University of Nigeria
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Author 1
ISSN:978-8137-13-x
OBIKWELU, D.O.N.
Author 2
Author 3
Title
Practice of Metallurgical and
Materials Engineering
Keywords
Description
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Practice of Metallurgical and
Materials Engineering
Engineering
Practi e of Metallur ical an
Materials E
Obikwelu, D.O.N
23.1 ROLES OF METALLURGICAL AND MATERIALS ENGINEERS,
n the broad sense they are concerned with producing and applying to usefui
enginecring purposes metals, polymers, ceramics, composites and all types
of materials.
I
In playing this role the metallurgical and materials engineer joins in the policyprescription and decision making in all the areas of solid minerals, mining and
exploitation.
Specifically the metallurgical and materials engineer maps out engineering
strategies and design systems for extracting metals from their ores, refining,
alloying, casting, fabricating and heat treating and continually developing
better methods for carrying out these operations.
Plant and process design, operation and optimization in the metallurgical and
materials industries are the professional responsibilities of this professional.
The fast depleting non-renewable resources of the earth re challenges to the
metallurgical and materials engineers.
The Metallurgical and Materials Engineer is expected to provide leadership in
(a)
Transportation systems by improving the existing materials in that
sector with minimum disturbance to the environment and minimum
consumption of energy.
An Introduction to Engineering
Communication systems from telephones to satellites by developing
ultra-pure silicon for transistors, germanium for diodes, cesium for
electronic emitters, tungsten for hot filaments and copper for electronic
communication.
Nuclear energy for production and fabrication of the uranium fuel to the
massive steel structure of the reactor to the radiation shielding which
makes it safe.
I n solving social problems for making the environment safe by
rccycling scrap materials, developing process and equipment for use in
removing impurities from our air and water.
In Quality Control and Assurance of all input and output materials in
the fast growing metallurgical and materials industries, using nondestructive testing techniques in detecting defects in materials for
quality control purposes.
In Matcrials' Rcscarch to meet thc challenges in the expanding
mani~facturingsector..
STATUS OF THE PROFESSION IN NIGERIA
The Profcssion of Metallurgical and Materials' Engineering came fully to
prpmincncc in '1976 when the Federal Government of Nigeria awarded
scholarships to young Nigerians to study various aspects of the field overseas
in ordcr to man thc Federal Government owncd Steel Industries being
established. These industries were to be sited at Ajaokuta,, ltakpe all in Kogi
State of Nigeria and Ovwia-Aladja in Warri, Delta State of Nigeria.
'
Thc Federal Government also cstablished Metallurgical Training Institutes at
Onitsha and Ajaokuta for training the middle-level manpower for thesc
inclustries.
Elaborate overseas in-service-training programme was also embarked upon for
on-the-job training of staff of these stecl industries.
23. Pract~ceof Metallurgical and Materials Engineering
Metallurgical and Materials Engineers had their golden age from around 1980
to 1985 after which there was a downturn in the steel industries.
This downturn was as a result of mismanagement in the industries and other
extraneous factors.
At the present time these industrics have not fully recovered because the
Federal Government of Nigeria lcascd them to foreign investors.
InLereslingly the melallurgical and materials engineers are now establishing a
foothold i n the Oil and Gas Industry, Class Industry, Petrochemical and
Ccment Industries.
Resourceful ones engage gainfully in private foundries and fabrication shops.
In Quality Control, Welding, Corrosion Prcvcntion and Control in the Oil and
Allied Industries the Metallurgical and Materials Engineers are indispensable.
In thc manufacturing industries, Standard Organization of Nigeria arid
Malerials Research Inslilutes these professionals are veritable human resource.
As previously stated professional interaction thrivcs i n The Nigerian Society
of Enginccrs , Nigerian Melallurgical Socicty and The Materials Sociely of
Nigeria.
It is also gladdening to note that with the promincnt role materials play in [he
industrial economy in Nigeria i n particular and the world in general
metallurgical and materials profcssionals will be i n high demand in the years
ahcad.
23.3
POTENTIALS
As discussed previously the Metallurgical and-Materials Engineers are at the
centre of the fast and ever expanding manufacturing economy of both
developed and developing countries.
An Introduction to Engineering
All of our raw materials from the industry come from nature - either from the
earth or its atmosphere or both or even from other planets. Thcse raw materials
are characterized as coming from renewablc or non-renewablc resources of the
earth. Renewable rcsources arc agricultural "derived matcrials or forest-derived
rnatcrials: wood, cotton, foodstuff and to extent air.
Non-renewable resources are minerals: metallic, non-metallic or fucl. The
Metallurgical and Materials Engineers are concerned with non-rencwable
natural resources. This fact challenges the profession of Metallurgical and
Materials Engineering to new direction and brings it to greater importance. We
must provide for the needs of society and solve its problems, for the world's
known mineral and fuel resources are being depleted faster than we are finding
new supplies.
