Materials Science and Engineering

This course is intended to serve as a general introduction to various aspects pertaining to the application of synthetic and natural materials in medicine and healthcare. This course will provide the student with a general understanding of the properties of a wide range of materials used in clinical practice. The physical and mechanical property requirements for the long term efficacy of biomaterials in the augmentation, repair, replacement or regeneration of tissues will be described. The physico-chemical interactions between the biomaterial and the physiological environment will be highlighted. The course will provide a general understanding of the application of a combination of synthetic and biological moieties to elicit a specific physiological response. Examples of the use of biomaterials in drug delivery, theranostic, orthopedic, dental, cardiovascular, ocular, wound closure and the more recent lab-on-chip applications will be outlined. This course will highlight the basic terminology used in this field and provide the background to enable the student to review the latest research in scientific journals. This course will demonstrate the interdisciplinary issues involved in biomaterials design, synthesis, evaluation and analysis, so that students may seek a job in the medical device industry or pursue research in this rapidly expanding field. Students cannot receive credit for this course if they have received credit for the Special Topics (ME 593/MTE 594) version of the same course, or for ME/BME 4814 Biomedical Materials.

This course emphasizes research applications of advanced surface metrology, including the measurement and analysis of surface roughness. Surface metrology can be important in a wide variety of situations including adhesion, friction, catalysis, heat transfer, mass transfer, scattering, biological growth, wear and wetting. These situations impact practically all the engineering disciplines and sciences. The course begins by considering basic principles and conventional analyses, and methods. Measurement and analysis methods are critically reviewed for utility. Students learn advanced methods for differentiating surface textures that are suspected of being different because of their performance or manufacture. Students will also learn methods for making correlations between surface textures and behavioral and manufacturing parameters. The results of applying these methods can be used to support the design and manufacture of surface textures, and to address issues in quality assurance. Examples of research from a broad range of applications are presented, including, food science, pavements, friction, adhesion, machining and grinding. Students do a major project of their choosing, which can involve either an in-depth literature review, or surface measurement and analysis. The facilities of WPI’s Surface Metrology Laboratory are available for making measurements for selected projects. Software for advanced analysis methods is also available for use in the course. No previous knowledge of surface metrology is required. Students should have some background in engineering, math or science. Students cannot receive credit for this course if they have received credit for ME 5371/MTE 5843/MFE 5843 Fundamentals of Surface Metrology or the Special Topics (ME 593/MTE 594/MFE 594) version of Fundamentals of Surface Metrology.

Surface Metrology is about measuring, characterizing, and analyzing surface topographies or textures. This course covers conventional and developing measurement and characterization of roughness. It emphasizes research and covers a wide variety of applications, including, adhesion, friction, fatigue life, mass transfer, scattering, wear, manufacturing, food science, wetting, physical anthropology, and archeology. Surface metrology has applications in practically all engineering disciplines and sciences. Research principles are applied to critical evaluations of research methods. Students learn multiscale methods for discovering correlations between processing, textures, and behavior, and for discriminating surface textures supposed to be different because of their performance or manufacture. Results support product and process design, and quality assurance. Students create detailed project proposals on topics of their choosing, including literature reviews, preparation and testing of surfaces, measurements, characterizations, and analyses. Students cannot receive credit for this course if they have received credit for the Special Topics (ME 593/MTE 594/MFE 594) version of this course, or for ME 5370/MTE 5841/MFE 5841 Surface Metrology.

Additive Manufacturing (AM), popularly known as 3D printing, is a technique in which parts are fabricated in a layer-by-layer fashion. The focus of this course is on direct metal AM processes that are used in aerospace, automobile, medical, and energy industries. The objective of the course is to enable students to understand the working principles of various additive manufacturing processes, assess the suitability of metal AM processes for different designs and applications, apply process design concepts to metal AM processes via analytical and finite element modeling approaches, and have an introductory-level understanding of design for AM. Through the course project, students will have the opportunity to experience hands-on design, manufacturing, and characterization of additively manufactured materials, and will work in an interdisciplinary team of mechanical, materials, and manufacturing engineers. The economics of the manufacturing process will also be addressed, with an emphasis on determining the major cost drivers and discussing cost minimization strategies. Students cannot receive credit for this course if they have received credit for the Special Topics (ME 593/MTE 594) version of the same course.

