Course Meeting Times
Lectures: 2 sessions / week, 1.5 hours / session
Recitations: 1 session / week, 1 hour / session
Prerequisites
3.012 Fundamentals of Materials Science
3.022 Microstructural Evolution in Materials
Course Description
This course provides an introduction to materials processing science, with an emphasis on heat transfer, chemical diffusion, and fluid flow. We use an engineering approach to analyze industrialscale processes, with the goal of identifying and understanding physical limitations on scale and speed, and cover materials of all classes, including metals, polymers, electronic materials, and ceramics. Specific processes, such as meltprocessing of metals and polymers, deposition technologies (liquid, vapor, and vacuum), colloid and slurry processing, viscous shape forming, and powder consolidation are considered.
Grading Components
ACTIVITIES  DESCRIPTIONS  PERCENTAGES 

2 Tests  There will be two tests focused on concepts, which will take place in class.  40% 
Final Exam  There will be a comprehensive final at the end of the course.  35% 
Homework  6 problem sets are planned, each with about 1.5 weeks between distribution and due date. These will likely be more mathematical than conceptual.  25% 
Note that for all assignments and exams, every problem will be equally weighted (5 points).
Calendar
LEC #  TOPICS  KEY DATES 

1 
What is materials processing? Course overview Heat conduction equation 

2  Heat conduction equation review  Homework 1 out 
3 
Comparing heat transfer processes Three important cases 

4 
Biot number Newtonian heating / cooling Transient solutions and dimensionless variables 

5 
Glass fibers & thermal spray industrial processes Analyzing thermal spray coatings 
Homework 1 due Homework 2 out 
6 
Hot rolling steel 2D analysis, superposition & friction welding setup 

7 
Friction welding Introduction to radiation Black bodies, emissivity & radiation M number 

8 
Introduction to solidification Stefan condition, simplifying thermal profile Solidification in a thick mold 
Homework 2 due 
Test I  
9 
Sand casting, lost foam, & cooled molds Interface resistancelimited solidification Single crystal production Introduction to binary solidification 

10 
Binary solidification, no diffusion in the solid Solute balance, partition coefficient 
Homework 3 out 
11 
Zone refining Solidification with finite diffusion in liquid Unstable solidification fronts Engineering binary alloy microstructures 
Video project out 
12 
Fluid mechanics Introduction to fluid flow 

13 
Fluid flow Momentum conservation Flow between parallel plates Fluid free surface boundary condition 
Homework 3 due 
14 
1D fluid flow with body forces Flow through plates Chart of all math in 3.044 Introduction to glass production 
Homework 4 out 
15 
Pilkington glass process–fluid flow Pilkington glass process–heat transfer Drag force 

16 
NavierStokes equation Reynolds number 

17 
Class canceled 

18 
Newtonian flow Introduction to nonNewtonian Solid state shape forming 
Homework 4 due 
19  More on Newtonian and nonNewtonian flow  Homework 5 out 
Test II  
20 
Blow molding, compressive forming Introduction to powder processing Sintering, slurry processing 

21 
Colloid processing Slurry settling / casting 
Homework 5 due 
22 
Introduction to steel making Steel fluid flow analysis Steel solidification analysis 
Video project due 
23 
Steel solidification (cont.) Steel factory design A bit about electronics manufacturing 

Final Exam 