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Material Processing (Metallurgical Aspects): Fundamental, and Practical

By Prof. D K Dwivedi   |   IIT Roorkee
Learners enrolled: 417   |  Exam registration: 11
ABOUT THE COURSE:

It is proposed to include the fundamentals of deformation processing related to various manufacturing processes, metallurgical aspects and fundamentals of common metal joining processes of various engineering alloys, solidification and its physical metallurgy, processing of ceramic and their comparison with other materials. Additionally, the practical related to the course will be included so as to get idea of conducting processing experiments in lab such as casting, welding and forming besides knowledge on experimental tools and machinery required to conduct above experiments.

INDUSTRY SUPPORT: All metal fabrication / manufacturing linked industries
Summary
Course Status : Upcoming
Course Type : Core
Language for course content : English
Duration : 12 weeks
Category :
  • Mechanical Engineering
  • Minor in Metallurgy
Credit Points : 3
Level : Undergraduate
Start Date : 21 Jul 2025
End Date : 10 Oct 2025
Enrollment Ends : 04 Aug 2025
Exam Registration Ends : 15 Aug 2025
Exam Date : 01 Nov 2025 IST
NCrF Level   : 4.5 — 8.0

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
Module 1 Materials Processing: Scope
Module 2 Materials Processing: Introduction
Module 3 Materials Processing: Metal Forming and Plasticity
Module 4 Materials Processing: Plasticity and Structure
Module 5 Materials Processing: Cold and Hot working
Week 2
Module 1 Materials Processing: Recovery and Recrystallization
Module 2 Metal forming: Rolling
Module 3 Metal forming: Forging
Module 4 Metal forming: Extrusion
Module 5 Metal forming: Wire Drawing
Week 3
Module 1 Sheet Metal Operations: Fundamentals
Module 2 Sheet Metal Operations: Drawing
Module 3 Press for metal forming I
Module 4 Press for metal forming II
Module 5 Additional metal forming processes
Week 4
Module 1 Advances in Metal Forming
Module 2 Die, Die-set and Die materials for metal forming
Module 3 Sheet metal forming: Stock Layout-Nesting
Module 4 Metallurgy and metal forming
Module 5 Heat treatment in metal forming
Week 5
Module 1 Joining of metals: Fundamentals I
Module 2 Joining of metals: Fundamentals II
Module 3 Joining of metals: Fundamentals III
Module 4 Joining of metals: Fundamentals IV
Module 5 Welding of metals: Metal Characteristics
Week 6
Module 1 Welding of metals: Arc welding I
Module 2 Welding of metals: Arc welding II
Module 3 Welding of metals: Arc welding processes I
Module 4 Welding of metals: Arc welding processes II
Module 5 Welding of metals: Arc welding processes III
Week 7
Module 1 Welding of metals: Heat affected zone of TH metals
Module 2 Welding of metals: Heat affected zone of WH and PH metals
Module 3 Welding of metals: Solid state joining process I
Module 4 Welding of metals: Solid state joining process- II
Module 5 Welding of metals: SSJ and RSW
Week 8
Module 1 Welding of metals: Welding metallurgy I
Module 2 Welding of metals: Welding metallurgy- II
Module 3 Welding of metals: Dissimilar metal welding
Module 4 Welding of metals: Hybrid joining 
Module 5 Welding of metals: Improving weld joint properties I
Week 9
Module 1 Welding of metals: Improving weld joint properties II
Module 2 Metal casting: Overview
Module 3 Metal casting: Pattern and Mould
Module 4 Metal casting: Moulding
Module 5 Metal casting: Casting processes
Week 10
Module 1 Metal casting: Quality of casting
Module 2 Metal casting: Casting defects
Module 3 Metal casting: Metallurgical issues of casting
Module 4 Metal casting: Die casting and Sand mould casting comparison 
Module 5 Metal casting: Improving the performance of casting 
Week 11
Module 1 Metal casting: Heat treatment of castings
Module 2 Powder Metallurgy: Scope
Module 3 Powder Metallurgy: Powder characteristics 
Module 4 Powder Metallurgy: Steps of manufacturing
Module 5 Practical & Lab Demonstration: Pattern making, moulding and casting
Week 12
Module 1 Practical & Lab Demonstration: Shielded metal arc welding of steel- microstructure and mechanical properties
Module 2 Practical & Lab Demonstration: Controlling microstructure by heat treatment, TIG re-melting & friction stir processes and image analysis
Module 3 Practical & Lab Demonstration: Gas welding and gas cutting of steel-characteristics of cut edge
Module 4 Practical & Lab Demonstration: GTAW of similar and dissimilar steels
Module 5 Practical & Lab Demonstration: Friction stir welding

Books and references

  1. R S Parmar, Welding process and technology, Khanna Publisher, New Delhi 
  2. Welding handbook, American Welding Society, 1987,8th edition, volume 1 & 2, USA 
  3. D K Dwivedi, Fundamentals of Metal Joining, Springer, (2022), New Delhi 
  4. R. W. Haine, C. Loper, and P. C. Rosenthal, Principles of Metal Casting, McGraw Hill Education, 2001 
  5. D K Dwivedi Materials Engineering, AICTE (2022) and Manufacturing Processes, AICTE (2024) 
  6. GE Dieter, Mechanical Metallurgy, Mc Graw Hill, USA

Instructor bio

Prof. D K Dwivedi

IIT Roorkee
Prof.D K Dwivedi obtained BE (mechanical engineering), in 1993 from GEC Rewa, ME (welding engineering) Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 29 years at IIT Roorkee of subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 145 research papers in SCI/SCIE indexed journals and undertaken more than 24 sponsored research and 56 industrial consultancy projects. Instructor has authored six books namely “Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013), Surface Engineering, Springer, New Delhi (2018) and Fundamentals of Metal Joining, Springer, (2021), Materials Engineering, AICTE (2022), Dissimilar metal joining, Springer Nature (2023) and Manufacturing Processes, AICTE (2024).

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: November 01, 2025 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

Please note that assignments encompass all types (including quizzes, programming tasks, and essay submissions) available in the specific week.

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 Roorkee .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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