MSE 4005: PROCESSING OF MATERIALS IN THE LIQUID AND VAPOR

STATE

Spring 2016

Instructor Professor Theo Z. Kattamis, Phone, cell: (617) 733-6601

tkattami@gmail.com, Office: IMS Room 310

Prerequisites MSE 2101 or MSE 2001

Textbook S. Kalpakjian and S. R. Schmid, “Manufacturing Processes

for Engineering Materials”, 5th Edition, Prentice Hall, Upper
Saddle River, NJ, 2003. Notes and homework assignments will be
distributed.
Major
References (1) M. C. Flemings, “Solidification Processing”, McGraw-Hill,
1974.
(2) B. S. Mitchell, “An Introduction to Materials Engineering and Science for
Chemical and Materials Engineers”, John Wiley & Sons, Hoboken, NJ, 2004.
(3) G. Humpston and D. M. Jacobson, “Principles of Soldering
and Brazing”, ASM International, Materials Park, OH, 1998.
(4) J. S. Reed, “Introduction to the Principles of Ceramics Processing”, John
Wiley & Sons, NY, 1988.

Grade Homework (10%), Midterm (35%), Final (35%), Term Paper (20%)

Office Hours TUE, THU: 8:45-9:05 am (Up and Atom Café), 1:40-2:00 (outside
the classroom), or by appointment.

Syllabus

I. MELTING, CASTING AND SOLIDIFICATION

A. Single Crystals

 Growth processes, heat transfer considerations, solute redistribution, interface

stability
 Zone melting and refining

B. Polycrystalline Ingots and Shaped Castings

 Static Casting Processes

Heat transfer and fluid flow considerations, Risers and Gating Systems. Cellular and
dendritic microstructures, solute redistribution, interface stability, grain structure,
 post-solidification solution treatment. Directional solidification under steady or
nonsteady state conditions.
 Continuous Casting, Novel Casting Processes
 Semi-Solid Processing, Rheocasting, Thixocasting
 Metal Atomization. Thermal Spray
 Melt Spinning

C. Casting of Composites

 Processing of reinforcements from the melt or the vapor state

 Processing of composites by pressure infiltration
 Compocasting

II. SOLID AND LIQUID PHASE SINTERING

III. MATERIALS JOINING IN PRESENCE OF A LIQUID PHASE

 Comparative analysis of welding, brazing and soldering

IV PROCESSING OF CERAMICS IN PRESENCE OF A LIQUID PHASE

V PROCESSING OF POLYMERS

VI VAPOR DEPOSITION

 Methodology, principles, physical and chemical vapor deposition

 Structure and properties of thin films

Exams

There will be a mid-semester and a final exam. Both are closed-books and closed-notes exams.
Guidelines for preparing for the exams will be emailed in due time. There may also be 1-2
quizes.

Hws

The HWs will be e-mailed to you. You will return them when they are due. Soon after, I will e-
mail the answers to you and you will correct the HW with a RED PEN. You finally will grade
fairly and objectively each HW and keep it. Since you will need the HWs to prepare for the
exams, I will collect them after each exam.

Presence in Class

The course is mainly tailor-made for MSE majors. I do not follow the text-book, but I email
notes. You may already have the textbook if you have taken MSE 4004. If you do not, wait to
hear in class what I have to say before you buy it. Systematic absence from class will hurt your
comprehension of the material and performance.