Materials Processing and Characterization 

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Analysis and Characterization of Materials (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction to Metallographic Testing. Presentation. Structures of materials and relation with processing and properties: macrography; micrography. Aim of the analysis Layout of a metallography laboratory. Bodies of evidence or samples. Selection of the analysis region. Process of manufacturing or processing. Location of the sample. Precautions in taking samples: cutting; assembly or inlay. Identification. Sanding: manual, automatic, sequencing. Polishing: manual, automatic, electrochemical. Storage. Attacks. Chemical attacks. Macro-attack. Micro-attack. Special attacks: electrolytic, ionic, oxidation. Main reagents and procedures. Print from Baumann. Visual methods: visual; photography; microscopy; optics. Making replicas. Fracture surface. Quantitative analysis. Methods of determination of grain size (ASTM E 112-96). Comparison method. Austenitic and ferritic grains. Grain fracture. Planimetric or Jeffries method. Intersection method. Linear intersection or Heyn's procedure. Simple circular procedure (Hilliard) or 3 circles (Abrams). Non-equiaxed grains. Materials with multi-phases or constituents (ASTM and 1181). Scanning and Transmission Electron Microscopy. X-ray diffraction. Description and Operation of M.E.V .; Detection Systems and modes of operation of the instrument. Grain count, porosity and dendritic spacing. Visualization of macro and micrographs. Crude melting structures: carbon steels, white cast iron, gray, nodular, non-ferrous metals, pure metals, non-ferrous metals, pure metals, pure metals. Structures conformed: traction, compression, lamination, traction, compression, lamination. Thermally treated structures, carburizing, hardening by precipitation, quenching.

Characterization of Metallic Materials (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction; factors that influence the selection of materials; tests on metallic materials related to the composition and structure; thermal and metallographic analysis; plastic forming tests; optical microscopy, scanning electron microscopy, XRD; case study in fault analysis.

Polymer Science (4 Credit Units, 60 Credit Hours)

Syllabus: Molecular structures, molar masses, configuration and conformation of polymer chains; thermodynamics of primary and secondary transitions; behavior of polymers in solution; blends, additives and compatibilizations; crystalline morphology; mechanisms and kinetics of polymer crystallization; XRD diffraction and FTIR spectroscopy; TGA thermogravimetry and DSC enthalpy changes; thermomechanical analysis by TMA and dynamic mechanics by DMA.

Control of Solidification Structure (4 Credit Units, 60 Credit Hours)

Syllabus: Crystalline structures: introduction. Main crystalline structures. Cubic Crystals Simple Cubic (CS), Cubic Centered Faces (CFC), Cubic Centered Body (CCC). Crystalline Hexagonal Structures. Hexagonal Simple (HS), Hexagonal Compact (HC). Crystalline directions and crystalline planes. Crystal clear imperfections. Solidification of metals: introduction. Main objectives of the study of metal solidification. Math analysis. Main methods developed for the study of heat transfer in the solidification of metals. Nucleation and Growth: introduction. Homogeneous nucleation. Heterogeneous nucleation. Main characteristics of a substrate. Growth morphology of the solid core. Solidification microstructure: introduction. Microstructures of pure metals. Impure metal microstructures and single-phase binary alloys. Microstructures of Polyphase Binary Alloys-Eutectic System, Perithetic System. Solidification Macroestructures: introduction. Main Solidification Structures - Coquilhada Zone, Columnar Zone, Central Equiaxial Zone. Control of solidification structures: introduction. Objectives of the control of the Solidification structures - Coquilhada Zone, Colunar Zone, Central Equiaxial Zone. Grain Refining Methods and Processes Based on the Mechanical Method, Grain Refining Processes Based on the Chemical Method, Grain Refining Processes Based on the Thermal Method. Final considerations.

Wear of Materials (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction; definition of wear; generalities; ranking; wear mechanisms: by adhesion, abrasion, oxidation, surface fatigue, corrosion, etc .; Design for wear; wear-resistant materials; equipment for simulation of wear: rubber wheel, CIAT (Continuous Impact and Abrasion Test), etc.

Solidification Structures (4 Credit Units, 60 Credit Hours)

Syllabus: Initial considerations: technological importance of the solidification phenomenon of metals; interfacial coefficient of heat transfer; unidirectional solidification; solidification macrostructures; columnar-equiaxial transition; solidification microstructures; correlation between thermal parameters, structural parameters and properties of metallic materials.

Fracture (4 Credit Units, 60 Credit Hours)

Syllabus: Theoretical resistance of materials and state of tension and flat deformation. Modes and mechanism of fracture. Failure analysis diagram. Mechanics of elastic linear fracture (K). Elastoplastic fracture mechanics (COD and integral J). Fragile fracture mechanism. Mechanism of ductile fracture.

