Introduction
to
Mechanical Processing
and
Materials Processing
Structure of Materials L-T-P-CR:3-1-0-4
Unit-1: Classification of materials. Geometry of crystals, symmetry and point groups, Bravais lattice, unit
cells. Atomic packing factor and theoretical density. Fractional coordinates, Crystallographic directions and
planes. Interplanar spacings and angles, zone axis, space groups.
Unit-2: Diffraction of X-Rays, Bragg’s Law, structure factor and intensity calculations. Applications of XRD:
Identification of phases, lattice parameter determination, solvus line, crystallite size, superlattice lines.
Unit-3: Amorphous materials and glasses. Polymeric structures.
Unit-4: Defects in crystals. Point defects, dislocations, Burgers vector and its representation. Planar defects:
stacking faults, twins, grain boundaries.
Unit-5: Equilibrium phase diagrams, cooling curves.
Syllabus in GATE#2026
Mechanical Working
Unit-I Introduction:- Classification of Forming Processes, Mechanism of metal working, Flow stress
determination, Temperature in metal working, Strain-rate effect, Metallurgical structure, Friction and
lubrication.
Classification of Forging Processes, Open-die forging, Closed-die forging, Forging loads in closed-die
forging, forging defects, Residual stresses in forging.
Unit-II:- Classification of Rolling Processes, Types of rolling mills, Hot rolling, Cold rolling, Rolling of
bars and shapes, Forces and Geometrical relationships in rolling, Defects in rolled products, Theories of
Cold-rolling and hot-rolling.
Classification of Extrusion Processes, Hot extrusion, Deformation, Lubrication and Defects in extrusion,
Analysis of extrusion process, Cold extrusion and Hot forming, Hydrostatic extrusion, Extrusion of tubing,
Seamless pipe.
Unit-III:- Drawing of Rods, Wires and Tubes: Rod and Wire drawing, Analysis of wire drawing, Tube
drawing, wire and tubes.
Sheet-Metal Forming: Sheet metal forming methods, Shearing and blanking, Bending, Stretch forming,
Deep drawing, Forming limit criteria, Defects in formed parts.
Materials Processing
• Unit-3: Amorphous materials and glasses.
• Casting: Moulding methods, materials and processes, with special reference to patterns, sand and binders.
Solidification of short & long freezing range alloy castings, Gating and Risering of castings. Melting
practices for ferrous and non-ferrous, Casting defects. (Optional)
• Welding: Theory and classification of welding processes Gas, arc, resistance, pressure, submerged arc, TIG,
MIG, plasma arc and electron beam welding including spot welding laser welding and diffusion welding.
Metallurgy of welding of structural steels, HAZ. Metallurgy of fusion welding of ferritic and austenitic steels,
cast iron etc. welding pool solidification. Welding stresses and stress relieving treatments. Brazing and
soldering. Joining of ceramics and plastics. (Optional)
• Powder Metallurgy: Basic processes in Powder Metallurgy, Characteristics of powders. Compaction in rigid
dies. Sintering of metal powders. Application of powder metallurgy products-their relative advantages.
Comparison of processing and applications of different materials (Optional)
Subject outcome
• Ability to design a system, component or process to meet desired needs.
• Understand operating principles of casting, forming, welding advanced manufacturing processes.
• Recommend appropriate manufacturing processes when provided a set of functional requirements and
product development constraints.
• Interpret the advantages and limitations of each process and influence of process parameters while
processing of the material in the finished component.
• Ability to measure manufacturing process variables in a manufacturing laboratory and make technical
inference about the process.
Books
• William D. Callister, Materials Science and Enggineering: An Introduction
• G. E. Dieter and David Bacon, Mechanical Metallurgy, McGraw-Hill,
1988, 3ed
• Ghosh A. and Mallik A.K., Manufacturing Science, Affiliated East-West
Press Pvt.. Ltd..New Delhi.
• Kalpakjin S, Manufacturing Engineering and Technology,
• Sarma P C, Production Technology