Atomic and crystal structure. Crystal imperfections. Simple phase diagram of alloys. The relationship between structure and properties. Mechanical, Electrical, Magnetic and  Optical properties of engineering materials. Stability of materials in the service environment, corrosive media, sub-zero and elevated temperature, irradiation. Basic criteria for the selection of materials for engineering applications. Engineering properties of wood, concrete, ceramics, polymers, ferrous and non-ferrous metals and alloys; cryogenic, corrosive media and nuclear applications. Basic Engineering raw materials-mineral rocks, metallic and non-metallic mineral deposits, rocks for bulk use, tar sand, graphites. Mineral prospecting and exploration. Relation between mining, mineral/material processing. Introduction to mineral processing. Introduction to joining and casting processes.

The course will consist of informal seminars and audio-visual demonstration and illustrations of the following: Materials in the service of mankind, etc. The scope of Materials Engineering. History of metallurgical operations in Nigeria. Modern engineering materials processes and operations. Introduction to new and emerging materials-nano and bio-materials. Extraction of metals from ores; materials production and finishing processes. Identification and selection of engineering materials. Laboratory procedures for the investigation of materials structures and properties. Heat treatment equipment and procedures. Property classification. The roles and functions of Materials Engineers in metallurgical, ceramic and plastic industries.

Occurrence and nature of major metalliferous ores. Introduction to industrial mineralogy. Screen distribution analysis of ores. Use of sampling equations e.g. Gy Sampling Equation.

Comminution theory; Classification.of ores. Mineral concentration techniques: Gravity concentration, Heavy medium separation, Froth floatation, Magnetic and electrostatic separation; Selection of mineral concentration equipment. Beneficiation of coals using gravity methods, froth flotation. Leaching methods to produce ultra clean coals (UCC).

Dewatering and tailings disposal. Design, testing and evaluation of mineral beneficiation flowsheets.Introduction to pilot plant ore beneficiation. Raw materials preparation for metal extraction. Factors governing the choice of extraction routes.

Case Studies: Iron ore and coal preparation and agglomeration processes, beneficiation of tin and lead ores

Introduction; lattices; simple and Bravais lattices; crystal system, symmetry, lattice directions and planes; reciprocal lattice, crystal structure; atom sizes and coordination; form, zones, crystal habit; Hermann-Muggin notation, Point groups, Space groups; Intergrowth of crystals: parallel growth, epitaxis, twinning; stereographic projection.

Pre-requisite: MSE 201

Classification and properties of fuels. Fossil fuels and analyses, coal and coke. Charring chemistry, heat treatment and pyrolysis (carbonization). Fuel combustion: flames, chemical kinetics, heat and mass transfer, mathematical models, burning velocities, flame temperatures. Coal carbonization, coking improvement methods. Manufacture of carbon products. Classification of metallurgical furnaces and reactors. Furnace design principles with examples of blast furnace, heat treatment furnace, re-heating furnace. Refractories: Classification and properties, manufacture of alumino-silicates. Polymorphic transformations in SiO₂. Important refractory raw materials: alumina, silica, etc. Application of thermodynamics in refractory selection.

Basic equations of fluid statics and dynamics, Fluxes, Phenomenological laws, and Conservation law, Momentum transfer and viscosity, Convective and diffusive momentum transport. Modes of heat transfer (Conduction, Convection, and Radiation), Steady and unsteady state heat conduction, Heat transfer coefficients. Fick’s law and diffusivity of materials, Mass transfer in fluid systems, mass transfer coefficient. Diffusion as random thermal jumps of atoms (1 d random walk), Self-diffusion coefficients, Vacancy and interstitial mechanisms of self-diffusion, Diffusion in presence of driving force and mobility, Interdiffusion and Darken’s equation, Simple solution of diffusion equation, Grain boundary and surface diffusion. Rate controlling steps in processes, Interface reaction controlled processes, Diffusion controlled processes

One-, two- and three-dimensional stress and strain.  Application of Mohr’s circle for the analysis of stresses and strains. Tensor analysis of stresses and strains.  Creep and fatigue-Theories and experimental techniques. Introduction to fracture toughness of materials. Design against fatigue and fracture failures in critical structures such as aircraft. Experimental stress analysis.

