MSE489 : Materials Processing Design

The design of production and refining systems for engineering materials. Design of problems for the extraction and refining of metals, production and processing of ceramics, polymeric materials, and electronic materials. Written and oral presentations of solutions to processing design problems.

Prerequisites: MSE 330 and MSE 335 (enforced)
Cognizant Faculty: Kieffer, Laine, Halloran, Shtein

Course Topics:

DESIGN PROCESS 
Thermodynamic Limits in Materials Processing 
Molecular and Mass Balances 
Generalized Energy Balance 
Rate Laws 
Mass Transport 
Heat Transfer 

PROCESS MODELING 
Heat Exchangers 
Reactor Types 
Non-isothermal Continuous Process 
Flowcharting 
Balance Spaces 
Dynamic Process Models 

PROCESS CONTROL 
Process Design Equations 
Transfer Function 
Dynamic Behavior 
Feedback Control 
Transient Response and Controller Design


Course Objectives:

In the course of the semester, the students learn to:

  1. Analyze and evaluate global and personal energy demands and usage patterns.
  2. Learn the mechanisms and physical principles governing energy conversion.
  3. Estimate the energy generation and storage potential of a wide range of materials.
  4. Use quantitative methods to analyze existing technology and identify environmental, economic, and societal impacts.
  5. Identify viable new technology on the basis of efficiency, economic feasibility, and other considerations.
  6. Design processes for manufacturing materials and devices that will make renewable energy an economically feasible alternative to fossil fuel combustion.
  7. Research, select, retrieve, and analyze highly technical information using modern scholarly search tools.
  8. Work effectively in teams.
  9. Effectively communicate findings and results in written and oral form.
  10. Defend their findings in an open forum consisting of peers and experts.

Course Outcomes:

After taking this course, the students will be able to:

  1. Analyze the efficiency of energy generating and conversion devices.
  2. Calculate the energy density and storage capacity of various devices and materials.
  3. Principles and selection of materials in photovoltaic, piezoelectric, thermoelectric devices, batteries, capacitors, etc.
  4. Evaluate the feasibility of various materials systems for energy conversion and storage.
  5. Relate materials properties to their economic, societal, and environmental impacts.
  6. Develop methods for materials processing based on materials properties and desired device performance.

Assessment Tools:

  1. Written problem sets (E.g., Objectives 1, 2, 4, 8, 9; student performance).
  2. Written reports and oral presentations (E.g., Objectives 1-10; student performance).
  3. Peer / Self / Team evaluation reports (E.g., Objectives 4, 8; student performance).