MSE 36700 Materials Processing Laboratory

Credits and Contact Hours: 3 credits. Weekly Schedule for 15 weeks: two 50 minute lectures, one 3 hour laboratory session.

Instructors or Course Coordinators: K. P. Trumble, J. P. Youngblood, C. Martinez, K. Erk, D. Bahr.

Textbook: No required textbook.

Specific Course Information

  1. Catalog Description: This laboratory is intended as an intensive experience in processing techniques used for ceramics, metals, and polymers. Sintering of a ceramic, casting and post-processing (work hardening, heat treatment, etc.) of a metal, and preparation and extrusion of a polymer are typical of the processes examined in this laboratory. The measurements (e.g., powder particle size, compaction, force, temperature, grain size, molecular weight, density) applicable to the successful processing of the material and the final properties (e.g., hardness, ductility, strength, stiffness) will be emphasized.
  2. Prerequisites: None, Corequisites: MSE 33000
  3. Course Status: MSE 36700 is a required course.

Specific Goals for the Course

1. All Students

A. Demonstrate the use of a variety of processing techniques for metals, ceramics, and polymers and to identify the changes in microstructure and properties they cause.  Examples:

  • Describe the use and internal workings of processing equipment.
  • Describe changes in microstructure and properties of a metal alloy through casting, deformation and heat treat processes.

B. Demonstrate basic teaming skills. Examples:

  • Divide and work on different aspects of the same problem through use of division of labor.
  • Communicate data efficiently and accurately to other members of the laboratory team.

C. Demonstrate effective written communication in lab reports. Examples:

  • Include required subsections in reports
  • Present data in laboratory reports via Tables, Plots and Figures.

D. Demonstrate effective oral communication in final project presentation. Examples:

  • Accurately present basic description of the materials being studied, the processing steps necessary to take the starting materials and create the desired end material and structure.

E. Demonstrate the ability to differentiate chemical and structural processing methods and major types of structural processing. Examples:

  • Understand which types of processing are appropriate for different types of materials

2. Most Students

A. Characterize the physical mechanisms that underlie the basic interactions between macroscopic shaping processes and microstructure development for the core bulk processing routes of each of the main classes of materials and how they relate to properties. Examples:

  • Are able to describe how cooling of a thermoplastic polymer at different rates in extrusion affects crystallinity which in turn affects modulus.
  • Are able to describe how different cold-rolling strains giving different cold-work degrees affecting hardness.
  • Are able to describe the effects of dispersant on the stability of ceramic suspensions and how binder concentration affects green and final bulk density.

B. Assess validity of experimental data and recognize experimental factors affecting data. Examples:

  • Can ask and answer question, “Do experimental values make sense relative to expected values?”
  • Can ask and answer question, “How does thickness variation or presence of pores affect tensile strength values?”

C. Identify specific processing capabilities and limitations for the main classes of materials.  Examples:

  • describe trade-offs of complex shapes and coarse microstructures in metal casting
  • describe why simple shapes are required for molecular alignment in polymers.
  • describe the relationship between formability/densification.

3. Some Students

A. Develop, implement, and communicate plans for multi-step processing experiments.  Apply the objectives listed above to a student-designed processing experiment.

B. Identify possible processing routes to obtain materials with specific shapes and properties.

Relation of Course to Student Outcomes:

(MSE-1, ABET-a) an ability to apply knowledge of mathematics, science, and engineering to problems in materials engineering.

(MSE-2, ABET-b) an ability to design and conduct experiments, as well as to develop engineering judgment through the analysis and interpretation of data.

(MSE-4, ABET-d) an ability to function on multi-disciplinary teams.

(MSE-5, ABET-e) an ability to identify, formulate, and solve engineering problems, particularly in the context of materials selection and design.

(MSE-7, ABET-g) an ability to exhibit effective oral and written communication skills.

(MSE-11, ABET-k) an ability to use the techniques, skills, and experimental, computational and data analysis tools necessary for materials engineering practice.

Topics Covered: Metals: solidification, hardness and deformation, recrystallization; Polymers: crystallization, extrusion, injection molding, mechanical behavior; Ceramics: powder sizing, suspension dispersion and rheology, tape casting, densification.