Pre-requisite: CVE 202

Electronic properties:  Conduction mechanisms (ionic and electronic, electrical and thermal),

semi-conductors, Hall effect, thermo-electric effect in semi-conductors.

Magnetic properties: Introduction, magnetic fields in materials, diamagnetism, paramagnetism, ferromagnetism, spontaneous magnetization, magnetic domains, hysteresis, properties of ferromagnetic and ferrimagnetic materials, magnetic materials.

Dielectric properties. Super conductivity.  Manufacture of superconducting materials.

Optical properties: Introduction, basic definitions, optical properties as a function of atomic bonding, birefringence, luminescence, photoconductivity, stimulated emission – masers and lasers, photographic images. Communication materials – optical fibres.

Pre-requisite: MSE 201

Chemical reaction equilibria: Review of thermodynamics function. Fugacity and Activity.

Free Energy. Partial and integral molar thermodynamics functions.  Gibbs-Duhem equations. Ellingham’s diagrams for metal-oxide, metal-chloride and metal-sulphide systems. Application of Ellingham diagrams in metal extraction and heat treatment. Assessment of the application of carbon, silicon, hydrogen and other reductants in metallic production. Theory of solutions:  ideal, actual and dilute solutions. Deviations from ideal behaviour. Raoult’s and Henry’s laws. Activity in multi-component system. Phase equilibria: Equilibria of two-component systems. Free energy composition diagrams; Construction of phase diagrams. Reactions between different phases i.e. slag/metal or slag/metal/gas.

Pre-requisite:  CHE 201.

Concept of solidification of metal – formation of nuclei and dendrites. Liquid-Solid Transformations. Solid-Solid Transformations. Growth and rate of growth. Metal ingot structure. Solidification of alloys, characteristics and types of alloys, theory of alloying,

Segregation: concept of segregation, micro-segregation and macrosegregation. Solute distribution. Solidification phenomenon and grain structure: constitutional supercooling, mechanism of dendritic formation and dendritic growth. Solidification rate, time and Chvorinov’s rule. Fluidity: influence of molten metal characteristics and casting parameters.  Shrinkage: solidification shrinkage, Solidification defects.

Metallography:  Sample preparation; Qualitative and quantitative microscopy; Introduction to photography and photomicrography. Metallographic study of as-cast structures.  Experiments in mineral identification and beneficiation. Simple experiments on extraction processes.

Mechanical Testing:  Tensile, compression, torsion, hardness and creep. Re-crystallization kinetics. Foundry – sand testing and characterisation of foundry materials. Factors affecting the grain structure in cast metal

Structure of the Electrical Double Layer: Helmholtz, Gony-Chapman and Stern models. Electric Potential Difference for Galvanic cell, Electromotive Force (EMF) of a cell. Polarity of an electrode; Reversible cells; Free energy and Reversible EMF; Types of Half-cells (Electrodes); Classification of cells. The standard EMF of cells; Standard electrode potentials; Calculation of EMF of a cell. Electrode concentration cells.

Electrode Kinetics: Homogeneous Chemical Reactions; Rate of electrochemical reactions; Overpotential; Transport or Concentration Overpotential. The hydrogen evolution reaction; Rate-determining step; Transfer coefficient; Symmetry factor and Stoichiometric number. Evaluation of the rate-determining step and the mechanism of the hydrogen evolution reaction. Pre-requisite:  CHM 207

Introduction;  Phases, components, phase rule.

Binary Phase Diagrams – Eutectic systems; Peritectic systems; Solid state transformations, Fe-C, Cu-Al, Pb-Sn systems, eutectoids. Ternary Phase Diagrams – Isothermal sections, isoplethal sections, applications in slag and systems, process of crystallisation, state spaces, state surfaces, system with two-ternary eutectics, system with a ternary eutectic and a ternary peritectic. Illustrations from Iron-Silicon-Aluminium, Tin-Zinc-Copper alloys; allotropic forms of iron in the ternary system. Pre-requisite: MSE 201.

Wave theory of the atom. Schrödinger wave equation and simple applications. Wave particle duality. Uncertainty principle. Exclusion principle. Electron diffraction. Nucleation of phase changes: homogeneous nucleation and heterogeneous nucleation. Diffusion in solids. Grain growth. Crystal Imperfection:  Theoretical strength of crystals; actual strength of crystal. Point defects;  effect of point defects on mechanical properties; observations of point defects.

