Materials and Corrosion Engineering Department Course Descriptions GE212Strength of Materials Concept of stress Axial loading, normal stress, shear stress Components of stress, ultimate and allowable stress Concept of strain Normal strain under axial loading, stress and strain diagram Hook’s law, modulus of elasticity Elastic and plastic behaviour of materials, Poisson’s ratio Stress and strain distribution under axial loading Torsion, stress in shaft, stress in elastic region Pure bending, stress in pure bending Bending of members made of several materials Transformation of stress and strain Transformation of plane stress Moher’s circle for plane strain MTE 225 Introductions to Materials Science Classes of engineering materials Symmetry – crystal systems Important metals and ionic crystals Lattice direction and planes Defect of crystal patterns Solid solution Diffusion in solids Point defect, linear defects and surface defects Properties of single phase materials Elastic behaviour Anisotropy of elastic limit Creep, fatigue and fracture Corrosion of metallic materials Ceramics and polymer MTE312Physical Metallurgy (I) Crystal structure, imperfection, voids, stacking sequence, Plastic deformation and annealing, recovery, recrystallization, grain growth Solid solution, humepothery rules Binary phase diagrams, miscibility, eutectic, eutectoid, pertitectic phase diagrams Fe-C systems, structure of steel, cast iron, heat treatment, grading and classification of steel Solidification of metals, thermodynamics, kinetics, and casting defects MTE313Mechanical Properties of Metals Stress and strain principles and relationship State of stress, State of strain in 2D and 3D, deformation of single crystal Dislocation concepts Introduction of theory of plasticity Strengthening mechanisms Tensile test, Compression test Hardness test Impact test Shear test Fatigue test MTE321 Physical Metallurgy II Diffusion in substitutional solid solutions and interstitial solid solution Theories of phase transformation Phase transformation of steel on heating, eutectoid transformation, binaite transformation, transformation associated with steel tempering. Heat treatment of metals and alloys Chemical thermal treatment of metal and alloys MTE322 Polymeric Materials Introduction, definition, classification, bonding, general physical properties Viscoelasticity models Design methodology Melt rheology (I) & (II), properties of polymer melts & types of flow Shaping methods of polymers Fiber& elastomers technologies Reinforcements & polymeric composites Processing – property interactions MTE323 (1) CORROSION PRINCIPLE Credits:3 The Technology and Evaluation of Corrosion: Signification of Corrosion, Cost of corrosion, Corrosion definition, Electrochemical nature of aqueous corrosion, Corrosion rate determination, Corrosion forms principles. Electro-chemical Thermodynamics and Electrode potential: Electrode potential / PH (Pourbaix) diagrams, Experimental measurements. Electro-chemical kinetics of corrosion: Faradays law, Exchange current density, Electrochemical polarization, Mixed potential theory, Experimental polarization curves, Instrumentation and Experimental procedures. Passivity Passive films, Active-passive corrosion behavior, Oxidizer-concentration effects, Solution velocity effects, Criterion of passivation, Experimental apparatus and procedures, Galvanic statics anodic polarization of active-passive alloys, Potentio-static and potentio-dynamics procedures, Variables affecting anodic polarization curves, Application of potentio- static anodic polarization, Anodic polarization, Properties of passive films. Polarization Methods to Measure Corrosion Rate: Tafel exploration, Polarization resistance method, Instrumentation method for polarization resistance, Commercial corrosion-monitoring probes, Error and polarization resistance measurements, Other methods to determine polarization resistance. The importance of corrosion science and engineering Corrosion classification Principles of electrochemical and electro-reactions Principles of thermodynamics and tendency of metal to corrosion Rate reactions Types of aqueous corrosion Pitting corrosion, galvanic corrosion, crevice corrosion, soils and atmospheric corrosion, microbiological corrosion. Measurement of corrosion control MTE326 Ceramics Introduction; ceramic materials in relation to metals and polymers (interatomic spacing and bonding, crystal structures, imperfections) Glass; structure, composition transformation range, crystallization Surfaces and interfaces; adsorption, ion exchange, interfacial energies Ceramic phase diagrams Structural ceramics and abrasives MTE411 (II) CORROSION