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Course Postgraduate
Semester Sem. II
Subject Code CHM621
Subject Title Processing and Design of Materials

Syllabus

Introduction to materials processing; Polymer processing - rheology of polymeric materials, Compounding and processing of plastics and rubbers,fibre spinning and manufacturing processes. Ceramic processing- Pressing, CIP, HIP, Slurry processing, Slip casting, Pressure casting, Tape casting, Gel casting, Rapid prototyping,Sol-gel processing, Thermal and plasma spraying, Thick and thin film coatings; Processing of Metallic materials-, Casting processes, Casting design and defects; Fundamentals of deformation processing, Hot and cold working, Metal joining process, Design aspects, Materials selection and design, Weighting factors, Materials performance index; Design of engineering structures, Case studies, Modern metallic, Ceramic, Polymeric and biomaterials devices and components

 

Detailed version

Introduction: Materials processing science with special emphasis on processing of polymers, ceramics and metals

Polymer processing: Rheology of polymeric materials, Compounding of plastics, processing techniques: Compression, Transfer, injection, blow molding, Extrusion, Calendaring, Thermoforming, Rotational molding,  Compounding and processing of rubber (both latex and dry rubber) with different formulations: Casting, rubber extrusion, Dip coating (gloves, balloons etc.), fibre spinning and manufacturing processes.

Ceramic processing: Processing of traditional ceramics- spray granulation, Pressing, CIP, HIP, Slurry processing, Slip casting, Pressure casting, Tape casting, Gel casting, Injection molding, Extrusion; Rapid prototyping through Additive manufacturing, Electrophoretic deposition, Production of ceramic fibres, Electro-spinning; Drying, Binder burnout, Green machining, Sintering; Sol-gel processing, Thermal and plasma spraying, Thick and thin film coatings- PVD and CVD techniques; Vapor infiltration techniques

Metallic processing: Casting process- major casting techniques, Solidification and volume shrinkage, Casting design and defects, Fundamentals of deformation processing, Deformation work, Hot and cold working, Few forming processes and defects; Metal joining process- Concepts of Fusion and solid state welding processes, Brazing and soldering, Welding defects;

Design aspects: General principles of materials selection and design based on requirements of function, Property, Processability and cost; Quantitative methods of materials selection, Materials performance index; Design of engineering structures from the atomic- and nano-scales to macroscopic levels; Case studies- modern metallic, ceramic, polymeric and biomaterials devices and components

Text Books

 1.   P. Boch, J-C. Nièpce, Ceramic Materials: Processes, Properties, and Applications, Wiley-ISTE,   

           2007.

1.        J-H. He, Electrospun Nanofibres and Their Applications, Smithers Rapra Technology, 2008.

2.        Z. Tadmor, C.G. Gogos, Principles of Polymer Processing, 2nd ed., Wiley International, 2006.

3.        T.A.Osswald, Polymer Processing Fundamentals, Hanser Publications, 1998.

4.        M.N. Rahaman, Ceramic Processing and Sintering, 2nd ed.,, CRC press

5.        F.C. Campbell, Elements of Metallurgy and Engineering Alloys, ASM International, 2008.

6.        J. Beddoes, M.J. Bibby, Principles of Metal Manufacturing Processes, Elsevier, 2003.

7.        G.E. Dieter, Mechanical Metallurgy, McGraw-Hill, 3rd ed., 1986.

8.        E. Degarmo, J.T. Black and R.A. Kohser, Materials and Processes in Manufacturing, 9th ed., Wiley, 2002.

S. Kalpakjian, S.R. Schmid, Manufacturing Engineering and Technology, 6th ed., Pearson, 2009.

References