Line defects; dislocation theory; observation of dislocations; behaviour of dislocation stress field around dislocation; energy of curved dislocation; forces acting on dislocations; dislocation forces. Planar defects, grain boundaries, domain boundaries, stacking faults, twin and twin boundaries. Slip phenomena. Pre-requisite:  MSE 201.

Two- and three-dimensional stress systems. Types of loads: tensile, compressive, torsional, bending, impact, creep and pulsating loads. Types of stresses:  external, internal and thermal stresses. Type of strains:  elastic, plastic and residual strains. Introduction to elasticity and plasticity theories. Dislocation mechanisms in metal deformation; strain hardening theories; deformation texture; anisotropy.  Friction theory and material deformation:  slipping and sticking friction. Yield criteria of metals:  Tresca and von-Mises criteria. Determination of yield stress for uniaxial plane strain and three-dimensional strain systems. Prediction of deformation strains and loads; introduction to slip line field theory; upper bound loads.

Pre-requisite:  MSE 305

Raw Materials Preparation–blending, roasting, agglomeration. Factors governing the choice of extraction process routes. Assessment of the application of carbon, silicon, hydrogen and other reductants in metallic production. Furnaces employed in pyrometallurgical operations; material balance calculations; condensation of metal vapours and associated problems; principles of metal refining; methods available for metal refining; Theory of slags and their roles in metal extraction, structure and properties of slags. Faraday’s laws of electrolysis, ohmic voltage drop in electrolytes, mass transfer controlled reactions, principles of electrochemistry, principles of electrowinning and electro-refining, eletrowinning and electro-refining, electrolysis of fused salts, current efficiency, Leaching reagents, thermodynamics of aqueous solutions, Eh-pH diagrams, aqueous stability diagrams, kinetics of leaching, purification of leach liquor, cementation reduction, thermodynamics of gaseous reduction, hydrogen and metal electrode potential, chemical precipitation, solvent extraction and ion exchange.

Pre-requisites: MSE 301, MSE 310.

Pattern: Types of pattern. Pattern  materials. Design of patterns. Gating system: gating elements and methods, design of gating elements and systems. Riser: Riser and risering curve. Principles of effective risering. Riser placement. Determination of various sections.

Mould and Coremaking: Types of mould and Mould materials. Mould making. Sand conditioning.  Cores: Core materials, Core print. Furnace charge calculations: Trial-and-error, analytical and graphical methods. Application of computer in charge calculations.

Melting and Ladle metallurgy: Melting practice: Types of melting furnaces, characteristics and area of applications. Treatment of melts, refining, gases in metals, degassing, desulphurization, liquid metal cleanliness, inoculation, benefits of ladle practice. Post-solidification processes – shakeout, fettling, cleaning. Casting defects. Metal Casting Processes: Features of various casting processes. Health, Safety and Environment (HSE) in Foundry. Introduction to heat treatment of materials.

Materials Testing: Design of experiments. Tension; Compression; Impact; Bending; Torsion; Hardness; Fatigue; Creep; Viscoelasticity. Analytical Techniques: Pyrometry. Optical and electron microscopy-scanning, transmission. X-ray,  Neutron diffraction. Optical Atomic Spectroscopy-AAS, AES, XRFS, UVS, FTIR. Non-Destructive Evaluation (NDE). Thermal Analysis Methods e.g. dilatometry, thermogravimetry (TG), differential thermal analysis (DTA),  thermomechanical analysis (TMA). Pyrometry.

Review of electrochemistry: Electrochemical basis of corrosion; electrode potentials, etc

Basic principles of corrosion: definition; classification; mechanisms and factors affecting corrosion, types of corrosion, de-alloying (dezincification). Hydrogen damage,  corrosion fatigue etc. Concept of polarization (over potentials): activation, concentration (transport); and resistance polarisation. Passivity/Passivation and Potential-pH (Pourbaix) diagram. High temperature oxidation (mechanism of oxidation, oxidation laws and Pilling-Bedworth  ratio). Case studies: corrosion of steel in the atmospheres, waters, and some chemicals, rebar corrosion, microbial corrosion, corrosion in oil and gas environment e.g. sweet and sour corrosion and corrosion of metals and alloys in high temperature gases and salts.

