J. B. Puthoff Cal Poly Pomona MTE 406

MTE 406 Physical Metallurgy – Solidification and Strengthening Reactions

Spring 2018

Syllabus

1. Timetable Information Course Number 32347 (Section 01) Class Time MoWe 12:00–01:15 PM Lab Time Mo 03:00–05:50 PM (section 10) Fr 08:00–10:50 AM (section 11) Th 01:00–03:50 PM (section 12) Room 17-1631 (lecture) and 17-1114 (lab) Credits 3 2. Instructor Name Jonathan Puthoff Office 17-2106 Telephone (909) 979-5678 Email jbputhoff@cpp.edu Office Hours MoWe 10:00 AM – 12:00 PM TuTh 01:00–02:00 PM By appt. (Please use your “@cpp.edu” email address to request an appointment.) 3. Text Phase Transformations in Metals and Alloys (3rd Edition, revised reprint) by D.A. Porter, K.E. Easterling, and M. Sherif (CRC Press, Boca Raton, FL, USA), 2009. ISBN: 978-1420062106.

The text is optional for this course (although you should note that the book is a paperback and can be obtained at low cost). There are few books out there on this subject that discuss the issues as effectively as this one. Reading this book will likely enhance your understanding of the course material. Books like Materials Science and Engineering - An Introduction (8th or 9th Edition) by William D. Callister, Jr. and David G. Rethwisch, Physical Metallurgy Principles by Reza Abbaschian and Robert E. Reed-Hill, and Metallography: Principles and Practice by George F. Vander Voort (available as a Google eBook) are good references. 4. Course Description The CPP catalog describes this course as involving the

[p]rinciples of solid-state reactions including elementary kinetics, nucleation and growth theory; annealing of cold-worked metals; diffusionless transformation, precipitation reactions and tempering; physical metallurgy of steels; relation between properties and microstructure. Laboratory experiments related to phase transformations in steel, solidification structures, precipitation hardening, and plant trips. 3 lectures/problem-solving and 1 three-hour laboratory. Prerequisites: MTE 207 (or ME 315); CHE 302 (or ME 301).

J. B. Puthoff Cal Poly Pomona MTE 406

The motto of materials science is “The microstructure determines the properties.” In practice, this means that the ability of a material to perform an engineering function depends on what it looks like under a microscope. In many materials, particularly metallic alloys, the microscope reveals a mixture of phases in a particular arrangement. To make materials with the required properties, we must first understand how these microstructures arise. When we do, the required microstructure can be achieved through the controlled transformation and/or redistribution of the phases.

The name of the course is “physical metallurgy,” and we will study the essential physics governing the development of microstructures. In particular, we can infer the transformations that are possible, and under what conditions they will occur, using thermodynamics. We can determine how long they will take using kinetics. Hence, the content of this course primarily involves these topics as they pertain to materials with different chemical makeups subjected to different conditions. Our in-class discussions will touch on many different chemical, physical, and engineering subjects, so expect to encounter topics that will be unfamiliar to you. We will investigate these topics using simple physical pictures and model systems, and the fundamental principles we discover will provide a foundation for understanding processes and systems in more detail in our future work.

This course has a significant problem-solving component, and the wide range of topics that we will discuss indicates a correspondingly wide range of different types of problems that can be formulated and solved. In some cases, these problems are just extensions of problems considered in an introduction to materials course; in other cases, they will involve new and unfamiliar physical and engineering principles. They may seem difficult at first, but you will succeed at these problems with a thoughtful and dogged approach. Remember that problem-solving skills are what you are here to learn and that this is your opportunity to practice. 5. Course Objectives This is an upper-level course in materials science and engineering for College of Engineering majors. The course is primarily intended for students in mechanical, aerospace, and chemical engineering who wish to learn more about the physical basis of the development of microstructure in engineering materials. This course provides essential understanding of the thermophysical behavior of liquids, solids and transformations between different phases from a fundamental standpoint. At the end of this course, you should be able to:

a) Describe quantitatively the different types of crystalline structures, as well as the (qualitative) structure of noncrystalline materials;

b) describe qualitatively and quantitatively the predominant defects types in solids, their quantity and distribution, and analyze how they influence the kinetics of transformation;

c) describe the microscopic structure of solid-state solutions/alloys; d) understand the physical underpinnings/kinetics of solid-state diffusion and solve

problems in carburization/nitridization/aluminization and doping; e) interpret phase diagrams and relate their topology to the underlying solution

thermodynamics; f) differentiate the different types of phase transformations (melting, solidification,

precipitation, eutectic/peritectic cooling, diffusionless) commonly found in materials processing;

J. B. Puthoff Cal Poly Pomona MTE 406

g) analyze connections between processing conditions, transformation parameters, and the resulting microstructures; and

h) interpret the role of transformation kinetics in a number of systems of great practical importance, such as steel and aluminum.

