Some years ago, CarTech CEO told us:

1
Some years ago, CarTech CEO told us What I want
to see in our new hires is
2
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy
3
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy
4
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well
5
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well 310 requires lots of speaking,
writing
6
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well 310 requires lots of speaking,
writing They know how to work in
groups
7
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well 310 requires lots of speaking,
writing They know how to work in
groups 310 requires group work
8
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well 310 requires lots of speaking,
writing They know how to work in
groups 310 requires group work They
speak at least one language other than
English
9
Some years ago, CarTech CEO told us What I want
to see in our new hires is They know
a good bit of metallurgy 310 projects involve
lots of metallurgy They write and
speak well 310 requires lots of speaking,
writing They know how to work in
groups 310 requires group work They
speak at least one language other than
English Henceforth, all 310
classes work will be in Chinese
10
Major Course Objectives 1. Learn some
metallurgy/materials science through process of
solving an industrial problem Develop
proposal.........need knowledge, ideas,
support for ideas 2. Develop design skills
11
Major Course Objectives 1. Learn some
metallurgy/materials science through process of
solving an industrial problem Develop
proposal.........need knowledge, ideas,
support for ideas 2. Develop design skills 3.
Learn working group skills work closely w/
team members to solve problem 4. Develop
writing/speaking skills
12
4. Develop writing skills WHY?
13
4. Develop writing skills WHY? Scientists and
engineers have incredible amount of technical,
semi-technical, and non-technical material to
digest almost daily. Must be able to read and
comprehend material instantly.
14
4. Develop writing skills WHY? Scientists and
engineers have incredible amount of technical,
semi-technical, and non-technical material to
digest almost daily. Must be able to read and
comprehend material instantly. Question If
your writing is difficult to understand, who will
have time to read it?
15
4. Develop writing skills WHY? Scientists and
engineers have incredible amount of technical,
semi-technical, and non-technical material to
digest almost daily. Must be able to read and
comprehend material instantly. Question If
your writing is difficult to understand, who will
have time to read it? Delays in reading of even
fractions of a second are frustrating.
16
Example Qm (3 times)
17
Example Qm (3 times)............should be Qm
18
Example Qm (3 times)............should be
Qm Chuang and Rice
19
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills
20
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and Wilkinson
21
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby
22
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke
23
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin
24
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.
25
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson
26
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson 2gs
27
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson 2gs................should be 2gS
28
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson 2gs................should be
2gS (dr/dt)gen
29
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson 2gs................should be
2gS (dr/dt)gen.............should be (dr/dt)gen
30
Example Qm (3 times)............should be
Qm Chuang and Rice............should be Chuang,
Kagawa, Rice, and Sills Ashby and
Wilkinson.............should be Wilkinson and
Ashby Grabke............should be Grabke and
Martin McKimpson et al.............should be
McKimpson 2gs................should be
2gS (dr/dt)gen.............should be
(dr/dt)gen That is why, we are justified in
using for C, the value of ...........????
31
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............?????
32
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that
33
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by
34
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by high
pressure exponent (n)
35
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by high
pressure exponent (n)....................should
be (m)
36
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by high
pressure exponent (n)....................should
be (m) in Eq. 25...........there is no Eq.
25
37
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by high
pressure exponent (n)....................should
be (m) in Eq. 25...........there is no Eq.
25 value of A1 and n1 is given by Eq.
23.........????
38
Example values of A1 and n1 depends on whether
the accommodation occurs by diffusional of
dislocation creep...............????? It has
been show that A1 and n1 are given by high
pressure exponent (n)....................should
be (m) in Eq. 25...........there is no Eq.
25 value of A1 and n1 is given by Eq.
23.........???? Using the values for Ko and aC
indicated in Table I...........no aC values in
Table I !!
39
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
40
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
a. Names of those to lead a discussion
selected by lot prior to class
period. b. Informal talks will be
graded. If absent or unprepared,
grade is F. c. These talks begin in 2
weeks. d. Be prepared to lead a
discussion every class period.
e. All materials for discussions....diagrams,
tables, lists, text materials
must be placed on the computer
prior to class.
f. Appropriate to raise
questions that arise during your
reading and research in class
discussions.
41
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
a. First formal presentation to
industry people is literature review at mid
semester. b.
Second formal presentation to industry people is
final proposal at end of semester.
42
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
a. Submit on time with correct file name
by emailing to rx7_at_mail.psu.edu.
b. First paper is due 1 February, by
midnight. c. Only one file all figures,
tables, illustrations must be in
text file. d. Graded work emailed back to
you. Correct files when returned.
Use MS Word to read annotations in
text. See or email instructor if
questions about notations on your
papers. e. The two major
papers can be constructed from these
"mini-papers".
43
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
a. Submit on time with correct file
name by emailing to
rx7_at_mail.psu.edu. b. Due 7 March.
c. Only one file all figures, tables,
illustrations must be in text
file. d. Correct files when returned to
you and incorporate this work into
final proposal.
44
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
a. Submit on time with correct file
name emailing to rx7_at_mail.psu.edu.
b. Due 5 May. c. Only one file
all figures, tables, illustrations
must be in text file. d. Propose new
solution to problem in this proposal
and support your choice of a solution
in detail.
45
Class activities 1. Informal talks on
project work 2. Formal talks on project
work 3. Approx. 3 page papers on project
work 4. Review paper 5. Final proposal
e. Suggested outline for
final proposal I.
Introduction (General area
of project, objective of
proposal) II. Background
A. Current processes or
techniques B.
Scientific/Engineering analysis of
above III.
Alternatives
(Scientific/Engineering analysis of
alternatives) IV.
Proposed method or idea A.
Detailed account of approach
B. Scientific/Engineering support
V. Proposed studies
(Studies and information required to
implement process) Required!!!
46
Order of investigation 1. How is it done
now? 2. Why is it done this way? 3. What are
other possibilities? 4. Critique of these
possibilities
47
Order of investigation Journals Texts Symposia
proceedings Pop journals such as JOM and Advanced
Materials Processes Patent literature Theses Fac
ulty Advertising materials Personal
contacts Alumni Industry liaison
people Newsgroups Web gt gtSciFinder Scholar -
search CA electronicallylt lt
48
Team RAHL  Paul Hauge Sarah Mansuettis Tuan
Tran Team ZEDD  Brandon Ribic Christopher
Walton Craig McCann Team KAHLAN Kaylin
Kopcho Scott Moken Arwen Wilson
49
Team RAHL  Paul Hauge Sarah Mansuettis Tuan
Tran Team ZEDD  Brandon Ribic Christopher
Walton Craig McCann Team KAHLAN Kaylin
Kopcho Scott Moken Arwen Wilson
1st task - decide on new
team name
50
Team RAHL  Paul Hauge Sarah Mansuettis Tuan
Tran Team ZEDD  Brandon Ribic Christopher
Walton Craig McCann Team KAHLAN Kaylin
Kopcho Scott Moken Arwen Wilson
2nd task - arrange time (about
one hour) during which ALL team
members instructor (observer) can meet
EVERY WEEK to review work plan
next week's activities.
51
Team RAHL  Paul Hauge Sarah Mansuettis Tuan
Tran Team ZEDD  Brandon Ribic Christopher
Walton Craig McCann Team KAHLAN Kaylin
Kopcho Scott Moken Arwen Wilson
2nd task - arrange time (about
one hour) during which ALL team
members instructor (observer) can meet
EVERY WEEK to review work plan
next week's activities. MEET THIS
WEEK
52
Team RAHL  Paul Hauge Sarah Mansuettis Tuan
Tran Team ZEDD  Brandon Ribic Christopher
Walton Craig McCann Team KAHLAN Kaylin
Kopcho Scott Moken Arwen Wilson
3rd task - pick project
53