Strengthening Mechanisms and Processes: Mechanical treatments (e.g. work hardening, shot-peening), Solid solution hardening, Precipitation and Dispersion hardening, Fibre reinforcement, Martensitic strengthening, Grain size strengthening, Thermal treatments (e.g. induction hardening, flame hardening, laser hardening), Thermochemical processing (e.g. carburizing, nitriding, carbo-nitriding), Diffusion coating or Metallic cementation (e.g. aluminium impregnation, chromium impregnation, boron impregnation), Radiation strengthening, Ion implantation. Surface Engineering:  Introduction; Surface modification; Surface coatings. Composite Materials:  Introduction; Classification of composite materials; Fibres and Matrices:  Introduction, carbon fibres; glass fibres, organic fibres; Thermosetting resin, thermoplastics, ceramics and metals; Particulate and whisker reinforcements. Fibre-Matrix Interface:  Theories of Adhesion – Adsorption and wetting, Interfacial bonding, Measurement of bond strength. Unidirectional laminae – continuous fibres; short fibre composites; strength of unidirectional laminae and laminates; strength of short fibre composites. Processing of Metal Matrix Composites (MMC), Ceramic Matrix Composites (CMCs) and Polymer Metrix Composites (PMCs)

Materials casting: Casting of metals and ceramics and other material shaping processes.

Metal melting furnaces and kilns: characteristics and areas of application.Re-heating of slabs and ingots etc. Use of Finite Element method of estimating heat distribution in a slab. Metals Joining: Basic principles of metal joining; Main joining processes e.g. riveting, brazing. Applications for which they are suitable. Forming Processes: Hot and cold  forming processes. Drawing, extrusion, pressing, forging, rolling. Powder Processing: Introduction to processing of metals, ceramic and polymer powders; Diffusion processes in powder metallurgy; Material powder production; The powder metallurgy process,  mixing, blending, compacting, sintering, spark sintering. Forming of engineering ceramics from powders. Secondary operations: Sizing or coining, sinter-forging, extrusions from powders etc.

Properties of powder products; Design of powder metallurgy parts; Powder products; Advantages and shortcomings.

Heat Treatment: Effect of heat treatment on the microsructures of low carbon steels; Metallography of phase transformations. Production Metallurgy: Solidification analogue. Determination of the moisture and clay content of green sand. Determination of heat conduction shape factor by electrical analogue method. Non-Destructive Testings (NDT). Macrostructures and defects. Experiments on refractories: Testing of refractories. Measurements of thermal and electrical conductivity. Experiments on corrosion and wear.

Ironmaking: Review of raw materials for ironmaking. Iron Blast Furnace – Design, reactions and process control. Post-production treatment of the products of the Iron Blast Furnace –

Slag granulation and uses, gas cleaning, flue dust removal and hot metal treatment e.g. desulphurisation, dephosphorisation and desiliconisation; Direct reduction – Process description, reactions and products, process control. Steelmaking: Review of raw materials for steelmaking. Basic Oxygen Steelmaking – Design of the converter, physico-chemical reactions, process and quality control. Electric Arc Steelmaking – Reactor design, continuous feeding, power programme, process and quality control. Alloy steel production e.g.  stainless steelmaking – process and quality control; AOD. Secondary Steelmaking: Clean steel production processes e.g. vacuum induction melting, electroslag remelting, degassers. Other secondary steelmaking processes e.g. calcium treatment and steel desulphurisation. Stirring and injection techniques. Deoxidation of steel: Thermodynamic principles and methods.

Pre-requisite: MSE 301.

Review of the principles of pyrometallurgy, electrometallurgy and hydrometallurgy; Pyrometallurgical process routes and methods of extraction and refining of common non-ferrous metals – aluminium, copper, lead, tin, zinc; Less common non-ferrous metals – magnesium, nickel, cobalt, silver,platinum.

Electrometallurgical process routes of extraction and refining of aluminium, magnesium, titanium, beryllium, and the rare earth metals.

Hydrometallurgical process and methods of extraction and refining of gold, silver, nickel, cobalt, tantalum, uranium, copper, aluminium, hafnium, zinc.

