Lecture Notes


What is materials processing?

Course overview

Heat conduction equation

Lecture 1 (PDF)  
2 Heat conduction equation review Lecture 2 (PDF)  

Comparing heat transfer processes

Three important cases

Lecture 3 (PDF)  

Biot number

Newtonian heating / cooling

Transient solutions and dimensionless variables

Lecture 4 (PDF)   Transient heat conduction solutions (PDF)

Glass fibers & thermal spray industrial processes

Analyzing thermal spray coatings

Lecture 5 (PDF)

Glass fiber production

Gulf Broadcast. “Abahsain Fiber Glass.” March 23, 2011. YouTube. Accessed February 25, 2013. http://www.youtube.com/watch?v=GAlZc9v17bw

Adeelz channel [adeelahmed26]. “How it’s made s6 ep8 - Fibreglass Insulation.” December 1, 2008. YouTube. Accessed February 25, 2013. http://www.youtube.com/watch?v=1O0jFDdkyV8

Thermal spray

Avweld. “HVAF Thermal Spraying, Tungsten Carbide, Paper Industry Roll.” November 14, 2007. YouTube. Accessed February 25, 2013. http://www.youtube.com/watch?v=HQAdQvDrSl0


CatRCD. “Caterpillar Remanufacturing Overview.” February 14, 2012. YouTube. Accessed February 25, 2013. http://www.youtube.com/watch?v=sWKaB1MaUA0


Hot rolling steel

2D analysis, superposition & friction welding setup

Lecture 6 (PDF)

Steel heat treatment

CorusBCSATraining. “Steelmaking: Rolling.” July 26, 2007. YouTube. Accessed February 27, 2013. http://www.youtube.com/watch?v=6xnKmt_gsLs


Friction welding

Introduction to radiation

Black bodies, emissivity & radiation M number

Lecture 7 (PDF)

Friction welding

Doug W. “Inertia Friction Welding Demonstration - Manufacturing Technology, Inc.” January 18, 2009. YouTube. Accessed March 4, 2013. http://www.youtube.com/watch?v=-aEuAK8bsQg


Introduction to solidification

Stefan condition, simplifying thermal profile

Solidification in a thick mold

Lecture 8 (PDF)  

Sand casting, lost foam, & cooled molds

Interface resistance-limited solidification

Single crystal production

Introduction to binary solidification

Lecture 9 (PDF)

ManufacturingET. “Sand Casting.” April 11, 2008. YouTube. Accessed March 18, 2013. http://www.youtube.com/watch?v=rgL2Jn5mk1A

AutomotiveTv. “Ferrari V12 Engine.” February 21, 2008. YouTube. Accessed March 18, 2013. http://www.youtube.com/watch?v=AdcoVurVY30

Robert Lee. “Titanium Hammer Manufacturing.” February 7, 2008. YouTube. Accessed March 18, 2013. http://www.youtube.com/watch?v=NTclPnK9p9c


Binary solidification, no diffusion in the solid

Solute balance, partition coefficient

Lecture 10 (PDF) Jallepalli SATYA SUNITHA. “Dendritic Solidification.” August 24, 2008. YouTube. Accessed March 20, 2013. http://www.youtube.com/watch?v=S07fPo45BvM

Zone refining

Solidification with finite diffusion in liquid

Unstable solidification fronts

Engineering binary alloy microstructures

Lecture 11 (PDF)  

Fluid mechanics

Introduction to fluid flow

No lecture notes  

Introduction to fluid flow

Momentum conservation

Flow between parallel plates

Fluid free surface boundary condition

Lecture 13 (PDF)  

1D fluid flow with body forces

Flow through plates

Chart of all math in 3.044

Introduction to glass production

Lecture 14 (PDF)  

Pilkington glass process–fluid flow

Pilkington glass process–heat transfer

Drag force

Lecture 15 (PDF)

Pilkington glass

ProskillsUK. “Floatglass.mp4.” September 7, 2010. YouTube. Accessed April 17, 2013. http://www.youtube.com/watch?v=dw7623hu7wM

Corning: Fusion glass

CorningIncorporated. “The Fusion Process: At the core of Corning’s glass innovations.” January 11, 2012. YouTube. Accessed April 17, 2013. http://www.youtube.com/watch?v=q4ZU7zUxdM8


Navier-Stokes equation

Reynolds number

Lecture 16 (PDF)  

Class canceled

No lecture notes  

Newtonian flow

Introduction to non-Newtonian

Solid state shape forming

Lecture 18 (PDF) The Bluemint Video Haven. “How Plastic Bottles are Made.” September 10, 2006. YouTube. Accessed April 24, 2013. http://www.youtube.com/watch?v=T01i_vp2mJE
19 More on Newtonian and non-Newtonian flow Lecture 19 (PDF)  

Blow molding, compressive forming

Introduction to powder processing

Sintering, slurry processing

Lecture 20 (PDF)

Sunnyczh. “LDPE/HDPE Film Blowing Machine.” May 25, 2008. YouTube. Accessed May 6, 2013. http://www.youtube.com/watch?v=zgct8CpNWdg

ElkayPlastics. “How Poly Bags Are Made movie.wmv.” December 14, 2010. YouTube. Accessed May 6, 2013. http://www.youtube.com/watch?v=O7BLsexJn0c

Superformusa. “A Tour of Superform USA - Shaping the Future Together.” May 30, 2012. YouTube. Accessed May 6, 2013. http://www.youtube.com/watch?v=_zto5xDPIwo


Colloid processing

Slurry settling / casting

Lecture 21 (PDF)  

Introduction to steel making

Steel fluid flow analysis

Steel solidification analysis

Lecture 22 (PDF)


Dan Izzo. “Steel making.” July 29, 2007. YouTube. Accessed May 13, 2013. http://www.youtube.com/watch?v=wAcnOpOHeCU

CorusBCSATraining. “Steelmaking: Continuous Casting.” July 25, 2007. YouTube. Accessed May 13, 2013. http://www.youtube.com/watch?v=d-72gc6I-_E


Steel solidification continued

Steel factory design

A bit about electronics manufacturing

Lecture 23 (PDF)  

Course Info

Learning Resource Types

notes Lecture Notes
grading Exams with Solutions
assignment_turned_in Problem Sets with Solutions