history metallugy in nigeria

University of Nigeria Virtual Library

Serial No ISSN:978-8137-13-x

Author 1

OBIKWELU, D.O.N.

Author 2

Author 3

Title

Practice of Metallurgical and Materials Engineering

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Practice of Metallurgical and Materials Engineering

Category Engineering

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Practi e of Metallur ical an Materials E

Obikwelu, D.O. N

23.1 ROLES OF METALLURGICAL AND MATERIALS ENGINEERS,

I n the broad sense they are concerned with producing and applying to usefui enginecring purposes metals, polymers, ceramics, composites and all types of materials.

In playing this role the metallurgical and materials engineer joins in the policy- prescription 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 i t 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 non- destructive testing techniques in detecting defects in materials for quality control purposes.

In Matcrials' Rcscarch to meet thc challenges in the expanding mani~facturing sector..

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~ce of 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.


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) Metallurgical Engineering, Materials Science and Engineering,

(b) Metallurgy, Metallurgical and Materials Engineering, Metallurgy, (c) 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.


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) analyze and characterize these materials both i n the raw and refined forms.

(b) conduct major engineering tests on the properties of these materials. (c) conduct detailed materials research.


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.


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 i t deserves.

23.5.3 Professiona

Students and Staff belonging to their Nigeria.

Responsibility

alike are urged to show professional responsibility by appropriate professional societies within and outside

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.


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 spin- off 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).

history metallugy in nigeria

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