MATSE 441: Metals Processing

Homepage: http://courseinfo.cet.uiuc.edu (requires login and password)

Textbook: Principles of Metal Manufacturing processes, Beddoes and Bibby (Arnold, 1999).

References:

Metals Handbook, Desk Edition, Q.669.1Am35mabr;
Manufacturing with Materials, L. Edwards, M. Endean, 670.42M4181995;
Mechanical Metallurgy, G. E. Dieter, 3rd edition, 1986, 669.94 D56M1986

Catalog Description, Prerequisites and Schedule:

Discussion of melt, mechanical, thermal, powder and surface processing of metals. Extraction of metals, joining of metals, metal composites and metal recycling are also reviewed. The relationships between the processing of metals, the microstructures that are produced and the behavior of metal components are emphasized. Prerequisite: Senior standing in MATSE, or CEE 210 or M E 231 or MATSE 346 or consent of instructor. 3 hours or 3/4 unit. 3 hours lecture-discussion/week

Course Topics:

1. Extraction of Metals: Pyrometallurgical extraction, Hydrometallurgy, Electrometallurgy.
2. Casting: Sand Casting, Permanent Mold Casting, Solidification, Heat Transfer, Casting defects
3. Metal-working: Classification, Continuum Plasticity, Work Method, Slab Analysis, Forging, Rolling, Sheet Forming, Microstructural Evolution
4. Heat treating: Phase Equilibrium in Fe-C Alloys, Austenitization, Transformation of Austenite, Hardening, Tempering, Other Annealing Processes
5. Powder Metallurgy: Powder Production, Powder Characteristics, Compaction, Densification
6. Surface Processing: Thermal surface processing, Thermochemical surface processing, Coating Processes

Course Objectives:

1. To provide students with a broad knowledge of metals processing techniques commonly used in industry and in research laboratories, in particular extraction metallurgy, casting, forming, heat treating, powder metallurgy and surface processing.
2. To provide students with the chemical, physical and mechanical principles underlying these processing techniques.
3. To demonstrate the correlation between processing conditions, microstructures and properties in common metallic materials.
4. To review and explain the advantages and disadvantages of the different processes studied in class.
5. To give the students a direct contact with several processing techniques in their industrial context.
6. To present methods to optimize processing parameters: work and slab methods for the calculation of forming loads, diffusion equations applied to heat treating and surface processing, chemical and electro-chemical equations to determine conditions for extraction and refining of metals from their ores or compounds.
7. To help students improve their writing and oral skills.
8. To provide the students with an opportunity to study in depth a topic of their choice.

Course Outcomes:

1. Given a processing technique be able to indicate its domain of application, its advantages and its limitations.
2. Given a processing technique be able to identify the important chemical, physical and mechanical principles involved.
3. Given a material and its specifications be able to propose appropriate processing routes to synthesize the part.
4. For the student to have a comprehensive knowledge of steel processing, including iron making and steel making practices, rolling and heat treating.
5. For the student to identify sources of scientific and technological information on a given topic.
6. For the student to develop his/her writing and oral skills.

Assessment Tools:

1. Weekly homework problems involving the material discussed in class or some new material to read and review.
2. A written, close book midterm exam on the first part of the course (topics 1 and 2) designed to test the students ability to apply his/her knowledge.
3. A written, close book final exam on the second part of the course (topic 3 to 6) designed to test the students ability to apply his/her knowledge.
4. An individual term paper and oral presentation on one topic chosen by each student.

Contribution of Course to Meeting the Professional Component:

100%

Prepared by:

Pascal Bellon, updated 8/14/03