Metals and Alloys Course

Lesson 1 • Imperfections and Defects in Metals

Identifies point, line, and planar defects and their effects on mechanical behaviour. Shows how defect density controls strength and ductility trade-offs.

Lesson 2 • Atomic Structure and Metallic Bonding

Covers electron configuration, metallic bond formation, and the free-electron model. Establishes the atomic basis for conductivity, ductility, and luster.

Lesson 3 • Physical and Mechanical Properties

Defines density, thermal conductivity, electrical resistivity, hardness, and strength. Connects each property to atomic and structural origins covered earlier.

Lesson 4 • Crystal Structures in Metals

Examines BCC, FCC, and HCP lattice arrangements and their geometric properties. Links crystal structure to density, slip systems, and deformation behaviour.

Lesson 1 • Iron-Carbon Phase Diagram

Provides detailed analysis of the Fe-C system from pure iron to 6.67 wt% carbon. Identifies austenite, ferrite, cementite, and pearlite regions critical to steel processing.

Lesson 2 • Eutectic and Peritectic Systems

Covers invariant reactions including eutectic, peritectic, and eutectoid transformations. Connects reaction type to resulting microstructure and mechanical properties.

Lesson 3 • Binary Isomorphous Systems

Analyses complete solid-solution systems with liquidus and solidus lines. Introduces tie-line construction and lever rule for composition determination.

Lesson 4 • Introduction to Phase Equilibria

Defines phases, components, and degrees of freedom using the Gibbs phase rule. Provides the thermodynamic vocabulary needed to interpret all phase diagrams.

Lesson 1 • Grain Boundary and Composite Strengthening

Applies the Hall-Petch equation to grain refinement and covers dispersion-strengthened composites. Compares strengthening efficiency across all mechanisms for alloy design decisions.

Lesson 2 • Solid Solution Strengthening

Quantifies strengthening from substitutional and interstitial solute atoms via lattice strain. Connects solute concentration and size mismatch to yield strength increments.

Lesson 3 • Precipitation and Dispersion Hardening

Covers age hardening cycles, coherent precipitate formation, and Orowan bypass mechanism. Explains overaging and optimal aging time for peak strength.

Lesson 4 • Plastic Deformation and Slip Systems

Analyses dislocation motion, slip planes, and Schmid’s law for single crystals. Provides the mechanistic basis for all strengthening strategies covered in this section.

Lesson 1 • Steel Classification and Designation Systems

Covers carbon, alloy, stainless, and tool steel families with standard designation logic. Enables rapid identification of composition and intended application from grade codes.

Lesson 2 • Surface Hardening Techniques

Covers carburising, nitriding, induction, and flame hardening for surface property enhancement. Addresses case depth control and core-to-case property gradients.

Lesson 3 • Martensite Formation and Hardening

Analyses diffusionless transformation to martensite and its tetragonal structure. Connects carbon content to hardness, brittleness, and hardenability.

Lesson 4 • Annealing, Normalising, and Tempering

Details softening and stress-relief heat treatments and their microstructural outcomes. Provides process parameters for restoring ductility after hardening operations.

Lesson 1 • Magnesium, Zinc, and Lead Alloys

Surveys lightweight magnesium alloys, die-cast zinc alloys, and lead-based materials. Addresses flammability, corrosion, and recycling considerations for each system.

Lesson 2 • Nickel and Cobalt Superalloys

Covers gamma-prime strengthened nickel superalloys and cobalt-based alloys for high-temperature service. Explains creep resistance mechanisms and directional solidification processing.

Lesson 3 • Titanium Alloys

Analyses alpha, beta, and alpha-beta titanium alloys and their processing windows. Highlights strength-to-weight ratio and biocompatibility advantages for aerospace and medical use.

Lesson 4 • Aluminium Alloys: Wrought and Cast

Covers the 1xxx–8xxx wrought series and common casting alloys with temper designations. Links alloying elements to strengthening mechanisms and corrosion behaviour.

Lesson 1 • High-Temperature Oxidation

Covers oxide scale formation, Pilling-Bedworth ratio, and parabolic vs. linear growth laws. Addresses protective vs. non-protective oxide behaviour in service environments.

Lesson 2 • Electrochemical Basis of Corrosion

Establishes oxidation-reduction reactions, galvanic series, and Nernst equation fundamentals. Provides the electrochemical framework for all corrosion forms discussed in this section.

Lesson 3 • Forms of Aqueous Corrosion

Identifies galvanic, crevice, pitting, intergranular, and stress corrosion cracking mechanisms. Links each form to specific microstructural or environmental conditions.

Lesson 4 • Corrosion Testing and Monitoring

Introduces weight loss, electrochemical polarisation, and salt spray testing methods. Connects test data to service life prediction and maintenance scheduling.

Lesson 1 • Sheet Metal Forming Operations

Covers deep drawing, stamping, bending, and hydroforming with formability limits. Introduces forming limit diagrams and springback compensation techniques.

Lesson 2 • Powder Metallurgy and Sintering

Explains powder production, compaction, and sintering mechanisms for near-net-shape parts. Addresses density, porosity control, and post-sintering treatments.

Lesson 3 • Rolling, Forging, and Extrusion

Analyses hot and cold rolling, open and closed die forging, and direct extrusion mechanics. Addresses flow stress, friction, and die design for each bulk forming process.

Lesson 4 • Machining and Surface Finishing

Covers cutting mechanics, tool materials, and surface integrity in metal removal operations. Links machinability ratings to alloy composition and microstructure.

Lesson 1 • Fatigue Failure and Life Prediction

Covers S-N curves, fatigue limit, crack initiation and propagation stages, and Paris law. Addresses mean stress effects and surface treatment strategies to extend fatigue life.

Lesson 2 • Fracture Mechanics Fundamentals

Introduces stress intensity factor, fracture toughness, and critical crack size calculations. Provides the quantitative tools needed to assess structural integrity of metallic components.

Lesson 3 • Systematic Materials Selection

Applies Ashby performance indices and weighted property charts to multi-criteria selection problems. Integrates cost, availability, and sustainability into final material recommendations.

Lesson 4 • Creep and High-Temperature Failure

Analyses primary, secondary, and tertiary creep stages and Larson-Miller parameter use. Connects microstructural stability to creep resistance in superalloys and steels.