Pre-requisite: MSE 415.

The problem of materials selection, Performance characteristics of engineering materials: physical, mechanical, thermal, electrical, optical and other properties of materials. Factors affecting the selection of engineering materials: fabricability, availability, properties of unique interest, and cost (or economics). Materials selection processes: Sources of information on materials properties. Economics of Materials. Evaluation methods for materials selection: cost versus performance indices, weighted property indices, value analysis, failure analysis and benefit-cost analysis. Case studies in automobile, aircraft, furnace/kiln in construction industries etc.

Heat treatment processes: annealing, normalizing, quenching, tempering, austempering, case hardening, precipitation hardening, solution treatment.  Basic principles of selection of heat treatment conditions using the phase diagram.  Heat treatment of ferrous metals and alloys, cast irons, carbon steels, low alloy steels, tool steels, stainless and heat resisting steels.  Heat treatment of non-ferrous metals, aluminium and alloys, copper and alloys.  Heat treatment defects.  Safety considerations in heat treatment plant.  Heat treatment of glasses (annealing, tempering, etc). Treatment of solid state transformation in some common conventional ceramics like quartz, aluminosilicates, magnesite ceramics among others.

Pre-requisite:  MSE 311.

Process and Plant Design: Technical and economic problems of planning, commissioning and operation of material and mineral processing plants with particular reference to developing countries.  Fundamental principles of material process and plant design.  The design steps; definition of the design problem; development of the basic design module; information sources; conceptualization; development of flow diagrams; selection of processes and equipment; evaluation of design.  Materials-design interaction.  Optimization of design. Problems of safety, hazardous effluent disposal and environment pollution in  materials production Computer-Aided-Design (CAD) and Computer- Aided- Manufacturing (CAM).

Materials Recycling: Economic and environmental benefits of recycling of materials with examples in metals, ceramics, glass and polymer production.

Case Studies: Selected case studies in mineral processing, furnace design, plastic forming of ceramic products,  electroplating, mechanical metallurgy and extrusion of plastics.

Introduction; Structure of ceramic materials;

Fracture strength; Impact resistance and toughness; statistical variations in strength and Weibull distribution. Thermal shock resistance and Thermal spalling resistance; Refractoriness.Deterioration: Chemical attack (e.g. on concrete) at high temperatures (e.g. on ceramic refractories); Nuclear radiation damage. Structure of glass; Transformation Temperature of glass. Glass forming materials, Types of glasses, Properties and Applications.

Glass-Ceramics:  Properties and Applications. Classes of polymers viz: thermoplastics; thermoset; rubbers and elastomers.  Structure of polymers: Chemical composition,  polymerisation, cross-linking and chain branching, molecular weight and molecular-weight distribution, chemical and steric isomerism and stereoregularity, blends, grafts and co-polymers.   Physical structure:  Rotational isomerism, orientation and crystallinity.

Introduction to the basic mechanical properties of polymeric materials. Relationship between structure and properties. Glass transition temperature. Engineering and domestic applications of polymers.

Importance of failure analysis. Procedures and methods of failure analysis. Non-destructive testing methods. Modes of failure. Types of failure. Causes of failure. Stages of failure. Root Cause Analysis. Theoretical and experimental techniques in failure prediction, monitoring and analysis. Fractography. Relationship of failure analysis to design and material selection.

Legal issues involved in failure analysis. Selected case studies.

Introduction; Types of fracture; Crack initiation and propagation. Dislocation theories of fracture. Linear Elastic Fracture Mechanics: Stress concentrators; Griffith theory of brittle fracture; Orowan/Irwin relationship; strain-energy release rate; stress intensity factor; fracture toughness and its determination. Fracture Mechanics for Ductile Materials: Plastic zone correction; crack-opening displacement; J-contour integral; R-curve. Fatigue crack growth.

Probabilistic aspect of fracture mechanics e.g. in ceramic materials. Methods to improve fracture toughness of materials.Interrelation between heat treatment, hardenability, strength and fracture toughness of materials. Materials selection for fracture toughness.

Pre-requisite: MSE 305.

