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Syllabus ( MSE 502 )


   Basic information
Course title: Processing of Materials
Course code: MSE 502
Lecturer: Prof. Dr. Hüseyin YILMAZ
ECTS credits: 7.5
GTU credits: 0 (3+0+0)
Year, Semester: 1/2, Fall and Spring
Level of course: Second Cycle (Master's)
Type of course: Scientific preparation
Language of instruction: English
Mode of delivery: Face to face
Pre- and co-requisites: none
Professional practice: No
Purpose of the course: To understand powder processing and forming operations in manufacturing advanced ceramics having the required properties and specifications. In this course principles of ceramic processing are addressed, including powder synthesis and characterization, organic additives, forming operations, sintering and the basic physical chemistry underlying these operations.
   Learning outcomes Up

Upon successful completion of this course, students will be able to:

  1. Gain knowledge about materials processing.

    Contribution to Program Outcomes

    1. Define and manipulate advanced concepts of Materials Science and Engineering
    2. Formulate and solve advanced engineering problems
    3. Review the literature critically pertaining to his/her research projects, and connect the earlier literature to his/her own results
    4. Embrace modern methods and tools in the field of materials science and engineering
    5. Acquire scientific knowledge
    6. Design and conduct research projects independently
    7. Work effectively in multi-disciplinary research teams
    8. Write progress reports clearly on the basis of published documents, thesis, etc
    9. Defend research outcomes at seminars and conferences.

    Method of assessment

    1. Written exam
  2. To gain knowledge about processing property relationships.

    Contribution to Program Outcomes

    1. Define and manipulate advanced concepts of Materials Science and Engineering
    2. Formulate and solve advanced engineering problems
    3. Review the literature critically pertaining to his/her research projects, and connect the earlier literature to his/her own results
    4. Embrace modern methods and tools in the field of materials science and engineering
    5. Acquire scientific knowledge
    6. Design and conduct research projects independently
    7. Work effectively in multi-disciplinary research teams
    8. Develop an awareness of continuous learning in relation with modern technology
    9. Find out new methods to improve his/her knowledge.
    10. Effectively express his/her research ideas and findings both orally and in writing
    11. Write progress reports clearly on the basis of published documents, thesis, etc
    12. Defend research outcomes at seminars and conferences.

    Method of assessment

    1. Written exam
  3. To design and control ceramic microstructureç

    Contribution to Program Outcomes

    1. Define and manipulate advanced concepts of Materials Science and Engineering
    2. Formulate and solve advanced engineering problems
    3. Embrace modern methods and tools in the field of materials science and engineering
    4. Acquire scientific knowledge
    5. Design and conduct research projects independently
    6. Work effectively in multi-disciplinary research teams
    7. Develop an awareness of continuous learning in relation with modern technology
    8. Find out new methods to improve his/her knowledge.
    9. Effectively express his/her research ideas and findings both orally and in writing
    10. Write progress reports clearly on the basis of published documents, thesis, etc
    11. Defend research outcomes at seminars and conferences.

    Method of assessment

    1. Written exam
   Contents Up
Week 1: Introduction to Ceramic Fabrication Processes; Overview of ceramic materials and processing; Definition of ceramics and the distinctions between ceramic, metals, polymers; Ceramic materials and products; Classification by function; Steps in ceramic processing.
Week 2: Synthesis of Powders; Desirable powder characteristics; Preparation techniques by mechanical and chemical methods; Oxide and nonoxide powders.
Week 3: Powder Characterization; Physical characterization; Chemical and phase composition; Surface characterization.
Week 4: Science of Colloidal Processing; VdW forces; Electrostatic forces; DLVO theory; non-DLVO forces
Week 5: Science of Colloidal Processing VdW forces, electrostatic forces, DLVO theory, non-DLVO forces.
Week 6: Sol-Gel Processing; Acid/base catalysis; Controlled drying agents; Powders; Fibers; Monoliths.
Week 7: Rheology of suspensions; Organic additives.
Week 8: Midterm Exam.
Week 9: Mixing and Packing of Powders Beneficiation and processing additives, comminution, batching, mixing, and granulation.
Week 10: Forming of Ceramics; Powder consolidation and forming of ceramics; Colloidal forming methods; Drained techniques, direct casting and solid freeform fabrication; Pressing; Extrusion; Injection molding.
Week 11: Drying; Debinding and microstructural characterization of green bodies.
Week 12: Sintering and Microstructure Development; Classification of sintering; Importance of sintering; Sintering property relationship; Driving forces for sintering; Diffusion; Defects and defect chemistry; Mechanisms of sintering; Models and sintering equations; Densification; Grain growth; Effects of heterogeneities; Sintering; Liquid-phase sintering.
Week 13: Sintering and Microstructure Development; Classification of sintering; Importance of sintering; Sintering property relationship; Driving forces for sintering; Diffusion; Defects and defect chemistry; Mechanisms of sintering; Models and sintering equations; Densification; Grain growth; Effects of heterogeneities; Sintering; Liquid-phase sintering.
Week 14: Hot pressing; hot isostatic pressing; Microwave sintering; SPS.
Week 15*: General Review.
Week 16*: Final Exam.
Textbooks and materials: M.N. Rahaman, "Ceramic Processing," CRC, Taylor and Francis, 2007.
Mohamed N. Rahaman, "Ceramic Processing and Sintering," Taylor & Francis, 2003.
Terry A. Ring, "Fundamentals of Ceramic Powder Processing and Synthesis," Academic Press, 1996.
Recommended readings: Randal German and G.L. Messing, "Sintering Technology," Taylor & Francis,1996.
Suk-Joong L. Kang, "Sintering: Densification, Grain Growth and Microstructure," Butterworth-Heinemann, 2004
J.S. Reed, "Introduction to the Principles of Ceramic Processing," John Wiley & Sons, NY, 1989.
  * Between 15th and 16th weeks is there a free week for students to prepare for final exam.
Assessment Up
Method of assessment Week number Weight (%)
Mid-terms: 8 40
Other in-term studies: 0
Project: 0
Homework: 0
Quiz: 0
Final exam: 16 60
  Total weight:
(%)
   Workload Up
Activity Duration (Hours per week) Total number of weeks Total hours in term
Courses (Face-to-face teaching): 3 14
Own studies outside class: 3 14
Practice, Recitation: 0 0
Homework: 6 10
Term project: 0 0
Term project presentation: 0 0
Quiz: 0 0
Own study for mid-term exam: 15 1
Mid-term: 1 1
Personal studies for final exam: 10 2
Final exam: 2 1
    Total workload:
    Total ECTS credits:
*
  * ECTS credit is calculated by dividing total workload by 25.
(1 ECTS = 25 work hours)
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