Materials Processing (Casting, Forming and Welding)

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.

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