• Projects
• Roping in Ferritic Stainless Steels
• Formability of T409 Stainless Steel
• 3. Localized Quench Strain Marks on Ferritic
  Stainless Steels
• 4. Surface Evaluation on Bright Annealed
  Stainless Steels
• 5. High Speed Steels by Powder Metallurgy
• 6. Hip Prosthesis Materials and Processing
• 7. Advanced Combat Mobility Concepts
• 8. Characterization of Material Flow Around
  Different Friction-Stir Welding Pin Tools
• 9. Heat Treatment of Titanium Alloy Forgings
• 10. Heat Treatment of Titanium Alloy Castings
• Surface Modification of Magnesium Alloys for Wear
  and Corrosion Resistance
• 12. Friction Stir Welding Process
• 13. Shot Peening Effects and Residual Stress
  Measurement in Ti Alloys

54

• Projects
• Roping in Ferritic Stainless Steels
• Flat-rolled ferritic stainless steels (type
  400s) are used widely in the automotive and
  appliance industries. These are prone to a defect
  called roping. Roping, or ridging, is a shape
  defect which is caused during a drawing
  operation. Roping is possibly caused by the
  texture of the material from casting, and the
  texture can be manipulated through hot and cold
  processing. The project can roping be controlled
  or minimized through chemistry and hot/cold
  processing? Target grades T409, T439, T436,
  T441.
• 2. Formability of T409 Stainless Steel
• Type 409 flat-rolled ferritic stainless steel is
  used widely in the automotive industry for
  emission control systems. In today's automotive
  production environment, it is important that T409
  can be used to form complex parts such as
  expanded tubes, connectors, and deep drawn
  catalytic converter heat shield and muffler caps.
  Currently, our sister company in Brazil, makes a
  superior T409 product as far as mechanical
  properties and roping are concerned. The project
  how do the chemistry, refining steps, and hot
  rolling process influence the formability and
  affect roping defects.