The Extractive or Chemical Metallurgy branch of the Metallurgical and
Materials family is challenged to find new ways of economically utilizing
mctals which are already available and design engineering strategies to extract
metals from lower grade sources with minimum disturbance to the
environment and with minimum consumption of energy.
In some countries like Nigeria, iron ore ,the source of iron for steelmaking
occurs in chemical combination with Sulphur or Phosphorus. The profession
has the potential to develop ways and means of beneficiating these ores to
increasc the iron content and minimize the effects of Sulphur and Phosphorus
i n the eventual stc'el product.
The materials for transportation systems - air, land and sea transport depend
on the expertise of the profession. The materials are continually being
improve3 for better and safer performance: alloy design and development for
light-weight high strength material and composite materials for the family car,
corrosion-resistant, fatigue-resistant super alloys for air crash engines,
titanium alloys for space and sea vehicles and aluminum-alloys for the air craft
body.
23. Practice of Metallurgical and Materials Engineering
23.4
IMPEDIMENTS
The practice of Metallurgical and Materials Engineering has formidable
impediments in most developing countries like Nigeria.
It was noted previously that," Metallurgy, the core of Metallurgical and
Materials Engineering is one of the oldest of arts and one of the newest of the
sciences". The profession was for a very long time submerged in the traditional
engineering disciplines of mechanical, civil, and electrical. Science and
Strength of Materials, Electronic Materials, Fabrication, Welding and Foundry
practices, Manufacturing and related areas are in the domain of Metallurgical
and Materials Engineering. The situation has deprived the professionals of this
field the opportunity of getting appropriate employment.
Unlike most other disciplines in Engineering, Metallurgical and Materials
discipline has nomenclature problem. Below are listed various names of this
discipline in various countries:
(a)
(b)
(c)
Metallurgical Engineering, Materials Science and Engineering,
Metallurgy, Metallurgical and Materials Engineering, Metallurgy,
Mechanics and Materials Science, Ceramic Engineering, Polymer
Engineering, Metal Science and Engineering etc.
This iiomenclature problem arises from the concept of the Material family,
namely metals, ceramics and polymers. This is the tripod of the profession.
Structurally speaking Ceramics and polymers are derivatives of the metal
which may be called "an ideal material". For this reason it is appropriate to
adopt the popular nomenclature of "Metallurgical and Materials Engineering''
emphasizing the "Science and Engineering of Metals - Metallurgical
Engineering", even when "Metals" are included in "Materials".
With the clear understanding of the Materials family and the significance
"Metals" in that family, the impediment arising from nomenclature will be
removed and prospective students in the discipline will be well guided.
An Introduction to Engineering
The belief that "steel is strength and its consumption per capita in any country"
determines the country's industrial growth gave a wrong impression for the
control of the Steel Industry. In Nigeria, for example, the Steel Industry, which
is the highest employer of the professionals i n this field, was for a long time
under the Federal Government full control. This situation affected the growth
of this industrial sector. Consequently, "who controls the Steel sector" is an
impediment to the practice of Metallurgical and Materials Engineering in that
sector.
The practice of this profession depends on the healthful state of the
manufacluring sector, especially the metallurgical and allied industries. It is
~mlorrunate that the technologies employed in most of the manufacturing
industries in Nigeria are imported. As a consequence the equipment are
imported, spares and raw materials are imported. This leads to grossly low
capacity utilization, poor maintenance and very high operational costs,
resulting to premature collapse of the industrics.
Availability of raw materials is a positive catalyst for industrial growth. Raw
materials for the industries should be locally sourced and engineering studies
done to access and exploit these raw materials, where necessary to upgrade the
ore deposits. Unavailability of local raw materials is an impediment to the
practicc of this profession.
The dearth of professionals i n this area is an impediment to the practice of the
profession. Good number of the professionals in the area is necessary to form a
critical mass to move the profession forward in a fast growing industrial world.
Practice of Metallurgical and Materials' Engineering centers partly on the
study and understanding of the chemical composition and other engineering
properties of the materials. A major impediment to this is lack of cquipment
and facilities to
(a)
(b)
(c)
analyze and characterize these materials both i n the raw and refined
forms.
conduct major engineering tests on the properties of these materials.
conduct detailed materials research.
23. Practice of Metallurgical and Materials Engineering
23.5 RECOMMENDATIONS
As the profession and discipline of metallurgical and materials engineering
face many formidable challenges recommendations for the correct positioning
of the field fall under the following areas:
23.5.1 Nomenclature
At the present time, many institutions have various names for this field and
this situation may create a wrong impression in the minds of prospective
students of this field.
Which name suffices to be adopted depends on the students, the staff and the
environment.
Students are expected to understand the programme they are entering into, the
staff qualified on the programme they are expected to operate and the
environment (society) willing to accept the products of the programme.
It is therefore necessary that a committee is set up by The Nigerian Society of
Engineers and/or The Nigerian Metallurgical Society to discuss this
nomenclature problem and decide on a fitting name for this programme. All
aspects of Metallurgical and Materials Engineering are expected to fall under
the same umbrella programme instead of having splinter and incomplete
departments.
