DEPARTMENT OF METALLURGICAL AND MATERIALS

ENGINEERING

COURSE STRUCTURE OF M.TECH

in

Foundry Technology
 DEPARTMENT OF METALLURGICAL AND
MATERIALS ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

M. Tech. (Foundry Technology)

CREDIT STRUCTURE

Course Work 1st Sem 2nd Sem 3rd Sem 4th Sem Total Credits

Core Course 12 12 - - 24

Electives 0 3 - - 3

Lab Course 4 4 - - 8

Seminar 1 1 - - 2

Course Total 17 20 - - 37

Project 4 5 20 20 49

Total 21 25 20 20 86
 NATIONAL INSTITUTE OF TECHNOLOGY
JAMSHEDPUR – 831014

M.Tech. Curriculum in Foundry Technology

in Department of Metallurgical & Materials Engineering
(Semester I to IV)

I – SEMESTER
Sl. Course Subject L-T-P Credits
No. Code
1. MT41101 Metallurgical Thermodynamics and Kinetics 3-0-2 4
2. MT41102 Metal Melting Technology 3-0-2 4
3. MT41103 Transport Phenomena in Metallurgy 3-0-2 4
4. MT41104 Solidification of Metals and Alloy 3-0-2 4
5. MT41201 Foundry Lab.- I 0-0-3 2
6. MT41202 Transport Phenomena in Metallurgy Lab 0-0-3 2
7. MT41301 Seminar 0-0-2 1
TOTAL 12-0-16 21

II – SEMESTER
Sl. Course Subject L-T-P Credits
No. Code
1. MT42101 Mathematical Modeling and Computer 3-0-2 4
application in Metallurgy
2. MT42102 Structure and Properties of Cast Metal 3-0-2 4
3. MT42103 Quality Control of Casting 3-0-2 4
4. MT42104 Advanced Foundry Technology 3-0-2 4
5 Elective - I 3-0-2 4
6. MT42201 Structure and Properties of Cast Metal Lab 0-0-3 2
7. MT42202 Foundry Lab. –II 0-0-3 2
8. MT42301 Seminar 0-0-2 1
TOTAL 15-0-18 25
 III – SEMESTER
Sl. Course Subject L-T-P Credits
No. Code
1. MT 43401 Thesis Part – I 20
TOTAL 20

IV – SEMESTER
Sl. Course Subject L-T-P Credits
No. Code
1. MT 44401 Thesis Part – II 20
TOTAL 20

Elective –I:

MT42105 Secondary Steelmaking

MT42106 Advances in Metal Casting
MT42107 Advanced Processing of Materials
MT42108 Manufacturing Processes
MT42109 Powder materials and processing
 NATIONAL INSTITUTE OF TECHNOLOGY
JAMSHEDPUR – 831014

Syllabus for M. TECH. in Foundry Technology

Department of Metallurgical & Materials Engineering
(Semester I to IV)

MT41101: Metallurgical Thermodynamics and Kinetics: 4 Credits [3-0-2]

Introduction, Definition of thermodynamic terms, First law of thermodynamics, Heat capacity

and enthalpy, Second law of thermodynamics and entropy, Auxiliary function, Maxwell's
relations, Transformation formula, Gibbs-Helmhottz equation, Third law of thermodynamics,
Fugacity, Activity and equilibrium constant, Ellingham. Richardson diagram, Thermodynamics
of solutions, Interaction parameter with respect to iron and steel making, Thermodynamics of
slag-metal reaction, Phase rule, phase equilibria and free energy-composition diagram. Rate
process in metallurgy, Rate limiting phenomenon, Heterogeneous reaction kinetics. Kinetics of
slag-metal reaction.

