MSE220 : Introduction to Materials and Manufacturing

Introduction to Materials Engineering and materials processing in manufacturing. The engineering properties of metals, polymers, semiconductors, ceramics, and composites are correlated with the internal structure of the materials and the service conditions.

Prerequisites: CHEM 130 or CHEM 210 (enforced)
Textbook: William Callister, Materials Science and Engineering: An Introduction,9th Ed.
Cognizant Faculty: Robertson, Halloran, Wynarsky, Millunchick
Instructor: John Heron
Instructor: Kathleen Sevener

Course Topics:

  1. Atomic bonding, crystallography, defects.
  2. Diffusion.
  3. Mechanical properties, strengthening mechanisms.
  4. Failure of materials and engineering components.
  5. Phase diagrams.
  6. Microstructural and nanostructural design of materials.
  7. Heat treatment processes for metallic alloys.
  8. Polymers and polymer processing.
  9. Composites and composite processing.
  10. Ceramics and ceramic processing.
  11. Electrical properties.
  12. Semiconductor device processing and thin films.

Course Objectives:

  1. To teach students the elementary relationships between structure, properties, processing and performance of materials that are essential for understanding the role of materials in the design of engineering systems.
  2. To introduce students to the various classes of materials (metals, ceramics, polymers, semiconductors, composites) and their fundamental chemical and structural nature.
  3. To illustrate application of thermodynamics (through phase diagrams) and kinetics (through diffusion) to the design of materials and their properties.
  4. To introduce students to the functional properties of materials and the roles that microstructure, defects, and environment play in typical engineering applications.
  5. To introduce students to manufacturing methods for engineering materials.
  6. To stimulate student interest in and appreciation of Materials Science and Engineering by critical examination of engineering case studies.

Course Outcomes:

  1. Using concepts of inter-atomic bonding, be able to predict fundamental physical properties of different classes of materials.
  2. For a particular crystal structure, determine the crystallographic directions and planes, and the linear and planar atomic densities.
  3. Related plastic deformation and cold work to strength of metals.
  4. From fracture toughness, mechanical strength and loading configuration of a material component, calculate the maximum tolerable flaw size within a practical safety factor.
  5. Given a binary phase diagram and a particular alloy composition at a given temperature, determine the phases expected to be present, and calculate their compositions and the volume fraction of each phase.
  6. For a binary eutectic phase diagram, determine the microstructures expected for various alloy compositions cooled from the melt at different cooling rates.
  7. Using the concept of a TTT diagram, determine the heat treatment of a eutectoid steel required to produce a specified strength, hardness and ductility.
  8. Demonstrate knowledge of the relation between semiconductor conductivity and band gap energy states.
  9. Demonstrate ability to relate structure of polymers to properties and processing methods.
  10. Demonstrate relationship of composite properties to the properties of constituents.
  11. Demonstrate ability to predict corrosion behavior of materials.
  12. Be able to assess appropriate manufacturing methods for diverse items from various materials.

Assessment Tools:

  1. In-class closed-book exams and quizzes test outcomes #1-8 for individual students.
  2. Weekly problem sets test outcomes #1-8 under less time pressure and with allowable student collaboration.
  3. Weekly discussion sections for student-instructor interaction on learning.
  4. End-of-term written evaluations by students allow instructor to improve the next offering of the course.