Materials processing

Lectures: 2 sessions / week, 1.5 hours / session

Recitations: 1 session / week, 1 hour / session

3.012 Fundamentals of Materials Science

3.022 Microstructural Evolution in Materials

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.

Note that for all assignments and exams, every problem will be equally weighted (5 points).

What is materials processing?

Course overview

Heat conduction equation

Comparing heat transfer processes

Three important cases

Biot number

Newtonian heating / cooling

Transient solutions and dimensionless variables

Glass fibers & thermal spray industrial processes

Analyzing thermal spray coatings

Homework 1 due

Homework 2 out

Hot rolling steel

2D analysis, superposition & friction welding setup

Friction welding

Introduction to radiation

Black bodies, emissivity & radiation M number

Introduction to solidification

Stefan condition, simplifying thermal profile

Solidification in a thick mold

Sand casting, lost foam, & cooled molds

Interface resistance-limited solidification

Single crystal production

Introduction to binary solidification

Binary solidification, no diffusion in the solid

Solute balance, partition coefficient

Zone refining

Solidification with finite diffusion in liquid

Unstable solidification fronts

Engineering binary alloy microstructures

Fluid mechanics

Introduction to fluid flow

Fluid flow

Momentum conservation

Flow between parallel plates

Fluid free surface boundary condition

1D fluid flow with body forces

Flow through plates

Chart of all math in 3.044

Introduction to glass production

Pilkington glass process–fluid flow

Pilkington glass process–heat transfer

Drag force

Navier-Stokes equation

Reynolds number

Class canceled

Newtonian flow

Introduction to non-Newtonian

Solid state shape forming

Blow molding, compressive forming

Introduction to powder processing

Sintering, slurry processing

Colloid processing

Slurry settling / casting

Introduction to steel making

Steel fluid flow analysis

Steel solidification analysis

Steel solidification (cont.)

Steel factory design

A bit about electronics manufacturing

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