B. Course Syllabi for Materials Engineering

1. Course Name: Mat E 443 Ferrous Metallurgy

2. Catalog Description: Mat E 443. Ferrous Metallurgy. (2-3) Cr. 3. S. Extraction of pig iron from ore. Steelmaking processes. Equilibrium and non-equilibrium phases in the Fe-C system. Properties and processing of cast irons, plain carbon and alloy steels, stainless and specialty steels. Transformation diagrams, hardenability, and surface treatments. Continuous casting, forging, hot rolling, quenching, and tempering as they apply to ferrous materials. Cost and mechanical performance considerations in cast iron and steel selection and heat treatment.

3. Prerequisites: MatE 341.

4. Textbook/Materials: Steels: Microstructure and Properties, R.W.K. Honeycombe and H.K.D.H. Bhadeshia, 2nd ed., Edward Arnold, 1995.

5. Course Learning Objectives:
The specific objectives of this course are to:

• Enable students to predict mechanical behavior and microstructure as a function of specific thermo-mechanical processing conditions.
• Provide students in-depth knowledge of ferrous metallurgy through hands-on laboratories.
• Enable students to select appropriate steels and design processing conditions to produce desired properties.

The student will be able to:

• Select and specify ferrous alloys for desired applications and design ferrous processing and heat-treating conditions to meet specified property goals.
• Identify the microstructure of steels and cast irons in various heat-treated conditions using metallographic techniques.
• Predict potential problems associated with heat treatment, welding, and deformation of ferrous alloys.
• Communicate clearly and effectively by presenting both oral and written reports.
• Work effectively as part of a team by conducting laboratory experiments in groups.

6. Topics Covered:

• Iron and Steel Making Process - Reduction of ore, survey of steel furnaces (blast, basic oxygen, electric arc) continuous casting.
• Plain Carbon Steel - Production and properties of austenite, ferrite, pearlite, bainite, spheroidite, and martensite.
• Alloying Effects - Austenite and ferrite stabilizers, solute effects on the kinetics of phase transformations, transformation diagrams for steels.
• Cast iron - Types of cast iron, solidification and casting, effect of inoculants, austempered-ductile iron.
• Heat Treatment - Transformation diagrams; hardenability (effects of grain size and composition); precipitation hardening, tempering, surface treatments (carburization, nitriding, induction hardening).
• Industrial Processes - Effects on microstructure and properties from hot and cold rolling, thermo-mechanical processes (extrusion and drawing, forging, and sheet metal forming), coatings.
• Welding - Heat affected zone (HAZ) effects specific to plain carbon and stainless steels and cast irons, weld design.
• Specialty Steels - Stainless steels, maraging steels, HSLA steels.
• Alloy Selection and Specification.

Laboratory Descriptions:


Title:		Outcome:
Lab Tour, safety discussion/ quiz		Must pass safety quiz
Carburization of Steel		Produce and characterize a carburized steel part
Jominy end quench of three AISI steels		Measure hardenability and develop the ability to predict how it is affected by alloying additions
Evaluation of retained austenite using x-ray diffraction		Use X-ray diffraction techniques to determine microstructural consitituents
Weld microstructural analysis and strength in cast iron, martensitic stainless steel and two AISI steels		Perform a fusion weld on three types of ferrous alloys and predict the effect on welded assemblies of subsequent heat treatments
Heat treatment and tempering of AISI steels		Design a heat treatment process to meet specified mechanical properties
Yield point phenomena in steel		Use tensile testing and aging techniques to define and modify upper and lower yield points in stee
The Charpy test and ductile-brittle transition in plain carbon steel		Develop a DB curve for a plain carbon steel

7. Class/Laboratory Schedule: To be determined. The course format will be two lectures and one laboratory session each week.

8. Professional Component: Mat E 443 contributes 3 credits to Engineering Topics and to the professional component of this program through lecture presentations and the discussion of case studies which include economic, environmental, sustainability, manufacturability, and social considerations.

9. Relationship of Course to Program Learning Outcomes and Program Educational Objectives: Objectives: A, C, E Outcomes: a-c, e, g, k-o, r (significant)

10. Prepared by: B. Gleeson, 1/00, rev. 5/24/00 KPC