## 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 industrial-scale 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 melt-processing 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 resistance-limited 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 | Navier-Stokes equation Reynolds number | |

17 | Class canceled
| |

18 | Newtonian flow Introduction to non-Newtonian Solid state shape forming | Homework 4 due |

19 | More on Newtonian and non-Newtonian 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 |