The objective of this course is to provide students with an understanding of the working principles, design, fabrication and characterization of established and emerging solar cell technologies. Students will be exposed to the electronic properties of semiconductor materials, which are the building blocks of solar cells, and the analysis of photo-generation and extraction of charges in these materials. The course will emphasize the influence of the atomic-, nano- and micro-scale structure of the materials on the solar cell performance. In addition, the challenges of economics and scalability that must be addressed to increase the deployment of solar cells will be discussed. Students cannot receive credit for this course if they have received credit for the Special Topics (ME 593/MTE 594) version of the same course.

The course starts with an in-depth study of axiomatic design. Applications of axiomatic design are considered primarily, although not exclusively, for the design of manufacturing processes and tools. Axiomatic design is a design methodology based on the premise that there are two axioms that apply to all good designs. These axioms facilitate the teaching and practice of engineering design as a scientific discipline. Manufacturing process analysis is considered from the perspective of supporting design. Methods of analysis of manufacturing processes with broad applicability are sought. Special attention is given to examples in machining (traditional, nontraditional and grinding), additive manufacturing, and to the production of surfaces. The ability to find commonalities across applications and generalize is emphasized to facilitate further development of principles with broad applicability. The content is delivered in video lectures and in readings from the technical literature. Homework and quizzes are given and delivered online. There is a project to design a manufacturing process. The topics can be from work or dissertations that can be interpreted as manufacturing processes and tools. Credit cannot be given for this course and any of the similar, in-class versions for 3 credits, MFE 520, MTE 520 and ME 543

This course begins with elements axiomatic design, the theory and practice. Design applications are considered primarily, although not exclusively, for the design of manufacturing processes and tools. Axiomatic design is based on the premise that there are common aspects to all good designs. These commons aspects, stated in the independence and information axioms, facilitate the teaching and practice of engineering design as a scientific discipline. Analysis of processes and products is considered from the perspective of supporting product and process design. Fundamental methods of engineering analysis of manufacturing processes with broad applicability are developed. Attention is given to examples from one or more of the following: machining (traditional, nontraditional and grinding), additive manufacturing, and to the production of surface topographies. The ability to generalize from detailed examples is emphasized in order to facilitate the students’ ability to development analyses and design methods with broader applicability. This course is offered live, in-class only, to be completed in one semester, for three credits. Credit cannot be given for this course and any of the similar, online versions of this material for 2 credits: MFE 521, MTE 521.

An introductory course on electrochemical engineering, fuel cells and batteries. With escalating oil prices and increasing environmental concerns, increasing attention is being paid to the development of electrochemical devices to replace traditional energy. Here several types of batteries and fuel cells will be discussed. Topics covered include: basic electrochemistry, lithium ion battery, proton exchange membrane fuel cell, solid oxide fuel cell, electrochemical method. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course.

This course introduces students to the theory, fundamental operating principles, and specimen preparation techniques of scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy dispersive x-ray spectroscopy (EDS). The primary emphasis is placed on practical SEM, TEM, and x-ray microanalysis of materials. Topics to be covered include basic principles of the electron microscopy; SEM instrumentation, image formation and interpretation, qualitative and quantitative x-ray microanalysis in SEM; electron diffraction and diffraction contrast imaging in TEM. Various application examples of SEM and TEM in materials research will be discussed. Lab work will be included. The course is available to graduate students.

