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 Natural & Applied Sciences Master's Degree
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 -


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 X
Major Area Courses
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 Ability to expand and get in-depth information with scientific researches in the field of mechanical engineering, evaluate information, review and implement.
2 Have comprehensive knowledge about current techniques and methods and their limitations in Mechanical engineering.
3 To complete and apply knowledge by using scientific methods using uncertain, limited or incomplete data; use information from different disciplines.
4 Being aware of the new and developing practices of Mechanical Engineering and being able to examine and learn when needed.
5 Ability to define and formulate problems related to Mechanical Engineering and develop methods for solving and apply innovative methods in solutions.
6 Ability to develop new and/or original ideas and methods; design complex systems or processes and develop innovative/alternative solutions in the designs.
7 Ability to design and apply theoretical, experimental and modeling based researches; analyze and solve complex problems encountered in this process.
8 Work effectively in disciplinary and multi-disciplinary teams, lead leadership in such teams and develop solution approaches in complex situations; work independently and take responsibility.
9 To establish oral and written communication by using a foreign language at least at the level of European Language Portfolio B2 General Level.
10 Ability to convey the process and results of their studies systematically and clearly in written and oral form in national and international environments.
11 To know the social, environmental, health, security, law dimensions, project management and business life applications of engineering applications and to be aware of the constraints of their engineering applications.
12 Ability to observe social, scientific and ethical values in the stages of data collection, interpretation and announcement and in all professional activities.

ECTS/Workload Table

Activities Number Duration (Hours) Total Workload
Course Hours (Including Exam Week: 16 x Total Hours) 16 3 48
Special Course Internship
Field Work
Study Hours Out of Class 16 1 16
Presentation/Seminar Prepration
Project 1 32 32
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