Dependence of macroscopic mechanical behavior of ceramics, metals, polymers, and composite materials on atomic-scale and micro-scale structure of these materials.  Effect of microstructure on elastic response (isotropic and anisotropic), plastic response (room T) and creep (elevated T), fracture and fatigue. Microstructural  contributions to fracture resistance. Effect of temperature, strain rate, and environment on fracture. Main processes of controlling microstructure – alloying,  heat treatment, combined deformation and heat treatment, powder processing. Mechanical properties of PM products.

Fundamental canons of materials engineering practice. Materials Planning Requirements (MRR). Rules for professional conducts. Entrepreneurship skills in Materials Engineering. Professional obligations for materials engineers. Materials engineering practice- public health, safety, environment and sustenable management of natural resources. Necessity of continuing education. Risks assessment, safe waste disposal and prevention of disaster in materials engineering practice.

Introduction to the science and engineering of materials having medical applications. Interactions between cells and surfaces of biomaterials. Surface chemistry and physics of selected metals, polymers, and ceramics. Surface characterization methodology. Modification of biomaterials surfaces. Quantitative assays of cell behavior in culture. Biosensors and microarrays. Bulk properties of implants. Acute and chronic response to implanted biomaterials.  Wear and Biodegradation. Topics in biomimetics, drug delivery, and tissue engineering. Introduction to the science and technology of extremely tiny (about 100 nanometers or less) areas of synthetic and biological materials. Physical and electronic properties of nanomaterials. Examples of current and future areas of application of nanotubes, nanowires, nano sensors, nanotransistors, etc.

Thermodynamics and kinetics of corrosion: potentiostatic/polarisation measurements; Tafel equations, plots and resistance polarisation. Corrosion control techniques: materials selection, materials property modification, modification of the environments, protective coatings, design considerations, cathodic protection and anodic protection.Case studies: protection against various types of corrosion and special cases.Corrosion monitoring techniques: non destructive testing (NDT) methods, Pre-treatment and design for metal finishing. Corrosion testing techniques: Gravimetric and polarisation methods (Tafel and resistance polarisation otherwise called Stern-Geary method).Pre-requisites: MSE 407.

Surface free energy; Gibbs absorption equation; Adsorption by surfactants Physi- and chemisorption on metals. Electroplating: Crystallisation, Addition agents, Electroforming, Electrodeposition. Electrochemical machining: Metal pickling, Restrainers. Friction, Boundary lubrication, Wear and fretting. Factors governing oxidation reactions; Shapes of oxidation curves (linear, parabolic, logarithmic, breakaway). Mechanism of formation of oxide films; Rate of formation of oxides films – defect structure of the oxide lattice in films (positive and negative holes); Effect of alloying on oxidation rate.

Case studies: oxidation of iron, low-alloy steels etc. Pre-requisite:    MSE 310.

Modeling of materials (metals, ceramics, semiconductors, and polymers) processing methods at different length scale using Finite Element, Molecular Dynamics and Monte Carlo methods with softwares such as ABACUS and LAMMPS. Basics of Numerical Computation. Errors and norms, computer arithmetic, condition and stability. Finding roots of nonlinear equations. Numerical quadrature.  Linear least squares and nonlinear fitting . Unit system, non-dimensionalization, dimensional analysis.  Description of a model; pendulum; one-dimensional traffic flow. Basic principles of constructing a model.

Case Studies:

Materials Transport Processes and Selected Materials Processing Problems

Stress-strain analysis of forming processes – wire drawing, forging, extrusion, rolling, Tube and bar drawing. Metal Sheet forming processes: formability, shearing and bending. Spinning, stretch forming, deep drawing, ironing, effect of anisotropic properties on formability, high-energy-rate forming (HERF). Welding: Classification of welding processes: pressure and fusion welding. Welding of alloys and oxidation-prone metals. Weldability of metals. Weld nature, quality, microstructure and properties, welding speed and defects. Heat transfer in welding processes; heat-affected zone.

