3
Level : Undergraduate
Start Date : 22 Jul 2024
End Date : 11 Oct 2024
Enrollment Ends : 05 Aug 2024
Exam Registration Ends : 16 Aug 2024
Exam Date : 27 Oct 2024 IST

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


Page Visits



Course layout

Week 1: Introduction to Materials processing - 1
  • Materials and microstructure evolutions
  • Basics of heat conduction and fluid flow - I 
  • Basics of heat conduction and fluid flow – II; Numerical problems 
Week 2: Introduction to Materials processing - 2
  • Solidification processing - I
  • Solidification processing – II; Numerical problems 
Week 3: Overview of casting, welding and forming processes
  • Casting and Welding; Numerical problems
  • Material forming; Numerical problems
Week 4: Melt processes – Casting - 1
  • Processing of metals, polymers and ceramics; Case studies
  • Shape casting, extrusion and injection molding; Case studies 
Week 5: Melt processes – Casting - 2
  • Blow molding and fused deposition modeling; Case studies
  • Sand casting, lost foam & cooled molds; Case studies 
Week 6: Melt processes – Fusion welding
  • Arc, laser and electron beam welding; Case studies
  • Advanced welding processes; Case studies 
  • Metallic wire additive manufacturing; Case studies
Week 7: Solid processes – Bulk deformation
  • Mechanical responses of metals and polymers; Numerical problems
  • Hot working and cold working; Case studies
  • Hot rolling of steel; Case studies 
Week 8: Solid state deformation
  • Solid state welding; Case studies
  • Ball Milling and friction Consolidation; Case studies
Week 9: Powder processing
  • Powder compaction; Case studies
  • Powder additive manufacturing; Case studies
  • Powder treatment; Case studies 
Week 10: Non-conventional processing
  • Colloidal processing and coating; Case studies
  • Dispersions and additive processes; Case studies
Week 11: Steel processing
  • Steel making and single crystal production; Case studies
  • Steel fluid flow analysis 
  • Steel solidification
Week 12: Processing of electronics, magnetic and optic materials
  • Electronics material processing; Case studies
  • Magnetic material processing; Case studies
  • Optic material processing; Case studies 

Books and references

1. Lorraine F. Francis, Materials Processing, Academic Press, 2016
2. John E. Neely and Thomas J. Bertone: Practical Metallurgy and Materials of Industry, 6th Ed, Prentice Hall, 2002.
3. D S Porter, K E Esterling and M Y Sherif, Phase Transformation in Metals and Alloys, 3rd Ed., CRC Press, 2016.
4. Sindo Kou, Welding Metallurgy, Wiley Interscience, 2nd Ed., 2003.
5. John D Verhoeven, Fundamentals of Physical Metallurgy, John Wiley & Sons, 1975
6. Vladimir B. Ginzburg, Steel-Rolling Technology: Theory and Practice, 1st Ed, CRC Press, 1989
7. W. Kurtz and D.J. Fischer, Fundamentals of Solidification, 3rd Ed., Trans Tech Publications, 1992
8. John Campbell, Castings, Butterworth Heinemann, 1st Ed., 1998.
9. D R Poirier and E J Poirier, Heat Transfer Fundamentals for Metal casting, TMS, 2nd Ed., 1993.
10. Chris Nielsen and Paulo Martins, Metal Forming, 1st Ed, Academic Press, 2021.

Instructor bio

Prof. Swarup Bag

IIT Guwahati
The broad area of instructor is teaching and research interest of materials and manufacturing processes through computational models using finite element method and experiments. The instructor completed his Ph.D on “Development of bi-directional heat transfer and fluid flow model for reliable design of GTA and laser welding processes” from Indian Institute of Technology Bombay. Later he has worked at the Center for Material Forming (CEMEF), MINES Paris Tech, France in Metallurgy, Structure and Rheology (MSR) group. Soon after post-doctoral research experience, he joined in the Department of Mechanical Engineering, Indian Institute of Technology Guwahati as a faculty member. His primary area of research is fundamental process modeling of welding and joining technologies, optimization of manufacturing processes and recrystallization in metal forming processes. Dr. Bag has published about 56 journal papers, 45 Conference papers, and 18 book chapters related to welding and joining processes. He is the author of the book ‘Computational models for GTA and laser welding processes’ and recipient of ‘Royal Arc Award 2009’ from Indian Institute of Welding for the best PhD thesis in welding. The instructor is involved in teaching the subjects like ‘Physics of Manufacturing Processes’, ‘Engineering Materials’, ‘Advanced Welding Processes’, ‘Mechanical Behavior of Materials’, ‘Solidification Processes’ and ‘Manufacturing Technology’ at IIT Guwahati. The subjects broadly covers the fundamentals of manufacturing processes, mechanical metallurgy, theory of plasticity, heat transfer in manufacturing processes, crystallography, dislocation mechanism, phase transformation and solidification.

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: 
27 October 2024 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.

CRITERIA TO GET A CERTIFICATE

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 Guwahati .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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