FORMS AND MECHNIZIM Galvanic and Concentration Cell Corrosion: Engineering aspects; Recognition, Galvanic series, Area affects, Fundamental aspects; Corroding metal-insert couple, Effect of exchange current density, Effect of surface area, Corroding metal-corroding couple, Experimental measurements; Polarization in galvanic couples, Zero-resistance ammeters, Galvanic current by polarization resistance, Determining of galvanic corrosion; Galvanic-current diagrams, Galvanic-passivation of titanium, Current and potential distribution, Concentration cells; Differential aeration cells, Partial immersion cells waterline, Full immersion cells. Pitting and Crevice Corrosion: Examination and Evaluation; Conditions causing pitting and crevice corrosion, Evaluation of crevice corrosion, Mechanism of pitting corrosion, Mechanism of crevice corrosion, Other forms of crevice corrosion, Pitting under localized deposits. Environmentally Induced Cracking: Characteristics of Stress Corrosion Cracking, Characteristic of Corrosion Fatigue Cracking, Characteristic of hydrogen- induced cracking, Typical cases of stress corrosion cracking, Testing methods, Proposed mechanisms of stress corrosion cracking. Effect of Metallurgical Structure on Corrosion: Intergranualar corrosion of Austentic stainless steels, Intergranualar corrosion of other alloy, Factors affecting weldement corrosion, Weldement corrosion of various alloy systems, Dealloying and dezincification. Corrosion-Related Damage by Hydrogen, Erosion and Wear: Hydrogen damage, Cavitation, erosion corrosion, Fretting, Erosive and corrosion wear. Corrosion in Selected Corrosive Environments: Water and aqueous solution, Biological influenced corrosion, Soils, concrete, Acid process streams, Alkaline process streams. Atmospheric Corrosion and Evaluated Temperature Oxidation: Atmospheric corrosion; Atmospheric parameter affecting corrosion, Weathering steels, Electrochemical mechanism, Oxidation and evaluated temperatures; Oxidation reactions, Thermodynamics of oxidation, Oxide structure, Oxide-film growth processes, Oxide properties, Pitting- bed worth ratio, Oxidation rate; parabolic rate law, Oxidizing service environments. MTE412 Heat Treatment Introduction (hardening and annealing, grain structures Types of heat treatment; (normalizing, case hardening, precipitation hardening, tempering, quenching) Time-Temperature-Transformation TTT diagram for steel Strain hardening process Case hardening process (flame or induction hardening, nitriding, carbonizing, cyaniding, carbonitriding, steel chemical treatment, shot pinning) Tempering (isothermal heat treatment) Thermo mechanical treatment Quenching ( heat treatment of cast iron, Heat treatment of non-ferrous metals Surface treatment of aluminium Anodizing of aluminium alloys Heat treatment of special steels (high strength steel, boron steel, ultra high strength steel, martensitic stainless steel, tool steels, structural steel) MTE413 Metallography Experimental Lab. Mechanical testing of materials To be able to extract data from engineering stress-strain curves To demonstrate the difference in behaviour between different types of materials To be exposed to a range of mechanical tests (Tensile, Compression, Hardness, Impact, Bending, Fatigue) Heat Treatment Annealing Normalizing Tempering Quenching Construction of phase diagram from cooling curves To construct the equilibrium phase diagram of a binary system using the cooling curves of different alloy composition in the system Hardening and recrystallization of metals To demonstrate the hardening resulting from the process of solute atoms, or cold working of an alloy Construction of phase diagram from cooling curves To construct the equilibrium phase diagram of a binary system using the cooling curves of different alloy composition in the system Determination of cooling curves of alloys To get acquainted with pyro metric techniques and the characteristic cooling curves of different types of alloy compositions. MTE415 Powder Metallurgy Introduction Overview of Powder Metallurgy Definitions, Applications, Limitations Engineering Powders Classification of powders Particle’s Properties Production of Metallic Powders Powder Metallurgy Process ( Blending and Mixing, Compaction, Sintering, Finishing Operations) Design Considerations in Powder Metallurgy MTE416 Welding Metallurgy Basic welding processes (gas, arc, laser-beam, electron-beam welding) Heat and fluid flow during welding Chemical reactions Residual stresses and distortion Weld metal solidification (grain structure, subgrain structure, microsegregation, macrosegregation, porosity, inclusions, and cracking) Partially