This course, (along with its companion course MTE 512 Properties and Performance of Engineering Materials), is designed to provide a comprehensive review of the fundamental principles of Materials Science and Engineering for incoming graduate students. In the first part of this 2 course sequence, the structure in materials ranging from the sub-atomic to the macroscopic including nano, micro and macromolecular structures will be discussed to highlight bonding mechanisms, crystallinity and defect patterns. Representative thermodynamic and kinetic aspects such as diffusion, phase diagrams, nucleation and growth and TTT diagrams will be discussed. Major structural parameters that effect of performance in materials including plastics, metallic alloys, ceramics and glasses will be emphasized. The principal processing techniques to shape materials and the effects of processing on structure will be highlighted. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594S

The two introductory classes on materials science (MTE 511 and MTE 512) describe the structure-property relationships in materials. The purpose of this class is to provide a basic knowledge of the principles pertaining to the physical, mechanical and chemical properties of materials. The primary focus of this class will be on mechanical properties. The thermal, tensile, compressive, flexural and shear properties of metallic alloys, ceramics and glasses and plastics will be discussed. Fundamental aspects of fracture mechanics and viscoelasticity will be presented. An overview of dynamic properties such as fatigue, impact and creep will be provided. The relationship between the structural parameters and the preceding mechanical properties will be described. Basic composite theories will be presented to describe fiber-reinforced composites and nanocomposites. Various factors associated with material degradation during use will be discussed. Some introductory definitions of electrical and optical properties will be outlined. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594P).

Thermodynamics of solutions—phase equilibria— Ellingham diagrams, binary and ternary phase diagrams, reactions between gasses and condensed phases, reactions within condensed phases, thermodynamics of surfaces, defects and electrochemistry. Applications to materials processing and degradation will be presented and discussed. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594T).

The objective of this course is to introduce the basic principles of computational thermodynamics (CALPHAD). Students will be exposed to the basic thermodynamic simulation in single-component, binary, ternary, and higher-order systems for various alloys and ceramics systems. The course will emphasize the linkage of computational thermodynamics with the real industry challenges faced in the next-generation materials design. In addition, the fundamental concepts of multiscale modeling, including the atomic scale, mesoscale and macroscale modeling, will also be introduced to students. Recommended Background: A graduate major in engineering or science is recommended, but not required. It is preferred that students have taken MTE526/ME5326 Advanced Thermodynamics or equivalent courses.

This course discusses the fundamentals of crystallography and X-ray diffraction (XRD) of metals, ceramics and polymers. It introduces graduate students to the main issues and techniques of diffraction analysis as they relate to materials. The techniques for the experimental phase identification and determination of phase fraction via XRD will be reviewed. Topics covered include: basic X-ray physics, basic crystallography, fundamentals of XRD, XRD instrumentation and analysis techniques. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594C).

Heat transfer and diffusion kinetics are applied to the solution of materials engineering problems. Mathematical and numerical methods for the solutions to Fourier’s and Pick’s laws for a variety of boundary conditions will be presented and discussed. The primary emphasis is given heat treatment and surface modification processes. Topics to be covered include solutionizing, quenching, and carburization heat treatment.

This course is intended to provide a fundamental understanding of thermodynamic and kinetic principles associated with phase transformations. The mechanisms of phase transformations will be discussed in terms of driving forces to establish a theoretical background for various physical phenomena. The principles of nucleation and growth and spinodal transformations will be described. The theoretical analysis of diffusion controlled and interface controlled growth will be presented The basic concepts of martensitic transformations will be highlighted. Specific examples will include solidification, crystallization, precipitation, sintering, phase separation and transformation toughening.