55
Projects 3. Localized Quench Strain Marks on
Ferritic Stainless Steels Flat-rolled ferritic
stainless steels (type 400s) are used widely in
the casket industry. These are prone to a defect
called strain-yield point elongation, or Luders
bands. This localized strain defect is an
aesthetic defect which can be induced when quenchi
ng the material after annealing. Localized
strain looks like small xxx's that can be seen
through thickness and can not be ground out.  The
project can this strain be controlled or
minimized through quenching modifications, or
chemistry and hot rolling? Target grades T409,
T439, T441. 4. Surface Evaluation on Bright
Annealed Stainless Steels Flat-rolled
austenitic and ferritic stainless steels (types
300s and 400s) with a bright annealed mirror
finish are used widely in the automotive and
appliance industries.  There is
no qualitative method of rating surface
quality.  Currently, the surface is inspected
visually, and with a perthometer, which uses a
stylus that measures surface roughness.  The
project are there any other inexpensive
techniques that can be used to define the surface
quality? Target grades T304, T434, T430.
56
Projects 5. High Speed Steels by Powder
Metallurgy BACKGROUND You and your teammates
work for Nittany Powder Products, a division of
Nittany Specialty Alloys, in the RD laboratory.
Your company's primary product is high-speed
steel (HSS) bar and plate that is produced via
powder metallurgy (PM). Your current
manufacturing route is to air induction melt and
atomize using N2 gas. The loose powder is
collected and screened to 100 mesh. The screened
powder is then placed in mild C-steel cans. Lids
are welded on the top and the cans are evacuated
and degassed at 250F. Following the outgassing
operation, the cans are shipped to Bodycote IMT
in Andover, MA, for consolidation via hot
isostatic pressing (HIP). The as-HIP'd cans are
returned from your converter and then
manufactured into long bar and plate product
using the hot-working and finishing facilities of
your parent company, Nittany Specialty Alloys.
Your product is sold directly to your customer
base using your own sales and distribution force,
as well as distributors in regions where you do
not have a presence.
57
Projects 5. High Speed Steels by Powder
Metallurgy PROBLEM Your sales staff has been
receiving feedback from your customers of
problems with your PM HSS product. Specifically,
the reports center on toughness issues with the
material. As usual, the reports indicate that
your competitors (Wolverine Metals and Buckeye
Alloys) do not have this problem. Customers that
purchase plate product and remove parts via wire
electro-discharge machine (EDM) have indicated
that your product must be cut at slower feeds and
speeds compared to the competitors' material.
There is also a much higher incidence of wire
breaks with your product compared to your
competitors' products. All of these issues result
in reduced manufacturing efficiencies for your
customers and ultimately in reduced sales for
your product. Your company has a goal to
double its PM HSS sales over the next 3 years
however, the above referenced problem is viewed
as an impediment to this corporate goal. You and
your team have been charged with the task to
understand what is causing the EDM machining
problems with your product and to propose a
solution that will allow Nittany Powder Products
to overcome this technical obstacle and insure
that the corporate sales goal is met. In
addition, your team must develop a method to
quantitatively monitor the process to assess the
quality level of material once the root cause of
the problem is identified. Any such testing or
methodology should be incorporated into the
process as early as possible in order to minimize
the impact of non-compliant material.
58
Projects 6. Hip Prosthesis Materials and
Processing BACKGROUND You and your teammates
are Product Development Engineers working in the
RD laboratory for Happy Valley Medical Products.
Your company's primary product line is surgical
needle wire and catheter packages. Sales for the
past 2 years have been relatively flat. Your CEO,
with the approval of the Board of Directors, has
decided that it is time to offer a more
diversified line of medical products. Market
research has indicated that prosthetics for
implant applications is growing at an annualized
rate of 25 per year, and this trend is expected
to continue as a result of the world's aging, but
highly active population.
59
Projects 6. Hip Prosthesis Materials and
Processing PROBLEM Happy Valley Medical
Products' new line of prosthetic implants will
focus on joints, and your team has been charged
with developing the implementation plan for hip
joint implants. The primary requirement for this
new product line is a completely finished product
that is ready for implantation in the human body.
You will need to consider the material to use,
the method of primary manufacture and any
necessary secondary finishing operations. Your
CEO has given you free reign with regard to
choosing materials and processing as long as the
product is competitively priced. You will need to
consider the following materials-related issues
(1) bio-compatibility, (2) mechanical property
performance (i.e., strength, ductility, toughness
and fatigue) and (3) ease of fabricability. In
addition, you will need to determine method of
manufacture. Your options include, but are not
limited to, (1) 100 machining from a long-bar
product, (2) machining of forgings produced from
long bar product and (3) near-net-shape P/M
processes. Part of your charge will be to work
with your vendors to establish specification
limits for all stages of manufacture.
60

