ECTS - Design and Modeling of Casting and Solidification Processes

Design and Modeling of Casting and Solidification Processes (MDES652) Course Detail

Course Name Course Code Season Lecture Hours Application Hours Lab Hours Credit ECTS
Design and Modeling of Casting and Solidification Processes MDES652 3 0 0 3 5
Pre-requisite Course(s)
Background in Phase Transformations, Microstructures, Solidification and Casting Processes, Stress Analysis, Mathematical Modeling
Course Language English
Course Type N/A
Course Level Ph.D.
Mode of Delivery Face To Face
Learning and Teaching Strategies Lecture.
Course Coordinator
Course Lecturer(s)
Course Assistants
Course Objectives Solidification science is of paramount importance not only in understanding macro- and microscopic changes during the solidification of castings, but is also the basis of many new processes and materials such as semi-solid casting, laser melting, powder atomization, metal matrix composites, bulk metallic glasses. Many of the processes used in metal casting are still empirical in nature, but many others are deep-rooted in mathematics. The acceptance of computational modeling of solidification by metal casting industry is a direct result of the gigantic achievements made by solidification science in the last 25 years or so. Foundry reports indicate that solidification modeling is not only a cost-effective investment but also a major technical asset. It helps foundries move into markets with more complex and technically demanding work. The ability to predict internal soundness allows foundries to improve quality and deliveries, and provides the information required to make key manufacturing decisions based on accurate cost estimates before pattern construction even begins. This course aims at analyzing the solidification and crystallization processes from a general point of view and in accordance with generally accepted results and experimental evidence of modern research in the field, and attempts to synthesize the information that can be used for engineering calculations pertinent to computational modeling of casting solidification, and fundamentals of rapid solidification and bulk metallic glasses.
Course Learning Outcomes The students who succeeded in this course;
  • Students will be expected to gain ability to cite, design, model, calculate, determine and comment on computational modeling of casting solidification theory through the complex mathematical tools that include partial differential equations and numerical analysis, required for a fundamental treatment of the problem and be able to use this ability on the inputs and results of commercial solidification simulation software.
Course Content Theoretical background including fundamentals of casting process modeling, stress analysis, defect formation, microstructure evolution, thermophysical properties, and quick analysis techniques to solve casting problems; applications to shape castings, ingot castings and spray forming.

Weekly Subjects and Releated Preparation Studies

Week Subjects Preparation
1 Overview of Casting and Solidification Processes Related pages of the textbooks and other sources
2 Equilibrium and non-equilibrium during solidification Related pages of the textbooks and other sources
3 Macro-scale phenomena - Relevant Transport Equations Related pages of the textbooks and other sources
4 Macro-mass transport: Solute diffusion controlled segregation-Fluid dynamics during mold filling and solidification, macroshrinkage formation and feeding Related pages of the textbooks and other sources
5 Governing equation for energy transport: Analytical solutions for steady-state and non-steady-state solidification of castings Related pages of the textbooks and other sources
6 Numerical Macro-modeling of solidification: Finite Difference Method and Control-Volume formulations Related pages of the textbooks and other sources
7 Macrosegregation and Macroshrinkage modeling Related pages of the textbooks and other sources
8 Micro-scale phenomena and interface dynamics: Nucleation and microsegregation, Dynamic Nucleation Models Related pages of the textbooks and other sources
9 Cellular and dendritic growth: Analytical Tip Velocity Models, Dendritic Array Models Related pages of the textbooks and other sources
10 Eutectic solidification: Models for regular and irregular eutectic growth Related pages of the textbooks and other sources
11 Peritectic and Monotectic solidification mechanisms Related pages of the textbooks and other sources
12 Microstructures obtained through rapid solidification Related pages of the textbooks and other sources
13 Numerical micro-modeling of solidification Related pages of the textbooks and other sources
14 Nucleation and Growth Kinetics Related pages of the textbooks and other sources
15 Overall review -
16 Final exam -

Sources

Course Book 1. • Science and Engineering of Casting Solidification, 2E, D.M. STEFANESCU, Springer, 2009
2. • Solidification and Crystallization Processing in Metals and Alloys, H. FREDRIKSSON & U. AKERLIND, Wiley, 2012
3. • Theory of Solidification, S.N. DAVIS, CUP, 2001
4. • Modeling for Casting & Solidification Processing, Ed. K.O. YU, Marcel-Dekker, 2002
5. • Principles of Solidification: An Introduction to Modern Casting and Crystal Growth Concepts, M.E. GLICKSMAN, Springer, 2011
Other Sources 6. İlgili makaleler / Related papers

Evaluation System

Requirements Number Percentage of Grade
Attendance/Participation - -
Laboratory - -
Application - -
Field Work - -
Special Course Internship - -
Quizzes/Studio Critics - -
Homework Assignments 5 15
Presentation - -
Project 1 30
Report - -
Seminar - -
Midterms Exams/Midterms Jury 1 25
Final Exam/Final Jury 1 30
Toplam 8 100
Percentage of Semester Work 70
Percentage of Final Work 30
Total 100

Course Category

Core Courses
Major Area Courses X
Supportive Courses
Media and Managment Skills Courses
Transferable Skill Courses

The Relation Between Course Learning Competencies and Program Qualifications

# Program Qualifications / Competencies Level of Contribution
1 2 3 4 5
1 Gains the ability to understand and apply knowledge in the fields of mathematics, science and basic sciences at the level of expertise.
2 Gains the ability to access wide and deep knowledge in the field of Engineering by doing scientific research with current techniques and methods, evaluate, interpret and implement the gained knowledge.
3 Being aware of the latest developments his/her field of study, defines problems, formulates and develops new and/or original ideas and methods in solutions.
4 Designs and applies theoretical, experimental, and model-based research, analyzes and interprets the results obtained at the level of expertise.
5 Gains the ability to use the applications, techniques, modern tools and equipment in his/her field of study at the level of expertise.
6 Designs, executes and finalizes an original work process independently.
7 Can work in interdisciplinary and interdisciplinary teams, lead teams, use the information of different disciplines together and develop solution approaches.
8 Pays regard to scientific, social and ethical values in all professional activities and acquires responsibility consciousness at the level of expertise.
9 Contributes to the literature by communicating the processes and results of his/her academic studies in written form or orally in national and international academic environments, communicates effectively with communities and scientific staff working in the field of specialization.
10 Gains the skill of lifelong learning at the level of expertise.
11 Communicates verbally and in written form using a foreign language at least at the European Language Portfolio B2 General Level.
12 Recognizes the social, environmental, health, safety, legal aspects of engineering applications, as well as project management and business life practices, being aware of the limitations they place on engineering applications.

ECTS/Workload Table

Activities Number Duration (Hours) Total Workload
Course Hours (Including Exam Week: 16 x Total Hours) 16 3 48
Laboratory
Application
Special Course Internship
Field Work
Study Hours Out of Class 16 1 16
Presentation/Seminar Prepration
Project 1 32 32
Report
Homework Assignments 5 3 15
Quizzes/Studio Critics
Prepration of Midterm Exams/Midterm Jury 1 10 10
Prepration of Final Exams/Final Jury 1 15 15
Total Workload 136