Important Note for Candidates

Each of the following sections of Metallurgical Engineering covers core topics essential for understanding the field. Please refer to these topics for a comprehensive approach to your studies.

Section 1: Engineering Mathematics

Core Topics:

• Linear Algebra: Matrices and determinants, systems of linear equations, eigenvalues, and eigenvectors.
• Calculus: Limit, continuity, 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; Stokes, Gauss, and Green’s theorems.
• Differential Equations: Linear and non-linear first-order ODEs; higher-order linear ODEs with constant coefficients; Cauchy’s and Euler’s equations; Laplace transforms; PDEs – Laplace, one-dimensional heat, and wave equations.
• Probability and Statistics: Definitions of probability and sampling theorems, conditional probability, mean, median, mode, standard deviation; random variables; Poisson, normal, and binomial distributions; analysis of experimental data; linear least squares method.
• Numerical Methods: Solutions of linear and non-linear algebraic equations (Bisection, Secant, Newton-Raphson methods); integration by trapezoidal and Simpson’s rule; single and multi-step methods for differential equations.

Section 2: Metallurgical Thermodynamics

Core Topics:

• 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; Thermodynamics of point defects, surfaces and interfaces, adsorption and segregation phenomena.
• Electrochemistry: Single electrode potential, electrochemical cells, Nernst equation, potential-pH diagrams.

Section 3: Transport Phenomena and Rate Processes

Core Topics:

• 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 relations for forced convection; radiation – black body radiation, Stefan-Boltzman Law, Kirchhoff’s Law.
• Mass Transfer: Diffusion and Fick’s laws, mass transfer coefficients.
• Dimensional Analysis: Buckingham Pi theorem, significance of dimensionless numbers.
• 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

Core Topics:

Comminution techniques, Size classification, Flotation, Gravity and other methods of mineral beneficiation; Agglomeration: sintering, pelletizing and briquetting. Material and Energy balances in metallurgical processes; Principles and processes for the extraction of non-ferrous metals – aluminium, copper and titanium.

• Iron and Steel Making: Material and heat balance in blast furnace; structure and properties of slags and molten salts – basicity of slags, sulphide and phosphate capacity of slags; production of metallurgical coke; other methods of iron making (COREX, MIDRE); primary steel making, basic oxygen furnace, process dynamics, oxidation reactions, electric arc furnace.
• Secondary Steel Making: Ladle process – deoxidation, argon stirring, desulphurization, inclusion shape control, principles of degassing methods; basics of stainless steel manufacturing.
• Continuous Casting: Fluid flow in the tundish and mould, heat transfer in the mould, segregation, inclusion control.

Section 5: Physical Metallurgy

Core Topics:

• Chemical Bonding: Ionic, covalent, metallic, and secondary bonding in materials, crystal structure of solids – metals and alloys, ionic and covalent solids, and polymers.
• X-ray Diffraction: Bragg’s law, optical metallography, principles of SEM imaging.
• Crystal Imperfections: Point, line, and surface defects; coherent, semi-coherent, and incoherent interfaces.
• Diffusion in Solids: Diffusion equation, steady state and error function solutions; Examples- homogenenization and carburization; Kirkendall effect; Uphill diffusion; Atomic models for interstitial and substitutional diffusion; Pipe diffusion and grain boundary 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, spinoidal decomposition, ordering, massive transformation, discontinuous precipitation, eutectoid transformations; precipitate coarsening, Gibbs-Thomson effect; heat treatment principles, TTT, and CCT diagrams; surface hardening treatments.

Section 6: Mechanical Metallurgy

Core Topics:

• Strain and Stress Tensor: Representation by Mohr’s circle, elasticity, stiffness, and compliance tensor, yield criteria, plastic deformation by slip and twinning.
• Dislocation Theory: Edge, screw, and mixed dislocations, source 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 Behavior: Griffith theory, linear elastic fracture mechanics, fracture toughness, fractography, ductile to brittle transition.
• Fatigue: Cyclic stress-strain behavior – low and high cycle fatigue, crack growth.
• High-Temperature Deformation: Creep and stress rupture, stress exponent, and activation energy.

Section 7: Manufacturing Processes

Core Topics:

• Metal Casting: Mould design involving feeding, gating, and risering, casting practices, casting defects.
• 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.