BARC OCES Metallurgical Engineering Syllabus

BARC OCES Metallurgical Engineering: topic-wise syllabus

1. 1

   Engineering Mathematics

   ~8 marks

   • Linear Algebra — Matrices, Determinants, Eigenvalues, Eigenvectors, Systems of Linear Equations
   • Calculus — Limits, Continuity, Differentiation, Integration, Partial Derivatives, Vector Calculus
   • Differential Equations — ODEs, Laplace Transforms, PDEs
   • Probability & Statistics — Distributions, Sampling, Regression, Design of Experiments
   • Numerical Methods — Interpolation, Integration, Solutions of Algebraic Equations
2. 2

   Thermodynamics & Kinetics

   ~12 marks

   • Chemical Thermodynamics — Laws, Enthalpy, Entropy, Gibbs Free Energy, Fugacity, Activity
   • Phase Equilibria — Unary/Binary/Ternary Systems, Gibbs Phase Rule, Phase Diagrams, Free Energy Curves
   • Solution Thermodynamics — Raoult's Law, Henry's Law, Regular Solution Model, Quasichemical Model
   • Ellingham Diagrams — Oxide/Sulfide/Chloride Stability, Reduction Reactions
   • Reaction Kinetics — Rate Laws, Arrhenius Equation, Diffusion-Controlled Reactions, Nucleation & Growth
   • Diffusion in Solids — Fick's Laws, Kirkendall Effect, Darken Equations, Diffusion Coefficients
   • Solidification — Nucleation, Growth, Constitutional Supercooling, Segregation, Dendrite Growth
   • Phase Transformations — Diffusional & Displacive, TTT & CCT Diagrams, Martensitic Transformation
3. 3

   Extractive Metallurgy

   ~12 marks

   • Mineral Processing — Crushing, Grinding, Screening, Classification, Froth Flotation, Magnetic/ Gravity Separation, Leaching
   • Pyrometallurgy — Roasting, Sintering, Smelting, Reduction, Matte Smelting, Converting, Calcination, Refining
   • Hydrometallurgy — Leaching (Acid, Alkaline, Bacterial), Solvent Extraction, Ion Exchange, Precipitation
   • Electrometallurgy — Electrowinning, Electrorefining, Fused Salt Electrolysis, Aqueous Electrolysis
   • Iron & Steel Making — Blast Furnace, Direct Reduced Iron, BOF, EAF, Secondary Steel Making (Ladle, VAD, AOD), Continuous Casting
4. 4

   Physical Metallurgy

   ~12 marks

   • Crystal Structures — BCC, FCC, HCP, Miller Indices, X-ray Diffraction, Bragg's Law, Crystal Defects
   • Binary Phase Diagrams — Fe-C, Cu-Ni, Al-Si, Pb-Sn, Eutectic, Peritectic, Monotectic, Eutectoid, Intermediate Phases
   • Ferrous Alloys — Steels (Plain Carbon, Alloy, Tool, Stainless), Cast Irons (Grey, Ductile, White, Malleable)
   • Non-Ferrous Alloys — Al, Cu, Mg, Ti, Ni, Zn, Superalloys, Shape Memory Alloys
   • Heat Treatment — Annealing, Normalizing, Hardening, Tempering, Austempering, Martempering, Induction/Flame Hardening, Hardenability Tests (Jominy)
   • Precipitation Hardening — Age Hardening, GP Zones, Overaging, Applications in Al & Ni Alloys
   • Recovery, Recrystallization & Grain Growth — Annealing Stages, Texture, Grain Size Control
5. 5

   Mechanical Behaviour & Testing

   ~10 marks

   • Mechanical Testing — Tensile, Compression, Hardness (Brinell, Rockwell, Vickers), Impact (Charpy, Izod)
   • Plastic Deformation — Dislocation Theory, Slip, Twinning, Work Hardening, Strain Hardening Exponent
   • Fracture Mechanics — Ductile/Brittle, Griffith Theory, Stress Intensity Factor, Fracture Toughness (K_IC, J-Integral)
   • Fatigue — S-N Curves, Endurance Limit, Low/High Cycle, Crack Initiation/Propagation, Goodman Diagram, Fatigue Testing
   • Creep — Creep Curve, Mechanisms, Stress & Temperature Dependence, Larson-Miller Parameter
   • Non-Destructive Testing — Radiography, Ultrasonic, Magnetic Particle, Dye Penetrant, Eddy Current, Acoustic Emission
6. 6

   Materials Processing & Forming

   ~10 marks

   • Metal Forming — Forging, Rolling, Extrusion, Drawing, Deep Drawing, Defects, Load Calculation
   • Sheet Metal Forming — Bending, Stretch Forming, Spinning, Formability, FLC
   • Powder Metallurgy — Powder Production, Compaction, Sintering, Applications (Nuclear Fuel, PM Parts)
   • Metal Casting — Mould Design, Gating/Riser, Sand/Investment/Die Casting, Casting Defects
   • Welding & Joining — Arc, TIG, MIG, Resistance, Friction Stir, Laser Welding, Weld Metal and HAZ, Weld Defects
   • Brazing, Soldering & Diffusion Bonding — Joint Design, Filler Metals, Fluxes, Applications in Nuclear Industry
   • Surface Engineering — Coatings, CVD, PVD, Plasma Spray, Shot Peening, Surface Hardening
7. 7

   Nuclear Metallurgy & DAE Materials

   ~8 marks

   • Nuclear Fuels — Uranium Mining & Processing, Enrichment, Fuel Fabrication (UO2, MOX, ThO2)
   • Cladding & Structural Materials — Zircaloy, Stainless Steel, Zr-Nb, Applications in PHWR & FBR
   • Radiation Effects — Irradiation Damage, Void Swelling, Embrittlement, Radiation-Induced Segregation
   • Nuclear Fuel Reprocessing — PUREX Process, Waste Vitrification, Waste Form Materials
   • Advanced Nuclear Materials — ODS Steels, SiC/SiC Composites, Graphite, High Temperature Materials
8. 8

   Corrosion & Surface Protection

   ~8 marks

   • Corrosion Fundamentals — Electrochemical Basis, Pourbaix Diagrams, Corrosion Rate, Polarization
   • Types of Corrosion — Galvanic, Pitting, Crevice, Intergranular, Stress-Corrosion Cracking, Hydrogen Embrittlement, Erosion
   • High Temperature Oxidation — Pilling-Bedworth Ratio, Oxidation Kinetics, Oxide Scale, Spallation
   • Corrosion Protection — Inhibitors, Coatings, Anodic/Cathodic Protection, Material Selection
   • Corrosion Testing — Weight Loss, Electrochemical Methods, Salt Spray, SCC Testing
   • Corrosion in Nuclear Systems — Coolant Chemistry, PWSCC, IASCC, Zirconium Corrosion, Carbon Steel in Steam