The goal of 3.044 is to teach cost-effective and sustainable production of solid material with a desired geometry, structure or distribution of structures, and production volume. Toward this end, it is organized around different types of phase transformations which determine the structure in various processes for making materials, in roughly increasing order of entropy change during those transformations: solid heat treatment, liquid-solid processing, fluid behavior, deformation processing, and vapor-solid processing. The course ends with several lectures that place the subject in the context of society at large.

Special software is required to use some of the files in this course: .xls.

Syllabus

Subject Overview

The goal of 3.044 is to teach cost-effective and sustainable production of solid material with a desired geometry, structure or distribution of structures, and production volume. Toward this end, it is organized around different types of phase transformations which determine the structure in various processes for making materials, in roughly increasing order of entropy change during those transformations.

Solid Heat Treatment

This section will take advantage of the mathematical similarity between diffusion and heat conduction to introduce you to the phenomenon of heat transfer by conduction, convection and radiation. These tools will provide understanding on how to induce or avoid the various chemical reactions, precipitation, annealing and other solid-state phase transformations learned in 3.022.

Liquid-Solid Processing

Most large-scale processes for making solids involve the liquid state at some point, and the initial microstructure formed during the liquid-solid transition often persists into the final part. This section will deal with solidification and precipitation/coating reactions from solution, with a focus on the mechanisms which determine structure in this processing step.

Fluid Behavior

Fluid behavior and fluid-solid interactions are crucial to understanding many processes. This section will focus on concepts of drag force on solids and fluids in relative motion, from particles to flat surfaces to porous media. It will close with a discussion of overall mass and momentum balances on large control volumes.

Deformation Processing

This section will introduce mechanical deformation processes from sheet forming to sintering, which provide opportunities for inexpensively forming very advantageous structures on a large scale. It will build on concepts from the previous section to treat deforming solids as moving fluids, and also deformation mechanisms discussed in 3.032.

Vapor-Solid Processing

As the transformation with the largest entropy change, vapor-solid processes present unique opportunities for precise control of structure.

Special Topics

3.044 will close with a set of lectures summarizing and contextualizing course material and placing it in the context of society at large.

Prerequisites

3.012, 3.022

Textbook

There is no required text for 3.044. The topics and order of coverage are such that we will use excerpts from the following textbooks:

 Ashby, M. F. Materials Selection in Mechanical Design. 3rd ed. Boston, MA: Elsevier Butterworth-Heinemann, 2005. ISBN: 9780750661683.

 Bird, R. B., W. E. Stewart, and E. N. Lightfoot. Transport Phenomenon. New York, NY: J. Wiley and Sons, 2001. ISBN: 9780471410775.

 Flemings, M. Solidification Processing. New York, NY: McGraw-Hill, 1974. ISBN: 9780070212831.

 Incropera, F. P., and D. P. DeWitt. Fundamentals of Heat and Mass Transfer. 5th ed. New York, NY: J. Wiley and Sons, 2001. ISBN: 9780471386506.

 Poirier, D. R., and G. H. Geiger. Transport Phenomena in Materials Processing. Warrendale, PA: Minerals, Metals & Materials Society, 1998. ISBN: 9780873392723.

Grading

There will be two tests and a final exam. Grades will be determined from exams and eight homework assignments as follows:

Course gradings.

ACTIVITIES	PERCENTAGEs
Problem Sets	16%
Test 1	22%
Test 2	22%
Final Exam	40%

Calendar

The calendar below provides information on the course's lecture (L) and recitation (R) sessions.

AP = Prof. Adam Powell, RK = Prof. Randolph Kirchain, WP = Wanida Pongsaksawad (course TA)

Course schedule.

SES #	TOPICS	MOTIVATING PROCESSES	INSTRUCTORS	KEY DATES
L1	Introduction		AP
R1	Math Review		WP
I. Solid Heat Treatment
L2	Introduction Energy Conservation and 1-D Conduction	Various	AP
L3	Sphere Generation Multilayers		AP
L4	Multilayers (cont.) Biot # Finite Differences	Glass-ceramics	AP
R2	Heat Flow through Multilayer Sheet and Cylinder		WP
L5	Finite Differences (cont.) Radiation	Polymer Extrusion	AP
L6	Dimensional Analysis	Furnace Wall	David Dussault (Guest Lecturer)	Problem set 1 due
L7	Radiation (cont.) Convective Cooling Curves Dimensionless Graphs	Thermal Spray	AP
R3	Dimensional Analysis		Jose Vieyra
L8	Convective Cooling Curves (cont.)		AP
II. Engineering Economics
L9	Introduction		RK
L10	Cost Modeling I: Unit Operations	Pizza Oven	RK	Problem set 2 due
R4	Economic Models in Engineering		WP
L11	Cost Modeling II: Cost Factors and Scale		RK
III. Liquid-Solid Processing
L12	Moving Bodies	Vacuum Arc Remelting	AP
L13	Moving Bodies (cont.) Stability	Casting	AP	Problem set 3 due
R5	Casting: Solid-Liquid Process		WP
L14	Stability in Alloy Solidification	Injection Molding	AP
IV. Fluid Behavior
L15	Introduction Newtonian Fluids		AP
L16	Test 1		AP
R6	Fluid Flow and Drag Force on a Sphere, with Examples		WP
L17	Viscous Shear		AP
L18	Tubes Flow Rate Sphere Flow	Precipitation, Bubbles	AP
L19	Sphere Drag and Reynolds Number		AP
L20	Engineering and Society Particle Velocity	Lessons of 9/11	AP
L21	Friction Factors Boundary Layers		AP
L22	Plate Drag Turbulence	Fermentation	AP	Problem set 4 due
R7	Friction Factors and Drag Forces Turbulence		WP
L23	Turbulence (cont.)	Fermentation	AP
L24	Batch and Continuous Flow Reactors	Fermentation	AP	Problem set 5 due
L25	Chemical Reactors Porous Media		AP
R8	Batch/Continuous Flow Reactors Flow through Porous Media		WP
L26	Porous Media (cont.)		AP
V. Deformation Processing
L27	Non-newtonian Flow	Various	AP	Problem set 6 due
L28	Deformation Mechanisms	Polymers, Metals	AP
R9	Test 2 Review Warm Up Practice Problems		WP
L29	Sintering	HIP, CM	AP
L30	Test 2		AP
L31	Consolidation Processes	HIP, CM	AP
VI. Vapor-Solid Processes
L32	Evaporation Processes	Zirconia PVD	AP
R10	Sintering (Stage I and Stage II) Evaporation		WP
L33	Vapor Phase Transport Structure Formation	Thin Films	AP	Problem set 7 due
L34	Patterning Polymer Deposition	Polymer Sputter	AP
L35	Coherent/Expitaxial Films Nanostructure Formation	VLS	AP
R11	Mean Free Path Structure Zone Model Fabrication Processes		WP
VII. Special Topics
L36	Process Selection		AP	Problem set 8 due
L37	Costs of Materials Usage		RK
L38	Wrap Up		AP