MAE612: Materials Processing: Theory and Applications

Cornell University, Fall 2001

Professor Nicholas Zabaras



Lecture notes

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Homework

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Basic course info

Credit: 4 Units.

Lectures: Tues./Thurs. 2:55 -- 4:10, Upson 102.

Professor: Nicholas Zabaras, 188 Frank H. T. Rhodes Hall, (607) 255-9104, zabaras@cornell.edu

Office hours: Tuesdays 3:00 -- 4:00 p.m.; Fridays 3:00 -- 4:00 p.m.

References: The course lectures are available on the course web site. Important reference books are:

These books will be on reserve in the Engineering library and you will need to periodically consult them to supplement the lecture notes and to find support material for your project.

Homework: assigned each Thursday and due the following Thursday in the beginning of the class. We will not accept late homework. You are allowed, even encouraged, to work on the homework in small groups, but you must write up your own homework to hand in.

Grading: Homework 50% and Project 50%.

Prerequisites: Previous knowledge of Mechanics of Materials, Heat Transfer, Thermodynamics and Fluid Mechanics will be useful in appreciating the course material. Students will be allowed to concentrate on the Deformation or Solidification related topics of the course depending on their interests and background.

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Course description

This graduate course covers only a few selective topics in deformation and solidification processing. Even though no attempt will be made to cover all aspects of such processes, each student will be allowed as part of the course project to work in depth in a particular area of material processing that is mutually agreeable. Some of the topics to be covered include: Basic principles governing the inelastic behavior of solids. Work hardening, strain rate and temperature dependence of material response. Multiaxial plasticity and creep. State variable approach to constitutive modeling. Slab-analysis models and bound theorems for problems of forging, extrusion, and rolling. Ideal forming techniques. Analysis of sheet-metal forming including limit diagrams and springback. Defect initiation during forming processes. Multi-stage deformation process design. Directional solidification processes. Morphological instability of a solid/liquid interface, solidification microstructures, solute redistribution, micro- and macro-segregation. Thermomechanical defects in casting processes. Eutectic microstructures. Melt flow effects on solidification microstructures. Continuum mushy-zone models. Phase field methods.

Catalog description: Basic principles governing the inelastic behavior of solids. Slab-analysis models and bound theorems for problems of forging, extrusion, and rolling. Analysis of sheet-metal forming including limit diagrams and springback. Defect initiation during forming processes. Basic solidification processes. Morphological instability of a solid/liquid interface, solidification microstructures, solute redistribution, microsegregation, and macrosegregation. Thermomechanical defects in casting processes. Rapid solidification microstructures. Behavior and forming of metal alloys in the semisolid state.

Course objectives:

Intended audience: Graduate Students in Mechanical and Aerospace Engineering, Masters of Engineering students and MAE/MSE seniors (with permission of instructor).

Syllabus

  1. Review of the Mechanics of Materials
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