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MT METALLURGICAL ENGINEERING
Section 1: Engineering Mathematics
Linear Algebra: Matrices and determinants; systems of linear equations; eigenvalues and eigenvectors.
Calculus: Limit, continuity and differentiability; partial derivatives; maxima and minima; sequences and series;
test for convergence; Fourier series.
Vector Calculus: Gradient, divergence and curl; line, surface and volume integrals; Gauss theorem.
Differential Equations: Linear and non-linear first order ODEs; higher order linear ODEs with constant
coefficients; Cauchy’s and Euler’s equations; PDEs – one dimensional heat and wave equations.
Probability and Statistics: Definitions of probability; conditional probability; mean, median, mode and standard
deviation; random variables; Poisson, normal and binomial distributions; analysis of experimental data; linear least
squares method.
Numerical Methods: Roots of linear and non-linear algebraic equations of single variable (bisection, secant,
Newton- Raphson methods); numerical integration (trapezoidal rule) and differentiation (Taylor series expansion).
Section 2: Metallurgical Thermodynamics
Laws of Thermodynamics: First law – energy conservation, Second law - entropy; enthalpy, Gibbs and Helmholtz
free energy; Maxwell’s relations; chemical potential; applications to metallurgical systems; solutions, ideal and
regular solutions; Gibbs phase rule, phase equilibria, binary phase diagram and lever rule; free-energy vs.
composition diagrams; equilibrium constant, activity, Ellingham and phase stability diagrams.
Electrochemistry: Single electrode potential; electrochemical cells; Nernst equation; potential-pH diagrams.
Section 3: Transport Phenomena and Rate Processes
Momentum Transfer: Concept of viscosity; shell balances; Bernoulli’s equation; mechanical energy balance
equation; flow past plane surfaces and through pipes.
Heat transfer: Conduction - Fourier’s Law, 1-D steady state conduction; convection; heat transfer coefficient and
correlations; radiation; Stefan-Boltzmann Law; Kirchhoff’s Law.
Mass Transfer: Diffusion and Fick’s laws, mass transfer coefficients and correlations.
Dimensional Analysis: Significance of dimensionless numbers and their applications.
Basic Laws of Chemical Kinetics: First order reactions; reaction rate constant; Arrhenius relation; heterogeneous
reactions; oxidation kinetics.
Electrochemical Kinetics: Polarization.
Section 4: Mineral Processing and Extractive Metallurgy
Comminution; Size classification; Flotation, Gravity, magnetic and electrostatic separation methods of mineral
beneficiation.
Principles of pyro, hydro and electro metallurgy; unit processes for extraction of non-ferrous metals – aluminium,
copper, titanium, zinc, and associated heat and material balance.
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Ironmaking: Thermodynamics of blast furnace ironmaking; heat and material balance in blast furnace; production
of sinter, pellets, metallurgical coke and testing, alternative routes of iron making (rotary kiln, MIDREX, COREX).
Primary Steel Making: Structure and properties of slags; thermodynamics and kinetics of steelmaking; basic
oxygen furnace and electric arc furnace steel making.
Secondary Steel Making: Ladle process – deoxidation, degassing, argon stirring, desulphurization, inclusion shape
control; basics of stainless steel manufacturing.
Continuous Casting: Basics of continuous casting, casting defects, thin slab casting.
Section 5: Physical Metallurgy
Materials Characterisation: X-ray Diffraction-Bragg’s law; optical microscopy; imaging and spectroscopy in SEM.
Crystal Imperfections: Point, line and surface defects; coherent, semi-coherent and incoherent interfaces.
Diffusion in Solids: Atomic models for interstitial and substitutional diffusion; volume, surface and grain boundary
diffusion, Kirkendall effect; uphill diffusion.
Phase Transformation: Driving force; homogeneous and heterogeneous nucleation; growth kinetics; solidification
in isomorphous, eutectic and peritectic systems; cast structures and macrosegregation; dendritic solidification and
constitutional supercooling; coring and microsegregation.
Solid-state Transformations: Precipitation; eutectoid transformation, diffusionless transformations; precipitate
coarsening, Gibbs-Thomson effect; glass transition in ceramics and polymers.
Principles of heat treatment: Heat treatment of steels; time-temperature-transformation (TTT) and continuous
cooling transformation (CCT) diagrams; surface hardening; recovery, recrystallization and grain growth; heat
treatment of cast irons and aluminium alloys.
Corrosion: Basic forms of corrosion and its prevention.
Section 6: Mechanical Behaviour of Materials
Elasticity; strain tensor and stress tensor; representation by Mohr’s circle; uniaxial tensile testing and stress-strain
curves for metals, ceramics, and polymers; Tresca and von Mises yield criteria; plastic deformation by slip and
twinning.
Dislocation Theory: Edge, screw and mixed dislocations; sources and multiplication of dislocations; stress fields
around dislocations; partial dislocations; dislocation interactions and reactions.
Strengthening Mechanisms: Work/strain hardening, strengthening due to grain boundaries, solid solution,
precipitation and dispersion.
Fracture behaviour: Griffith theory; linear elastic fracture mechanics; fracture toughness; fractography; ductile to
brittle transition; toughening mechanisms in ceramics.
Fatigue: Low and high cycle fatigue; crack growth.
High Temperature deformation: Mechanisms of high temperature deformation and failure; creep and stress rupture,
stress exponent and activation energy.
Section 7: Manufacturing Processes
Metal Casting: Mould design involving feeding, gating and risering, casting practices, casting defects.
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Hot, Warm and Cold Working of Metals: Metal forming – fundamentals of metal forming processes of rolling,
forging, extrusion, wire drawing and sheet metal forming; defects in forming.
Metal Joining: Principles of soldering, brazing and welding; welding metallurgy, defects in welded joints in steels
and aluminium alloys.
Powder Metallurgy: Production of powders, compaction and sintering.
Non-destructive Testing (NDT): Dye-penetrant, ultrasonic, radiography, eddy current, acoustic emission and
magnetic particle inspection methods.
Section 8: Materials Science and Non-Metallic Materials
Classification of engineering materials; chemical bonding- ionic, covalent, metallic and secondary bonding in
materials; Structure of metals and alloys, ionic and covalent bonded solids and polymers.
Polymers: Molecular weight; thermoplastics and thermosets; copolymers; crystallinity of polymers.
Ceramics: Radius ratio and electroneutrality rules for determining crystal structure; Schottky and Frenkel defects,
non-stoichiometric defects.
Composites: Types of reinforcements and matrices; enhancement in modulus and strength; isostrain and isostress
loading conditions.
Electronic Properties: Band gap; Fermi energy; conductors, semiconductors and insulators.
Magnetic properties: Magnetization and B-H curves, principles of ferro-, ferri-, antiferro-, para- and dia-
magnetism.