melted zone (liquidation and cracking) Heat-affected zone (loss of strength, embrittlement and cracking in work-hardened materials, precipitation-hardening materials, transformation-hardening materials and corrosion-resistant materials) MTE419 Materials Engineering Lab Mechanical Testing Of Materials To be exposed to a range of mechanical tests (Tensile, Compression, Hardness, Impact, Bending, Fatigue) To be able to extract data from engineering stress-strain curves To demonstrate the difference in behaviour between different types of materials Microstructure analysis Preparation of specimens (Grinding, Polishing, Etching etc.) To get familiar with some grain size parameter determination techniques Using optical microscope to examine the microstructure of metals (grain size, grain boundaries, etc.). MTE420X-Ray Diffraction Properties of x-rays, electromagnetic riadation, continuous spectrum, absorption, filters, production of x-rays, detection and safety. Crystal structure, planes and directions, atomic size and coordination’s, stereographic projection Diffraction, Bragg’ law, diffraction methods, diffraction under non ideal condition Scattering by and electron, atom and unit cell, structure factor, multi ficity factor, Lorentz factor, absorption factor, temperature factor, intensive of powder diffraction pattern Debyischerrer method, Laue method, diffractometer, preparation counter,jeijer counter, sciltillation counter, Deformation of crystal strcture, indexing of powder pattern, effect of cell distortion Determination of precisc lattice parameter, method of last squares Phase diagram determination, parametrtic and disappearing phase method Qualitative and quantitative chemical analysis Stress measurement of its application Electron and nertron diffraction and its applications MTE423 Composite Materials introduction review of all classes of engineering materials (metals, ceramics, polymers, elastomers, composites) review of mechanical properties (strength, hardness, fatigue, toughness, creep, thermal shock resistance, wear, corrosion) composite definition, classification, prediction of mechanical properties reinforcement and reinforcement – matrix interface types of composite (metal matrix composite, ceramic matrix composite, polymer matrix composite) fracture and toughening mechanics, energy analysis, local stresses, fracture initiation, impact joining MTE424 Extractive Metallurgy Mineral dressing, beneficiation Ore preparation Production of metal oxides, smelting Hydrometallurgy Electrometallurgy Refining process Mass and energy balance MTE425 Engineering Alloys Classification of engineering materials Structural steel, tool steels, essential alloying elements in tool steel, heat treatment of tool steel Rules of structure and heat treatment, weldability Wear processes, wear resistance alloys, friction resistance materials, high temperature resistance materials and alloys Nickel alloys, stainless steel, cooper alloys, aluminium alloys, while alloys Materials with specific electrical properties, magnetic materials. MTE 426 Metal Shaping Metal casting; casting alloys, fluidity in casting, solidification characteristics, casting defects (e.g. shrinkages, porosities), macro and microstructure of casting Casting process, sand casting; design and requirements, sand molding, gating systems, cast inspection Fundamentals of metal working; classification of forming processes, mechanics of metal working, static equilibrium of forces, methods of analysis (slab – uniform deformation energy – slip line field) Forging processes; classification, equipments, forging in plane stain, open and close die forging, forging defects Rolling of metals; classification, equipments, hot and cold rolling, rolling defects Extrusion; classification, equipments, hot extrusion, lubrication and defects Wire and tube drawing; drawing processes, analysis of wire and tube drawing MTE511Research Methodology Writing technical report, report preparation and presentation Presentation of B.Sc. project literature review and project layout plan MTE512 Steel Making Introduction of steel making (irons, steels, iron phase diagram, steel types) Iron manufacturing processes Steel making process; (basic oxygen furnace technique) Steel making process; (electrical arc furnace technique) Principles reactions of steels making processes Thermodynamic aspects of steel making Thermo-chemical properties of gases in steel making; ( properties of molten steel, properties of molten slags) MTE513 Fracture Mechanisms &Failure Analysis Part 1: Ductile and brittle fracture Griffith theory of brittle fracture Ductile to brittle transition temperature Mode of