23.5.2 Professional Co-existence:
The Council for the Regulation of Engineering Education in Nigeria (COREN)
established the Engineering Team for all branches of Engineering. This Team
is made up of the functional hierarchy of The Engineer, The Engineer
Technologist, The Engineer Technician and The Engineer Craftsman.
The Metallurgical and Materials Team is as follows:
The Metallurgical & Materials Engineer, The Metallurgical and Materials
Engineer-Technologist, The Metallurgical and Materials Engineer-Technician,
The Metallurgical and Materials - Craftsman.
An Introduction to Engineering
Professional colleagues in other branches of engineering are expected to
respect this team concept in all branches and be ready to accord to each branch
of engineering the professional respect it deserves.
23.5.3 Professiona Responsibility
Students and Staff alike are urged to show professional responsibility by
belonging to their appropriate professional societies within and outside
Nigeria.
23.5.4 Emphasis on the Materials Family
Metals, Polymers and Ceramics form the fundamental tripod of the field of
metallurgical and materials engineering. In operating this academic
programme adequate recognition should be given to this concept at the
beginning so that students form the correct mindset of the programme.
23 S . 5 Prescription of Definite Policy on Materials
One of the problems that contributed to the collapse of the Steel Sector in
Nigeria is lack of strong will on the part of steel workers/supervising ministry
and the absence of a definite policy on the Iron & Steel Production in Nigeria.
Existing policies if any should be re-visited and appraised with a view to
remove the bottlenecking factors that made the steel venture in Nigeria a
dismal failure. Thus there is need for a definite policy to be prescribed in all
aspects of the materials industry. By so doing the professionals of this field
will not only be gainfully employed but the country as a whole will benefit in
the resulting industrial development. '
23.5.6 Need for More Graduates and Specialists in this Field
It is not an overstatement that all technological development programmes
depend on materials.
23. Practice of Metallurgical and Materials Engineering
It is therefore advisable for all faculties of engineering in Nigcria and other
developing countries to mount Metallurgical & Materials programmes to put a
capstone and completeness on the engineering education.
23.5.7 Local Content Condition
One of the subtle ways of supporting materials development in a developing
country is placing a pre-condition on the industrial development programmes
especially in the manufacturing sector.
Placing 50 percent local content condition to any prospective industrialist in
the country will enhance the status of the professionals in metallurgical &
materials engineering. This condition requires the prospective entrepreneur to
have in his or her production train 50 percent local input after a stipulated
number of years of production.
This precondition if instituted and implemented will have immeasurable spinoff effects on many aspects of the country's development especially in thc
exploitation and development of the local raw materials. Foreign exchange
will be conserved , the teeming unemployed technical and non-technical
graduates will be employed and wealth will spread amongst Nigerians.
23.5.8 Equipment for Materials Research and Analysis:
Most measurements on materials in Nigeria are done overseas because there
are no equipment for even simple analysis of materials for input into the
metallurgical and materials study.
There is need for appropriate equipment on measurement of various
engineering properties of- materials. Establishment of standard materials
laboratories will be a positive catalyst to the growth of the metallurgical and
materials engineering programme.
'
An Introduction to Engineering
A Career i n Metallurgical Profession, A Publication of The Metallurgical Society of
AIME, New York.
Cooper K.P, Producing near Net-Shape Products by Powder Metallurgy, ibid.
Dell K.Allen, Metallurgy Theory and Practice; American Technical Society ,
Chicago (1975)
Hull John R, Using High Temperature Superconductors for Levitation Applications,
Journal of Metals, vo1.51, 110.7 (1999)
Obikwelu D.O.N, The Nigerian Heritage of Non-ferrous Metallurgy, Proceedings of
the Technical Conference of The Nigeria Metallurgical Society held at
Ajaokuta (1986)
Obikwelu D.O.N, Metallurgical Education, for what? For whom? And how? Paper
Presented at Technical Conference of The Nigerian Metallurgical Society
held at Delta Steel Company Ovwian-Aladja (1983).
Obikwelu D.O.N, The Supervised Industrial Training Scheme for Engineers- A
Gateway to postgraduate Engineering Education, Paper presented at The
Nigerian Society of Engineers' Meeting at Warri. Delta State (2002).
Obikwelu D.O.N. and Talabi K.O. Reprocessing of Used Refractoiries in Delta Steel
Company, Ovwian-Aladja, Warri, Report on the National Seminar on
Ancillary Industries around the Nigerian Steel Industry (1986)
Regulqtion and Contfol of the Practice of Engineering Profession in Nigeria, A
publication of The Council for the Regulation of Engineering in Nigeria
(COREN)
The Nigerian Steel Industry: Problems and Prospects, Proceedings of The Nigerian
Metallurgical Society, held at the Nigerian Institute of Policy and Strategic
Studies, Kuru, ed. by D.O.N.Obikwelu (1988).