A material whose properties can respond to an external stimulus in a controlled fashion is referred to as a smart or intelligent material. These materials can be made to undergo changes modulus, shape, porosity, electrical conductivity, physical form, opacity, and magnetic properties based on an external stimulus. The stimuli can include temperature, pH, specific molecules, light, magnetic field, voltage and stress. These stimuli-sensitive materials can be utilized as sensors and as vehicles for the controlled delivery of drugs and other biomolecules in medical applications. Smart materials are also becoming important in other biological areas such as bio-separation, biosensor design, tissue engineering, protein folding, and microfluidics. The use of stimuli-sensitive materials is receiving increasing attention in the development of damage tolerant smart structures in aerospace, marine, automotive and earth quake resistant buildings. The use of smart materials is being explored for a range of applications including protective coatings, corrosion barriers, intelligent batteries, fabrics and food packaging. The purpose of this course is to provide an introduction to the various types of smart materials including polymers, ceramic, metallic alloys and composites. Fundamental principles associated with the onset of “smart” property will be highlighted. The principles of self-healable materials based on smart materials will be discussed. The application of smart materials in various fields including sensors, actuators, diagnostics, therapeutics, packaging and other advanced applications will be presented. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594).

This course will provide an integrated overview of the design, selection and use of synthetic plastics. The basic chemistry associated with polymerization and the structure of commercial plastics will be described. Various aspects of polymer crystallization and glass transition will be outlined. Salient aspects of fluid flow and heat transfer during the processing of plastics will be highlighted. Fundamentals of the diverse processing operations used to shape plastics and the resulting structures that develop after processing will be discussed. The mechanical behavior of plastics including elastic deformation, rubber elasticity, yielding, viscoelasticity, fracture and creep will be discussed. Plastic degradation and environmental issues associated with recycling and disposal of plastics will be examined. Typical techniques used in the analysis and testing of plastics will be described and a working knowledge of various terminologies used in commercial practice will be provided. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 594A).

The failure and wear-out mechanisms for a variety of materials (metals, ceramics, polymers, composites and microelectronics) and applications will be presented and discussed. Multi-axial failure theories and fracture mechanics will be discussed. The methodology and techniques for reliability analysis will also be presented and discussed. A materials systems approach will be used. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course (MTE 593C/MTE 594C).

This course introduces students to current developments in nanoscale science and technology. The current advance of materials and devices constituting of building blocks of metals, semiconductors, ceramics or polymers that are nanometer size (1-100 nm) are reviewed. The profound implications for technology and science of this research field are discussed. The differences of the properties of matter on the nanometer scale from those on the macroscopic scale due to the size confinement, predominance of interfacial phenomena and quantum mechanics are studied. The main issues and techniques relevant to science and technologies on the nanometer scale are considered. New developments in this field and future perspectives are presented. Topics covered include: fabrication of nanoscale structures, characterization at nanoscale, molecular electronics, nanoscale mechanics, new architecture, nano optics and societal impacts.

Reports on the state-of-the-art in various areas of research and development in materials science and engineering will be presented by the faculty and outside experts. Reports on graduate student research in progress will also be required.

Theoretical or experimental studies in subjects of interest to graduate students in materials science and engineering.

The objective of this course is to provide students with an understanding of the working principles, design, fabrication and characterization of established and emerging solar cell technologies. Students will be exposed to the electronic properties of semiconductor materials, which are the building blocks of solar cells, and the analysis of photo-generation and extraction of charges in these materials. The course will emphasize the influence of the atomic-, nano- and micro-scale structure of the materials on the solar cell performance. In addition, the challenges of economics and scalability that must be addressed to increase the deployment of solar cells will be discussed. Students cannot receive credit for this course if they have received credit for the Special Topics (ME 593/MTE 594) version of the same course.

This course develops an understanding of the processing, structure, property, performance relationships in crystalline and vitreous ceramics. The topics covered include crystal structure, glassy structure, phase diagrams, microstructures, mechanical properties, optical properties, thermal properties, and materials selection for ceramic materials. In addition the methods for processing ceramics for a variety of products will be included. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course.

An introductory course on corrosion; aqueous corrosion, stress corrosion cracking and hydrogen effects in metals will be presented. High-temperature oxidation, carburization and sulfidation will be discussed. Discussions focus on current corrosive engineering problems and research. Note: Students cannot receive credit for this course if they have taken the Special Topics version of the same course.