Metallurgical Engineer Course

Lesson 1 • Mechanical Properties Overview

Defines stress, strain, elasticity, and plasticity using tensile test data. Provides the property vocabulary used throughout the entire course.

Lesson 2 • Crystallographic Defects

Identifies point, line, and planar defects and their formation mechanisms. Explains how defects control strength and diffusion rates.

Lesson 3 • Atomic Structure and Metallic Bonding

Covers electron configuration, metallic bond formation, and resulting conductivity. Links atomic-scale interactions to bulk material behavior.

Lesson 4 • Crystal Structures in Metals

Examines BCC, FCC, and HCP lattice geometries and their packing factors. Connects crystal type to ductility and slip behavior.

Lesson 1 • Ternary and Multicomponent Systems

Extends binary concepts to ternary diagrams and isothermal sections. Prepares students for commercial alloy systems with multiple alloying elements.

Lesson 2 • Non-Equilibrium Transformations

Examines TTT and CCT diagrams to predict microstructures under rapid cooling. Bridges equilibrium thermodynamics with real processing conditions.

Lesson 3 • Reading Binary Phase Diagrams

Teaches lever rule, liquidus, solidus, and solvus line interpretation. Enables prediction of phase fractions at any temperature and composition.

Lesson 4 • Thermodynamic Fundamentals

Introduces Gibbs free energy, enthalpy, and entropy as drivers of phase stability. Establishes the thermodynamic framework for all subsequent phase analysis.

Lesson 1 • Steel Classification Systems

Surveys carbon, alloy, stainless, and tool steel families by composition and use. Enables engineers to navigate industry designation systems confidently.

Lesson 2 • Hardenability and Quenching

Explains Jominy end-quench testing and alloying effects on hardenability. Connects hardenability data to section size and quench media selection.

Lesson 3 • Iron-Carbon Phase Diagram

Details the Fe-C diagram including ferrite, austenite, cementite, and pearlite fields. Provides the foundation for all steel heat treatment decisions.

Lesson 4 • Tempering and Martensite Decomposition

Describes martensite formation, tetragonality, and staged decomposition during tempering. Guides selection of tempering temperature for target hardness and toughness.

Lesson 1 • Nickel Superalloys

Examines gamma-prime strengthening, creep resistance, and oxidation behavior in nickel superalloys. Prepares students for high-temperature turbine component selection.

Lesson 2 • Titanium Alloys

Distinguishes alpha, beta, and alpha-beta titanium alloys and their heat treatment responses. Highlights specific strength and corrosion resistance advantages.

Lesson 3 • Copper and Copper Alloys

Reviews brass, bronze, and cupronickel compositions, properties, and fabrication routes. Addresses dezincification and stress corrosion cracking risks.

Lesson 4 • Aluminum Alloys and Aging

Covers wrought and cast aluminum series, precipitation hardening, and T-temper designations. Links aging curves to GP zone and precipitate evolution.

Lesson 1 • Rolling and Extrusion Processes

Covers flat rolling, shape rolling, and direct and indirect extrusion mechanics and tooling. Calculates draft, reduction ratio, and extrusion pressure.

Lesson 2 • Texture and Anisotropy Control

Introduces crystallographic texture, pole figures, and ODF analysis in deformed metals. Explains how texture engineering improves formability and magnetic properties.

Lesson 3 • Plastic Deformation Mechanisms

Explains slip systems, dislocation glide, twinning, and work hardening at the microstructural level. Provides the mechanistic basis for all forming process analysis.

Lesson 4 • Forging and Drawing Operations

Analyzes open-die, closed-die forging, and wire drawing force requirements and die design. Connects forging flow lines to fatigue and impact performance.

Lesson 1 • Casting Process Overview

Surveys sand, permanent mold, die, and investment casting processes by tolerance and volume. Establishes selection criteria linking process to alloy and geometry.

Lesson 2 • Advanced Solidification Techniques

Examines directional solidification, single-crystal growth, and rapid solidification processing. Connects solidification rate to microstructural refinement and amorphous phase formation.

Lesson 3 • Solidification Defects and Control

Identifies shrinkage, porosity, hot tears, and inclusions with their root causes. Links mold design and alloy chemistry to defect prevention strategies.

Lesson 4 • Gating and Riser System Design

Applies fluid flow and Chvorinov's rule to design gating ratios and riser volumes. Prevents misruns, cold shuts, and shrinkage porosity through proper design.

Lesson 1 • Electrochemical Corrosion Fundamentals

Establishes galvanic cell theory, mixed potential, and Faraday's law for corrosion rate calculation. Provides the electrochemical basis for all corrosion analysis.

Lesson 2 • Protective Coatings and Inhibitors

Compares organic coatings, metallic platings, conversion coatings, and chemical inhibitors. Selects protection systems based on environment severity and service life.

Lesson 3 • Passivation and Polarization

Analyzes Evans diagrams, passivation curves, and transpassive dissolution behavior. Links alloy composition to passive film stability and breakdown potential.

Lesson 4 • Corrosion Types and Mechanisms

Classifies uniform, pitting, crevice, intergranular, and stress corrosion cracking by mechanism. Enables accurate diagnosis of field corrosion failures.

Lesson 1 • Fatigue Failure Analysis

Covers S-N curves, fatigue crack initiation, propagation, and Paris law crack growth rates. Connects surface finish, residual stress, and stress concentration to fatigue life.

Lesson 2 • Systematic Failure Investigation

Applies a structured protocol: evidence collection, fractography, chemical analysis, and corrective action. Produces defensible root cause reports meeting industry standards.

Lesson 3 • Non-Destructive Evaluation Methods

Surveys radiography, ultrasonic, magnetic particle, dye penetrant, and eddy current techniques. Matches NDE method to defect type, geometry, and material.

Lesson 4 • Creep and High-Temperature Failure

Analyzes primary, secondary, and tertiary creep stages and Larson-Miller parameter use. Applies creep data to component life prediction at elevated temperatures.