Text Book:
1. Introduction to the thermodynamics of materials. Fourth edition (or recent edition if
available) by Gaskell.
2. Thermodynamics of materials science, 2nd edition. Robort Dettoff.
3. Principle of Metallurgical Thermodynamics. Sanat kumar Roy & Subir kumar Bose.
4. Text book of materials and metallurgical thermodynamics A. Ghosh
5. Stoichiometry and thermodynamics of metallurgical process, Y.K. Rao
Reference Book:
1. Problems in Metallurgical Thermodynamics and Kinetics, G.S.Upadhaya and
R.K.Dubey.
2. Chemical and Metallurgical thermodynamics Vol I & II, M.L. Kapoor.
3. Kinetics of Metalluyrgical process, F. Habashi.

MT 41102: Metal Melting Technology: 4 Credits [3-0-2]

Melting furnaces for ferrous and non ferrous foundries. Electric and fuel fired furnaces. Recent
developments in energy considerations. Melting practice for carbon steel and alloy steel,
stainless steel, Manganese steel, high alloy aircraft, quality steel and super alloys. Secondary
refining of melting of cast iron-gray, malleable C.G., S.G., Ni-hard, Ni-resist, high silicon iron.
Inoculation methods and materials. Melting practice of non-ferrous alloys of Al, Cu, Mg, Zn and
Ni, Refining, Deoxidation, degassing and grain refinement treatments. Heat treatments of
castings, Shop floor melt quality tests.

Text Book:
1. Foundry technology- O. P. Khanna.
2. Material science and metallurgy, O. P. Khanna
Reference Book:
1. Modern fundamental practice-E.D. Howard.
2. Principle of foundry technology, Third edition, P.L.Jain.
3. Metallurgical furnaces, V. Krivandin, B.Markov
4. Industrial furnaces, E.I. Kazantsav
5. A general theory of furnaces, M.A. Glivkov, G.M. Glinkov

MT41103: Transport Phenomena in Metallurgy: 4 Credits [3-0-2]

Fluid Flow: Newton’s law of viscosity, Differential Analysis of flow- continuity equation and
Navier-Stokes Equation, Concept of boundary layer, solved examples of incompressible steady
state flow, Non-dimenstionalization and dimensionless numbers, Turbulent flow, Friction factor
and drag, coefficient, Packed bed fluidized bed system. Heat Transfer: Introduction to three types
of heat transfer, Conductive heat transfer, Fourier’s law of heat conduction, Thermal
conductivity of materials, Differential equation for heat conduction in rectangular, cylindrical
and spherical coordinate systems, Non-dimensionalization and dimensionless numbers, solved
examples of heat conduction. Convective Heat Transfer: Differential heat transfer /fluid flow
analysis for forced and natural convection, non-dimensionalization and dimensionless numbers,
concept of heat transfer coefficient and correlations, solved examples. Radiative Heat Transfer:
Black body radiation, Plank`s equation, radiative heat exchange between two black bodies, heat
transfer between two black walls in an enclosure, Grey body, effective view factor, Radiation
through absorbing media, Solved examples. Mass Transfer: Diffusive mass transfer in solids,
differential analysis of convective mass-transfer, non-dimensionalization and dimensionless
numbers, concept of mass transfer coefficient and correlations, solved examples. Use of
Computational Fluid Dynamics package and its application to steel industry;

Text Book:
1. An introduction to Transport Phenomena in materials engineering-David R. Gaskell,
Macmillan publishing company New York.
2. Transport Phenomena in materials processing- D.R. Poirier & G.H.Geiger, the minerals,
metals & materials society Pennsylvania, 1994.
3. An introduction to Transport Phenomena in metallurgical engineering, D.R. Gaskell.
4. Rate phenomena in process metallurgy, J. Szekely & N.J. Themelis.
5. Transport Phenomena, R.B. Bird, W.E. Stewart & E.N. Lightfoot.
Reference Book:
1. Fluid mechanics: fundamental and applications- Y.A. Cengel & J.M. Cimbala, Tata
McGraw Hill Publishing Company Ltd, New Delhi.
2. Fluid mechanics and hydraulic machine- R.K. Bansal, Laxmi publication, New Delhi.
3. Fluid mechanics-D.S. Kumar, S.K. Kataria & Sons, New Delhi.
4. Heat and mass transfer-R.K. Rajput, S.Chand & Co.
5. Fundamentals of Transport Phenomena, R.W. Fahien.
6. Rate process in metallurgy, A.K. Mohanty.
7. Transport Phenomena, R.S. Brodkey & H.C. Hershey
MT 41104: Solidification of metals and alloys: 4 Credits [3-0-2]

