The Gas Turbine Engine:
Major engine components, material trends, component operating environments and material requirements, compressor and turbine discs, blades. Combustion chambers, shafts, bearings.
Steels:
Compressor and turbine discs, processing of steel to billets, future trends in disc materials, compressor and turbine blading, transmission materials-bearings, shafts and gears
Titanium Alloys:
Classification of alloys, development of titanium alloys, production of titanium, Future development
Nickel Base Alloys:
Metallurgy of Nickel base alloys, Phases present in Nickel base alloys, Strengthening mechanism, Heat treatment of Nickel base alloys, application of Nickel base alloys for turbine discs and blades, powder metallurgy discs, sheet materials, dispersion strengthened alloys.
Composite materials:
Glass fibre reinforced plastics, high temperature glass fibre composites, carbon fiber reinforced plastics, pressure resisted resin injection, autoclave moulding resin system, future developments like organic resins, reinforcing fibres, high temperature materials. Ceramic materials, properties and their applications in rotating parts.
Casting Technology:
Light alloy casting, moulding practice, melting practice, precision investment casting, effect of casting parameters on properties, techniques for special or small quantity castings, titanium casting, directional solidification, hot isostatic pressing, future trends in casting technology, Processing of ceramics like slip casting, powder metallurgy technique.
Forging of Gas Turbine components:
Historical back ground, forging equipment, press, recent trends, quality control aspects of thermo mechanical processing, processing to improve mechanical properties, Incoloy 901, titanium 6-4 alloy,12% chromium steels, super alloy powder metallurgy. Forging of compressor and turbine blades.
Sheet Materials fabrication and joining:
Alloy requirements, sheet materials, steels, titanium alloys, high temperature super alloys, heat treatment and de-scaling, forming, chemical machining, electron beam welding, brazing of super alloys, ultrasonic machining, water jet cutting, electrochemical processing, laser cutting for rotating machinery components, Joining technologies like plasma technique, laser welding, use of rapid prototyping machines in manufacturing components.
Surface degradation and protective treatments:
Corrosion behavior, coatings and surface treatments, erosion behavior of compressor components, surface degradation and protection of combustor and turbine components, hot corrosion, high temperature coating technology.
Course outcomes:
At the end of the course the student will be able to:
1. Identify different materials for Gas Turbine Engines.
2. Distinguish alloys of Titanium, Nickel, Composite materials and their manufacturing processes.
3. Use casting and forging technology for Gas turbine components.
Question paper pattern:
The SEE question paper will be set for 100 marks and the marks scored will be proportionately reduced to 60.
Textbook/ Textbooks
1 Development of Gas Turbine Materials G. W. Meetham Applied Science Publications, London 1981
2 Metal Matrix Composites K. U. Krainer Wiley-VCH, Verlag GmbH & Co 2006
3 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems Mikell P. Groover Wiley 2nd Edition 2005
Reference Books
1 Materials for High Temperature Engineering Applications G. W. Meetham and M. H. Van de Voorde Springer 2006
2 Mechanical Metallurgy George E. Dieter, McGraw-Hill 1988
3 Materials Science and Engineering: an Introduction William D. Callister John Wiley and sons 6th edition 2005
4 Manufacturing Engineering and Technology Serope Kalpakjian, Steven R Schmid Pearson Education 2003