cracking propagation Linear elastic fracture mechanisms Stress intensity factor Plane strain and plane stress fracture toughness Plastic zone size estimation Determination of fracture toughness Correlation of impact energy to fracture toughness Factor affecting fracture toughness Ways to improve fracture toughness Part 2: Definition of failure Premature failure Catastrophic failure Fracturegraphy Fundamental source of failure Procedures for conducting failure analysis Failure analysis report Overload failure, elevated temperature failure Corrosion fatigue Wear and lubricant MTE514 (III) CORROSION PREVENTION Cathodic Protection: Principle and Application, Impressed current cathodic protection, Scarification-anode cathodic protection, coatings and catholic protection, Cathodic alkalinity, Controlled-potential cathodic protection, Comparison with anodic protection, Design factors; Potential gradients, Rectifiers, Current and Potential distributions on the protect structure, Cathodic protection criteria, Electrochemical basis for cathodic protection criteria, Current requirements, Impressed current anodes, Scarification anodes, Stray current corrosion, Monitoring and design procedure; Field- potential measurement, Monitoring in sea water, Monitoring in soil, Design procedure. Coating and Inhibitors: Liquid –Applied Organic Coatings; Classification and uses, Surface preparation, Exposure testing and Evaluation, Degradation and Failure mechanisms, Electrochemical testing, tick Non-metallic Coatings; insert liners, Porcelain enamels, Pipeline coatings, Metallic coatings; Hot-dip zinc and Aluminum, Electroplated chromium and other metals, Cladding inhibitors; Applications, Electrochemical behavior, Fundamentals of inhibitor function, vapor-phase inhibitors. Material Selection and Design: Alloy selection; carbon and low alloy steels, stainless steels, Nickel alloys, Copper alloys, aluminum alloys, Design to prevent corrosion; Important of design, Consideration affecting design, Corrosion-prevention measures, Economics of corrosion preventions; Significance, Discounted cash flow, Generalized equations, Examples of DCF calculations. MTE 515 Nano materials Introduction to nano materials Carbon nano tubes (types, synthesis, general properties, hybrids of carbon nano tubes, functionalization of carbon nano tubes) Nano particles (definitions, properties, functionalization, applications) Nano composites; (definitions, types, properties, applications) Nano catalysis ( definitions, adsorption process, types, applications) Mechanical properties of nano structures Characterization of Nano structures; ( atomic force microscope, scanning electron microscope, transmission electron microscope, Raman spectroscopy) MTE516 N.D.T Introduction; types of defects in metal forming methods, their effect on mechanical properties and need for N.D.T Visual aids; boroscopes, toboscope and their use in testing Liquid penetrant methods; principles, equipments of dye and fluorescent methods, application and their limitation, examples of such use in industry Magnetic methods; magnetic particles technique, magnetization and its principle, limitations, examples in industry. X-ray radiography ; geometrical factors, principles and industrial radiography practice, technique charts, penetrators, weld radiography, casting radiography, fine, radiography, reference radiography, neutron radiography, examples in industry Ultrasonic; types of waves, wave velocity, beam spreading, refraction, mode conversion, attenuation, wave production, equipments different probe, weld tubes, axles, shafts. Gamma radiography ; fundamentals of radioactivity, decay, absorption, Y-ray source, flims for x-ray radiography, safety, film protection, handling, storage and transportation, equipment and example in industry. Thickness measurements Eddy current methods Thermal methods MTE523 Materials Selection Brief introduction to metallic, polymeric, ceramic and composite materials Properties & selection relationship Materials identification & designation Degradation & stability of materials Materials & fabrication selection Economic analysis in materials selection Economic evaluation of materials, processes & project Quantitative and non-quantitative methods of selection Case studies of selection MTE524 (IV) ENVIROMENTS AND CORROSION TESTING: The atmosphere, Natural and sea waters, Soil in the corrosion process, The microbiology of corrosion, Effect of concentration, Velocity and temperature, Corrosion testing. CORROSION TESTING LAB. Corrosion Testing Electroplating Cathodic Anodic Impedance Corrosion Cell Surface Measurement Surface Roughness (Ra and Rz) Surface Wettability