Thermodynamic conditions for solidification, Solidification as atomic process Nucleation and

heat flow. Stability of nuclei and conditions for growth- Growth rate and heat flow relationships-
Controlling factors. Structure of cast metals and alloys. Distribution of solutes during
solidification, and seggregations. Solidification in continuous casting. Centrifugal casting.
Chilled castings- effect of pressure and other variables. Unidirectional solidification of castings
and effect on properties.

Text Book:
1. Theory of Solidification Stephen H Davis Cambridge University Press
2. Fundamentals of Solidification W. Kurtz and D. J. Fishers Trans Tech Publications USA
Reference Book:
1. A Guide to Solidification of Steels, Jernkontoret, Stockholm
2. Solidification and Crystallization Processing in Metals and Alloys Hasse Fredriksson and
Ulla Akerlind, Wiley Publishers Services John Wiley & Sons Ltd. U K.

MT 42101 Mathematical Modeling and Computer application in Metallurgy:

4 Credits [3-0-2]
Mathematical modeling: Basic equations of diffusive, convective heat, mass, momentum
transfer, turbulent system and concept of friction factor, heat & mass transfer coefficients and
correlations. Formulation of mathematical model. Case studies. Numerical solution of partial
differential equations.
Physical Simulation: Experimental design based on dimensional analysis, similarity criteria,
case studies.
Reactor Design: Ideal reactors (PFR, CSTR), real reactors, characterization of these reactors,
chemical performance of reactors, Modeling/design of reactors
Thermodynamic modeling.

Text Book:
1. Applied Numerical Methods with MATLAB for Engineers & Scientist S.C.Chapra
Reference Book:
1. Numerical Methods in Engineering & Science Dr. S.B.Grewal
2. A friendly Introduction to Numerical Analysis by Brian Bradie

MT 42102: Structure and Properties of Cast Metal: 4 Credits [3-0-2]

Structure-property relationship in cast alloys. Detailed study of mechanical and other properties.
Foundry properties, mechanabilities, weldability and response to heat treatment of various types
of C.I., steel, Response to heat treatment of various types of Cu, Al, Ni, Zn, Mg based alloys.
Outstanding characteristics of cast alloys. Techniques of strengthening and improving the
properties of cast metals and alloys.

Text Book:
1. Mechanical Testing and Evaluation ASM International, Vol. 8
2. Mechanical Metallurgy G. E. Dieter
Reference Book:
1. Fatigue and Fracture, ASM International, Vol. 19
2. De Gramo’s Materials and Processes in Manufacturing J. T. Black and R. E. Kohser
3. Steels: Processing, Structure. And Performance George Krauss ASM International
Materials Park Ohio

MT 42103: Quality Control of Castings: 4 Credits [3-0-2]

Aims and objectives of quality control. Analytical instruments used in foundries NDT, X-rays
Ultrasonic, magnetic flow detection and recent developments. Control charts. Computer
application in foundry process. Control using mathematical model. Linear programming CPM &
PERT, multiple linear regression analysis. Future application of computer for complete
automation in foundries. Statistical quality control in foundries. Surface quality and dimensional
tolerances.

