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ME 511 Advanced Materials and Processing (2-0-2-6)

July-Nov 2011

Lectures:Two hours per week(Monday: 11-11.55 AM; wednesday: 9-9.55 am)

Introduction of advanced materials and its manufacturing processes for engineering

applications.

1) Deformation of metals: Properties: Elastic and plastic deformation, Mechanicalbehaviour, tensile deformation, formability, yield locus & theories, electrical, thermal and

magnetic properties; forming processes & applications; Advances in automotive Steel and

Aluminium materials, their formability and weldability

2) Advanced High strength steel: High strength steels; Ultra high strength steels; their

properties, processing, formability and weldability; Automotive and aerospace Aluminium

alloys: properties; processing; formability and weldability

3) Powder metallurgy: Basics of powder metallurgy processes and applications

4) Composite materials: Design and manufacturing of polymer matrix, metal matrix and

ceramic matrix composites; Various forms and type of reinforcements, fillers and additives;

Design of composites for structural, wear resistance and high temperature applications

5) Shape memory alloys (SMA): Shape memory effect and the metallurgical phenomenon of

SMA; Temperature assisted shape memory effect; Visco-elastic behaviour, Magnetic shapememory effect; Various shape memory alloys; Manufacturing technology of SMAs

6) Polymer materials: Polymerisation; Plastics; High temperature polymers; Additive and

compounding of plastics; Processing of plastics

7) Piezoelectric materials: Piezoelectric effect; Di-electric hysterisis; Piezoelectric

constants; Piezoelectric charge constants; Dynamic behaviour of PZT transducers;

Piezoelectric materials and manufacturing techniques (stability, poling and depolarisation)

8) Electro rheological (ER) and magneto-rheological (MR) materials: Introduction and

Characteristics of ER and EM fluids, ER and EM materials

9) Micro-Electro-Mechanical Systems (MEMS): Introduction; Characteristics of silicon

wafers and other materials for MEMS applications; Various manufacturing techniques of

MEMS components

10) Materials for high temperature applications: Ni-Cr alloys, Ni base and Co based super

alloys; Carbon-carbon composites; Diffusion bond coating of high temperature materials

Textbooks / References:Dieter, G. E., Mechanical metallurgy, McGraw Hill, SI metric edition

William F. Hosford, Robert M. Caddell, Metal forming Mechanics and metallurgy, Prentice Hall,

1983

Smallman, R. E., Ngan, A. H. W., Physical metallurgy and advanced materials, 7th

edition, Butter-

Heinemann, 2007Gandhi, M.V. and Thompson, B.S., Smart materials and Structures, Chapman and Hall, 1992

Otsuka, K. and Wayman, C. M., Shape memory materials, C.U.P, 1998

Taylor, W., Pizoelectricity, George Gorden and Breach Sc. Pub., 1985

Mallick, P.K., Fiber Reinforced Composites Materials, Manufacturing and Design. Marcel DekkerInc, New York, 1993.

Bhargava, A. K., Engineering Materials Polymers, ceramics, composites, Prentice Hall India, 2004Angelo, P. C., Subramanian, R., Powder metallurgy - Science, technology and applications, Prentice

Hall India, 2008Charles, J. A.., Crane, F. A. A., Furness, J. A. G., Selection and use of engineering materials, Elsevier,

3rd edition, 2006

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Seminar topics for ME 511 (Seminar duration: 1 hour)1) Design of composites for wear resistance and tribology applications2) Lightweight automotive materials: Materials, processing and related processes3) Mechanical behaviour (creep, fatigue) of super alloys (Inconel etc.) at high temperature4) Semiconductor materials: Fabrication and applications5) Polymer coatings and applications6) Hydroforming of tubes7) Mechanical behaviour of High strength steel grade sheet material8) Titanium alloys: Deformation behaviour and application in bio-medical sector9) MEMS: Basics and applications in robotics and medicine fields10)Materials for turbine blades: processing and mechanical behaviour11)Friction stir welding of steel sheets12)Nano materials and their applications13)Micro forming Materials, Mechanical behaviour, and applications14)Recent advances in aluminium alloy processing15)High temperature shape memory alloys16)Laser assisted friction stir welding of sheet materials17)Mechanical properties of NiTi shape memory alloys18)Forming of Adhesive bonded blanks19)Materials issues in the processing, the operation and the reliability of MEMS20)Piezoelectric actuators for structural control

Tentative laboratory experiments for ME 511:

Testing and evaluation of tensile properties of low carbon and mild steel, Upsetting

experiments on aluminium and lead cylindrical billets, Ring compression testing on Al and

lead materials, Microstructural characterisation of annealed mild steel sample and Aluminium

reinforced with discontinuous carbon fibres, Experiments on Polymer processing by injection

moulding press, Experiments on powder metallurgy

Course evaluation plan

Quiz 1 : 10 % (Duration: 1 hour)

Quiz 2 : 15 % (Duration: 1 hour)

Midsem exam : 20 % (Duration: 2 hours)

Endsem exam : 40 % (Duration: 3 hours)

Seminar/lab report : 15 % (Duration: 1 hour)