Welding Metallurgy (4 Credit Units, 60 Credit Hours)

Syllabus: Heat flux in welding. Thermal cycle and thermal distribution. Metallurgical influences of the thermal cycle. Chemical reactions in welding. Residual tensions. Distortions and fatigue. Defects in welded joints. Case Study.

Physical Metallurgy (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction. Structure of metals. Recovery, recrystallization, and grain growth. Diffusion. General notions about alloys: phase diagrams. Solid solutions. Kinetics of phase transformation. Precipitation hardening. Martensitic transformations.

Composite Materials (4 Credit Units, 60 Credit Hours)

Syllabus: Micromechanics of composite materials. Dispersed phases and matrices. Connection between dispersed phase and matrix. Manufacture of composite materials. Mechanical properties. Application of composite materials.

Polymeric Materials (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction to polymers. Classification of polymers. Molecular structure and molecular weights. Morphology and crystallinity of polymers. Polymeric blends. Rheology and processing of polymers. Mechanical properties.

Nanomaterials (4 Credit Units, 60 Credit Hours)

Syllabus: Nanoescalas; heterogeneous surfaces; capillary force and percolation; techniques involving sol-gel and supramacromolecular crystallization; nanofibres, nanocones and nanotubes; organophilic clays and nanoapatites; preparation of samples for microscopy, diffractometry and magnetic resonance imaging.

Polymer Processing (4 Credit Units, 60 Credit Hours)

Syllabus: Raw material; Rheology; extrusion; thermoplastic injection; molds for injection; blowing and rotomoulding.

Welding Processes (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction (importance, definition and classification of arc welding processes). Hygiene and safety in welding. Physical phenomena of the voltaic arc (transfers of electric charge and metal, stability of the arc). Conventional arc welding processes (coated electrodes, submerged arc, electrodes, MIG, MAG, tubular wire and TIG). High energy density processes (plasma, laser and electron beam welding). Production, consumption and yield in welding. Case Study.

Solidification of Metals (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction. Redistribution of solute in the solidification of alloys. Heat transfer in solidification. Solidification of polyphase alloys. Correlation between thermal parameters and solidification structures. Segregation and defects. Current state and new solidification research trends.

Experimental Techniques in Solidification of Metals and Alloys (4 Credit Units, 60 Credit Hours)

Syllabus: Concepts and applications of the solidification process; solidification systems: vertical ascending, vertical descending and horizontal; correlation between thermal parameters and crude fusion structures with mechanical properties; experimental techniques; used in the solidification of metals and alloys: obtaining cooling curves, thermal mapping in metal-mold systems considering unidirectional solidification, experimental determination of the solidification kinetics and obtaining thermal parameters (liquidus isotherm velocity, temperature gradient, cooling rate and local solidification time); use of Software for data processing of solidification kinetics: Orign and Exel; Characterization of the crude fusion structure through traditional metallography techniques: obtaining and quantifying the solidification structures at macro and microstructural levels; use of Software specialized in Microstructural characterization and quantification (Image Tool and Image J); application of mathematical models predicted in the literature for dendritic growths.

Special Topics in Materials and Processes (4 Credit Units, 60 Credit Hours)

Syllabus: Discipline addressing diverse subjects, according to the interest and demand of regional themes.

Phase Transformation (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction: general concepts, states of equilibrium, structure of metallic materials. Phase equilibrium thermodynamics: introduction, free energy, equilibrium in systems with variable composition, systems with variable composition, systems with one component, phase rule, allotropy or phase diagrams. Introduction: isomorphic systems-ideal solution, phase diagram of an ideal system, solidification in equilibrium, determination of liquid and solidus lines in ideal systems, free energy of non-ideal solutions; two-component systems-eutectic system, peritetic-like systems, complex systems. Atomic diffusion: introduction, atomic flow equation (first Fick law), atomic diffusion in steady state, transient atomic diffusion (Fick second law), atomic motion mechanism, diffusion coefficient equation, atomic diffusion in binary alloys in which the two elements move. Solubilization and precipitation: introduction, precipitation hardening, hardening mechanisms, factors influencing precipitation, duplex precipitation. Ferro-Carbon system: iron-carbon balance diagram, isothermal transformations, transformations with continuous cooling, factors that influence TTT curves, austenite decomposition, final considerations.

Materials Usability (4 Credit Units, 60 Credit Hours)

Syllabus: Introduction to the machining of materials; geometry and kinematics of machining processes; machinability of materials: definition and calculation of machinability index, machinability of aluminum alloys, machinability of steel, machinability of cast iron, machinability of polymers, ceramics and composites, callus resistant alloys; metal machinability tests.