Text Book:
1. Mechanical behaviour and testing of materials, A.K. Bhargav & C.P. Sharma.
Reference Book:
1. Industrial engineering, B. Kumar
2. Design of experiment to find optimal conditions, Yu. Padler, E.V. Markove, Yu. Y.
Granovskey

MT 42104 Advanced Foundry Technology: 4 Credits [3-0-2]

Recent developments in design, materials and methods of manufacture of patterns. Modification

in casting design with reference to foundry and metallurgical principles. Principles design and
methods involved in gating and risering of ferrous and non-ferrous castings.
Recent developments in materials and methods of mould and core making such as high pressure
moulding. V- process, magnetic moulding, Sodium silicate based processes, shell process, Hot
box, cold box, full moulding etc.. Moulding and sand conditioning equipments. Sand
reclamation, principles, technology and scope of sand casting processes, Non-metallic mould etc.
Precision casting processes. Principles, technology and scope of Die casting. Continuous casting,
investment casting. Slush casting. Casting defects, metal-mould reactions, metal penetration and
burn-out etc. general principles and objectives of foundry mechanization and lay out.

Text Book:
1. P.R. Beeley, Foundry Technology, 2001 edition, Publisher – Butterworth & Co.
Reference Book:
1. P.C. Mukherjee, Fundamentals of Metal Casting Technology.
2. P.D. Webster, Fundamentals of Foundry Technology.

MT 42105: Secondary Steelmaking: 4 Credits [3-0-2]

Importance and economy of secondary refining of steels. Special features and their applications.
Critical studies of vacuum degassing. Vacuum-Arc and Electro-slag, Plasma Arc., Remelting,
AOD, VOD, RH and DH processes of refining of steels. Injection-Metallurgy.
Text Book:
1. Secondary Steel making by Dr. Ahindra Ghosh CRC Publication
2. Ladle Metallurgy, J. Szekely, G. Carlsson
Reference Book:
1. Scaninjet; International conference on injection metallurgy, 1977
2. The making shaping and treating of steel (IIth Edition) , Casting volume The AISE Steel
foundation
3. Vacumm Technologies in Metallurgy, J.A.Bell, Ditching Press
4. Electroslag Casting, G.A.Boiko, MIR Publishers
5. Principles and secondary Processing of liquid steel by Dr. Ahindra Ghosh CRC
Publication

MT 42106: Advances in Metal Casting: 4 Credits [3-0-2]

Recent developments in design, materials and methods of manufacture of patterns. Modification

in casting design with reference to foundry and metallurgical principles. Principles design and
methods involved in gating and risering of ferrous and non-ferrous castings. Recent
developments in materials and methods of mould and core making such as high pressure
moulding. V- process, magnetic moulding, Sodium silicate based processes, shell process, Hot
box, cold box, full moulding etc. Moulding and sand conditioning equipments. Sand reclamation,
principles, technology and scope of sand casting processes, Non-metallic mould etc.
Precision casting processes-Principles. Technology and scope of Die casting. Continuous
casting, investment casting. Slush casting. Casting defects, metal-mould reactions, metal
penetration and burn-out etc. general principles and objectives of foundry mechanization and lay
out.

Text Book:
1. Principle in metal casting, Mahi Sahoo & Sudhari Sahoo
2. Fundamental for metal casting, D.R. Poirier & E.J. Poirier.
Reference Book:
1. Principle in metal casting, Riechard Heine & Carl Loper
2. Metal casting: Principles & Practice, Ramana Rao

MT 42107 Advanced Processing of Materials: 4 Credits [3-0-2]

Rapid solidification, Powder processing, Preparation and consolidation of nanopowders,

