Teaching

Graduate Courses

• MMAE 533: Fatigue and Fracture Mechanics; Textbook: Deformation and Fracture Mechanics of Engineering Materials by R.W Hertzberg or Mechanical Metallurgy by G.E. Dieter

Course Information: This course mainly focuses on the mechanical deformation of structural materials such as metals and alloys. Fracture Mechanics is an essential tool to evaluate whether a component is likely to fail or not. Thus, in the first part of the course, elastic and plastic deformation are discussed. Additional focus is on the role of defects, microstructure on the mechanical response. In the second part, different types of failure modes will be discussed, including fracture, creep, fatigue under cyclic loading, corrosion, and radiation damage. This course is planned in a simple and step-wise manner to help students familiarize themselves with the basic and advanced topics. Elements of Fracture Mechanics comprehensively covers:

Topics to Be Covered:

Elastic deformation of solids • Plastic deformation of solids • Crystal structure and microstructural defects • Fracture under stress • Corrosion and radiation damage Mixed-mode fracture • Fatigue under cyclic loading • Creep deformation and rupture • Non-destructive test methods • Failure analysis related to material

Student Learning Objectives/Outcomes :

1. Acquire fundamental understanding of the fracture of solid materials.

2. Develop detailed understanding of fracture mechanics, creep, and fatigue.

3. Obtain fundamental knowledge of corrosion and environmentally-assisted cracking.

4. Acquire basic understanding of the techniques used to perform failure analysis.

5. Learn about large variety of fracture mechanisms and fracture modes associated with failure.

6. Become intimately familiar with macro-fractographic and micro-fractographic analysis of failures.

7. Apply understanding to relevant case studies.

• MMAE 588: Additive Manufacturing

Course Information: This course examines the fundamentals of a variety of additive manufacturing processes as well as design for additive manufacturing, materials available, and properties and limitations of materials and designs. It also examines the economics of additive manufacturing as compared to traditional subtractive manufacturing and other traditional techniques. Additive techniques discussed include 3D printing, selective laser sintering, stereo lithography, multi-jet modeling, laminated object manufacturing, and others. Advantages and limitations of all current additive technologies are examined as well as criteria for process selection. Processes for metals, polymers, and ceramics are covered. Other topics include software tools and connections between design and production, direct tooling, and direct manufacturing. Current research trends are discussed.

Topics to Be Covered:

An overview on additive manufacturing techniques • Fusion based additive manufacturing • Binder jet 3D printing • Dynamics of laser-powder interaction • Rosenthal Equation and its application in metal AM • Defects and anomalies in additive manufacturing • process-structure-defect-property relationship in additive manufacturing

Student Learning Objectives/Outcomes:

1. Acquire fundamental understanding of feedstock development for powder bed AM processes

2. Role of powder characteristics in process development and final microstructure of AM parts

3. Defect formation mechanisms

4. Advanced characterization tools such as synchrotron x-ray imaging and computed tomography in AM

5. Effect of heat treatment of microstructure evolution and resultant properties of AM parts

Undergraduate Course

• MMAE 485: Manufacturing Processes for Engineering Materials; Textbook: Manufacturing Engineering and Technology by S. Kalpakjian & S.R. Schmid

Course Information: Principles of material forming and removal processes and equipment. Force and power requirements, surface integrity, final properties and dimensional accuracy as influenced by material properties and process variables. Design for manufacturing. Factors influencing choice of manufacturing process.

Topics to Be Covered:

Introduction to manufacturing processes • Materials properties • Friction, wear, and lubrication in manufacturing processes • Primary manufacturing processes: casting, welding and joining, extrusion, forging, rolling • Secondary manufacturing processes: wire, rod, and tube drawing sheet metal forming, bending, deep drawing • Machining • Advanced manufacturing processes

Student Learning Objectives/Outcomes:

1. Describe the fundamental mechanical behavior of materials and how it relates to the development of manufacturing processes, and properties of commercial products

2. Solve engineering problems that utilize the principles of yield theories in estimating the forces and power required for metal and plastic forming operations

3. Derive and apply analytical relationships that describe the mechanisms related to material removal during machining: heat transfer, cutting tool wear and material removal rates