Note that there are objectives that merely require you to know something (“understand,” “identify,” “describe”) and some that require you to do something with the knowledge (“calculate,” “draw,” “apply”). Pay close attention when subjects associated with the latter objectives come up; important related problems will be developed and solved. If you can master the above objectives, you will become a much better engineer! 7. Class Schedule (subject to slight change)

Week Topics Reading/Problems

1 Introduction, materials chemistry, structure of crystals and

polycrystalline solids Reading 01

Problem Set 01

2 Thermo. review, point defects, solid solutions and mixtures Problem Set 02

3 Diffusion, Fick’s Laws Reading 02

Problem Set 03

4 Carburization, interdiffusion

5

Exam 01

Crystal interfaces and microstructure, annealing and grain growth

Reading 03 Problem Set 04

6 Phase diagrams Reading 04

Problem Set 05

7

Kinetics of nucleation and growth, solidification, diffusional transformations

Problem Set 06

8 Precipitation and precipitation hardening, transformations

in steel, TTT diagrams

9 Exam 02

Materials processing, steel & cast irons

Reading 05 Problem Set 07

10 Materials processing, superalloys, martensitic

transformations

11 FINAL EXAM PERIOD Wed., Jun. 6, 11:30 AM – 01:30 PM

J. B. Puthoff Cal Poly Pomona MTE 406

7. Grading Attendance/Participation 10% Quizzes 20% Problem Sets 10% Midterm Exam 1 20% Midterm Exam 2 20% Final Project 20% Extra Credit +2–5% 8. Laboratory This course includes a laboratory component in which we will conduct, discuss, analyze, and communicate the results of representative experiments in physical metallurgy. There are a number of goals for this laboratory:

a) Familiarize ourselves with the tools and techniques for the measurement/ investigation of materials phenomena;

b) investigate structure/property relationships in some important materials systems; c) apply the knowledge of materials processing acquired in the classroom in an practical

setting; d) practice good laboratory safety and record-keeping skills; and e) develop good technical communication (written, graphical, verbal) skills.

The laboratory will involve assignments in the communication of experimental results and conclusions. 9. Lab Schedule Please consult with the lab instructor. 10. Laboratory Safety As students, you are responsible for maintaining many aspects of laboratory safety. These aspects include the wearing of long pants, closed-toed shoes, safety goggles, and other protective apparel where necessary. In addition, long hair must be tied back, and willful disregard for safety principles will result in dismissal from the classroom. If you observe unsafe working conditions and alert the other students or go to extra lengths to ensure a safe working environment, the instructor can assign extra credit. 11. Class Participation, Attendance, and Communication Coming to class is an important part of any college course, so I encourage everyone to attend every lecture. I have deliberately structured the course so that you may obtain credit by attending lectures/problem-solving sessions. If you are not able to come to class, please let me know before the class session in question. The classroom is the ideal location for answering your questions about the course material and discussing how the subject matter is related to engineering more broadly, so it is to your advantage to attend and participate. Laboratory attendance and participation is mandatory in the strictest possible sense.

Course information and updates are posted to the Blackboard page for the course, so checking this resource frequently will help you succeed. It is also a good idea to communicate with your instructors using official University channels only. Always send emails from your “@cpp.edu”

J. B. Puthoff Cal Poly Pomona MTE 406

account. Also, please be sure to check this account frequently, since notifications and official emails about the course will be directed there. 12. Quizzes and Exams Quizzes are given at the beginning of class every Friday and will be around 20 min. Please be sure to attend class on these days and be on time. Under extenuating circumstances, missed quizzes can be removed from consideration in your final grade. There are no makeup exams without an excused absence (proper documentation is required to support absence from exams, e.g., a letter from a physician).

These quizzes are intended to be a low-stakes (though mandatory) opportunity to get feedback on your grasp of the material. The exams will establish whether or not you have met various learning goals. If you keep up with the reading, review the lecture notes, and understand the weekly problem-set solutions, you will succeed on the quizzes and exams.

13. Problem Sets This course is an opportunity to familiarize yourself with new types of engineering problems and their solutions. To get the most out of this component of the course, you should dedicate sufficient time to studying, solving, and writing up solutions to the problems. Feel free to work on these with classmates and use any computer resources you wish. Your instructor is always available for consultation, but you must ask for help well ahead of time. 14. Assignment of Final Grades You final grade is a real number in the interval [0, 100]. The grading scale is

Superior Work A

A– [96, 100] [92, 96)

Good Work B+ B

B–

[88, 92) [84, 88) [80, 84)

Adequate Work C+C

C–

[75, 80) [70, 75) [65, 70)

Minimally Acceptable Work

D+D

D–

[60, 65) [55, 60) [50, 55)

Unacceptable Work F [0, 50)

15. Cheating and Academic Misconduct All forms of academic dishonesty at Cal Poly Pomona are a violation of university policy and will be considered a serious offense. Academic dishonesty includes but is not limited to:

a) Plagiarism, falsification, fabrication; b) cheating during exams; c) use of unauthorized study aids; and

J. B. Puthoff Cal Poly Pomona MTE 406

d) falsifying any University document. See http://catalog.cpp.edu/content.php?catoid=10&navoid=1220#Academic_Integrity for more information.

Consequences for academic dishonesty will include retroactive assignment of grades of zero or dismissal from the class. Additionally, students may be referred to Judicial Affairs where they may face additional consequences. Please inform yourself about what constitutes academic dishonesty and follow the policy! Cal Poly Pomona students who come from various international educational systems and wish to understand better the expectations of the American educational system are encouraged to speak with an international student advisor in the International Center. 16. Accommodations for Students with Disabilities If you are a student with a documented disability and anticipate needing accommodations in this course, please contact me as soon as possible so that we can discuss your specific needs. You will need to bring your “Notification of Accommodations” issued by the Disability Resource Center which verifies the specific accommodations which you have been approved to use. 17. Technology in the Classroom Laptops and mobile devices have a place in the classroom, but they can also be sources of distraction. You are welcome to use these devices for academic purposes in class, but repeated difficulties may necessitate a policy change. Please disable audio notifications during class. Mobile devices must be secured during quizzes and exams (see “Cheating and Academic Misconduct,” above).