Sintering, Spark Plasma and Microwave sintering, Shock compaction, Severe plastic
deformation, Mechanical Alloying, near-net-shape forming, self-sustaining high temperature
synthesis, sol-gel processing, zone refining, molecular beam epitaxy, laser processing, EDM,
etching, glass-ceramic seals, solid oxide fuel cells, armor ceramics, Processing and
manufacturing technologies for non-oxide and oxide based structural ceramics, composites,
multifunctional materials; Stereolithography (SLA), selective laser sintering (SLS), direct metal
laser sintering; (DMLS) and laser engineered net shaping (LENS), Spray formed tooling for
rapid manufacture, Plasma spray coating; Preparation of single crystals, doping, sputter coating,
CVD and EVD process.
Text Book:
1. W.F. Smith, Principles of Material Science and Engineering, McGraw Hill, 1990.
2. O. Tatsuki, Advanced processing & manufacturing technologies for structural &
multifunctional materials, Lavoisier, 2007.
3. O.Tatsuki, M.Singh, J.Salem, D. Zhu, Advanced Processing and Manufacturing
Technologies for Structural and Multifunctional Materials, (eds.), Ceramic Engineering
and Science Proceedings. Vol. 28(7). 1st Edition 2007. ISBN-10: 0-470-19638-6 - John
Wiley & Sons.
Reference Book:

1. R. Hugon, Thin Film Technology, Elsevier Pub., UK, 1978.

2. L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, John Wiley
Publications, New York, 1995.
3. F. Kongoli (Editor), R.G. Reddy (Editor) Advanced Processing of Metals and Materials:
New, Improved and Existing Technologies: Iron and Steel; Recycling and Waste
Treatment Vol.5, Publisher: The Minerals, Metals & Materials Society ISBN-10:
0873396383.
4. G. Goodman, M. Dekkar, Ceramic Materials for Electronics, New York, 1968.
5. S. Kalpakjian, S. Schmid, Manufacturing Engineering and Technology, Prentice Hall; 5th
edition, ISBN-10: 0131489658, 2005.

MT 42108 Manufacturing Processes: 4 Credits [3-0-2]

General structure and properties of engineering materials, classification of common materials,

their unique properties and applications; metals and alloys, glass and ceramics, polymeric
materials and composites, behavior, testing and manufacturing properties of these materials.
Concepts of manufacturing, basic principles of engineering manufacturing; shaping, joining,
removal and regenerative processes, methods of applications of common manufacturing
processes; performing by casting, forging, rolling, melting, injection and compression moulding,
extrusion and drawing, press tool work, powder processing etc., finishing by machining, grinding
and superfinishing, Non-traditional manufacturing by chemical. Electro-chemical,
electrophysical and mechanical processes.

Text Book:
1. G.E. Dieter, Mechanical Metallurgy.
2. A. Ghosh & A. Mallick. Manufacturing Sciences.
Reference Book:
1. P. Polukhin, N. Fedosov, A. Korolyov& Y. Matveyer, Rolling Mill Practice, Making
Shaping and Treating of Steel.

MT 42109 Powder materials and processing: 4 Credits [3-0-2]

Introduction: Development of powder metallurgy, scope of powder metallurgy, characterization

of metal powders, physical properties-particle size and shape determination, technological
properties-apparent density, flow rate etc. and chemical properties, particle interaction and
control. Powder manufacturing: powder mixing and blending, dry and colloidal processing,
reduction, electrolysis, and atomization processes, shaping techniques such as compacting,
injection molding. Compaction and sintering: Die compaction and other consolidation
techniques, sintering, sintering with liquid phase. Powder metallurgy products: Bearing, filters,
friction parts, hard metals, refractory metals, contact materials, magnetic materials, structural
parts, dispersion strengthened materials.

Text Book:
1. Powder metallurgy science, Technology& Materials by Anish Upadhyay & G.S.
Upadhyaya.
2. Powder Metallurgy by B. K. Dutta
Reference Book:
1. TREATISE ON POWDER METALLURGY in three volumes by Glaus G. Goetzel
Volume 1: Technology of Metal Powders and Their Products
Volume II: Applied and Physical Powder Metallurgy
Volume III: Classified and Annotated Bibliography Introduction: Development of
powder metallurgy, scope of powder metallurgy