Introduction: Contact between Surfaces: Brief revision of three-dimensional stresses and Mohr’s circle for stress analysis; Contact stresses; Hertzian stress fields; Materials’ response (compression, tension, junction growth) to these stresses; Sharp contact stress fields; Boussinesq field. Friction: Introduction; Laws of friction; Origins of friction; Theories of friction; Friction of metals; Friction of non-metallic materials. Wear and Surface Damage: Introduction; Mechanisms of wear (e.g. seizure, melt wear, adhesive wear, abrasive wear, oxidation dominated wear, mechanical wear processes (adhesive, abrasive, delamination wear, etc.), fretting and corrosion wear, erosive wear, etc.); Third bodies and wear (e.g. contaminants, debris, etc.). Lubricants and Lubrication. Tribological properties of solid materials. Pre-requisite: MSE 305

Equilibrium and the undercooling requirements. Local equilibrium and interface non-equilibrium. Macro-analysis of solidification dynamics. Micro-analysis of microstructure formation. Nano-analysis of nucleation and growth. Nucleation. Micro-solute redistribution in alloys and microsegregation. Interface stability. Cellular and dendritic growth.. Morphology of primary phases. Interface undercooling and growth velocity models for dendrites. Eutectic, Peritectic and monotectic solidifications. Nucleation and growth kinetics. Formation of macrostructure. Relevant transport equations.  Mathematics of diffusive transport. Solute diffusion controlled segregation. Analysis of solute redistribution. Fluid flow controlled segregation. Governing equation for energy transport. Boundary conditions. Analytical solutions for steady and non-steady-state solidification of castings. Macro-modeling of solidification; Numerical approximation methods. Problem formulation.

Applications of macro-modeling of solidification

Froth flotation collectors, biosolids and other non-conventional collectors, pH in froth flotation, modelling and simulation in froth flotation, low and high intensity magnetic separators, industrial dense medium separations, electrostatic separation of beach sands, mineral processing plant design, introduction to pilot scale mineral processing, mineral processing for PGM ores, metallurgical coke making, current issues in mineral processing, environmental implications of mining and mineral processing operations. Land degradation, environmental pollution, mine and environmental safety, effluent disposal).   Case study: Tin, lead, zinc, tungsten ore processing. Pipeline design. Pre-requisite: MSE 301

Chemical methods for making ceramic powders, colloidal behavior of ceramic particulate suspensions, and the multicomponent, thermo-mechanically processed ceramics. Dry and Semi Dry forming operations; compaction mechanics; granulation, spray drying, plastic forming; drying, firing and fast firing; rheology of extrusion bodies;  binder systems; extrusion process and equipment; plastic molding; casting; interfacial chemistry; slip (filtration) casting; electrophoretic deposition; tape casting; gel casting; spin coating; screen printing; thin Films; PVD and CVD methods e.g. sputtering, laser ablation, etc.;  Formation of glass-ceramics. glass production processes. Glass properties. Glass structure and formation. Relation of physical properties to glass structure and composition.

Learning Outcomes: Specialized skills in ceramics processing

Polymer Engineering: Principles of polymer science and engineering. Structure/property relationships for new applications. Natural and synthetic polymers. Secondary Bonding Concepts/Properties. Molecular Architecture/Microstructure/Macrostructure. Polymer Crystallization and Thermal Transitions. Liquid Crystalline Polymers. Polymeric Additives. Polymer production and forming processes. Vulcanization. Properties/Characterization. Mechanical Properties. Product Design: Case Studies. Recycling and Photodegradants.  Conductivity. Major areas of applications of polymers. Wood Engineering: Types of wood; Composition of wood; Structure; Strength; Effects of service conditions (e.g. moisture and heat); Wood based panels; Degradation; Preservation; Applications.

Learning Outcomes: Knowledge of polymer and wood processing

Review of the unique structure, properties and applications of nanomaterials. Introduction to advances in the synthesis, lithographic patterning and characterization of nanomaterials. Semiconductor and metal nanoparticles and nanowires, carbon fullerenes and nanotubes, organic nanoparticles and dendrimers. Surface physics and chemistry, principles of nanotransistors and nanosensors. Theory and technology of micro/nano fabrication. Basic processing techniques- vacuum processes, lithography etc. Interrelationships between material properties and processing, device structure, and the behavior of devices. Deformation of nanomaterials. Lateral forces at the atomic scale, atomistic aspects of nanoindentation, molecular details of fracture, elasticity of individual macromolecular chains, intermolecular interactions in polymers, dynamic force spectroscopy, biomolecular bond strength measurements, and molecular motors. Nanopowder production and use; nano metal spraying.

Learning Outcomes: Basic knowledge of nanotechnology and processing methods