• Projects
• Advanced Combat Mobility Concepts
• This project involves a literature search,
  documentation of concepts (perhaps some ProE
  modeling) and tying in to an ongoing program
  (CVM).
• Characterization of Material Flow Around
  Different Friction-Stir Welding Pin Tools
• This project involves a detailed literature
  search, understanding material flow descriptions,
  and relating them to features on tools.
• Heat Treatment of Titanium Alloy Forgings
• Conduct a literature search of the various heat
  treatments used for titanium forgings to optimize
  the yield strength, ductility, and ballistic
  performance. The heat treatment concepts are to
  be applied to produce a microstructure that
  should yield balanced mechanical properties to
  reduce the spalling of titanium forgings during
  ballistic impact.

61
Projects 10. Heat Treatment of Titanium Alloy
Castings Conduct a literature search on the
various heat treatments of investment cast and
rammed graphite titanium castings to improve the
yield strength, fracture toughness and ductility.
Apply phase transformation principles to produce
a cast microstructure with a reduced amount of
intergranular primary alpha and a fine alpha-beta
microstructure with balanced mechanical
properties for aerospace applications.     11.
Surface Modification of Magnesium Alloys for
Wear and Corrosion Resistance Investigate the
various surface modification processes used to
modify the surface of magnesium alloys used in
aerospace applications, specifically, applied
surface modification/coating technologies to
modify the surface of magnesium alloy ZE41A. 12.
Friction Stir Welding Process Investigate all
possible metallurgical phenomena involved during
friction stir welding processing of aluminum
alloys. This includes metal behavior during
deformation (stirring), tool material(s)/alloy
interaction, effect of thermomechanical
processing on the welded material
microstructure. Apply metallurgical concepts to
develop tools and possible processing routes to
friction stir weld low alloy high strength steels
such as HSLA-100.
62
Projects 13. Shot Peening Effects and Residual
Stress Measurement in Ti Alloys In recent
years, we have made many more critical components
from titanium alloys to use on military
rotorcraft platforms such as the RAH-66 and V-22.
Traditionally, similar components have been
fabricated from HSLA (high strength low alloy)
steels that are shot peened to increase fatigue
life, a critical design characteristic for
rotorcraft components. Current coupon testing,
along with industry reports, indicate that 1)
shot peening titanium alloys may decrease fatigue
life, and 2) traditional x-ray diffraction
techniques to measure residual stress surface
profiles yield invalid results because of large
grains characteristic of the surface of titanium
parts (surface texture). We are currently
making efforts to 1) understand the technical
reasons for our apparently invalid residual
stress data (there may be effects other than
surface texture), 2) determine how (what method)
to measure residual stresses on shot peened
titanium (6Al-4V and 10-2-3 alloys), and 3) know
how shot peening affects fatigue life of titanium
alloys.
63

• Projects
• Roping in Ferritic Stainless Steels
• Formability of T409 Stainless Steel
• 3. Localized Quench Strain Marks on Ferritic
  Stainless Steels
• 4. Surface Evaluation on Bright Annealed
  Stainless Steels
• 5. High Speed Steels by Powder Metallurgy
• 6. Hip Prosthesis Materials and Processing
• 7. Advanced Combat Mobility Concepts
• 8. Characterization of Material Flow Around
  Different Friction-Stir Welding Pin Tools
• 9. Heat Treatment of Titanium Alloy Forgings
• 10. Heat Treatment of Titanium Alloy Castings
• Surface Modification of Magnesium Alloys for Wear
  and Corrosion Resistance
• 12. Friction Stir Welding Process
• 13. Shot Peening Effects and Residual Stress
  Measurement in Ti Alloys

64
4th task - prepare for industry visit
by finding out as much as possible about
problem
65
4th task - prepare for industry visit
by finding out as much as possible about problem
Other things to do - check email to
see when industry visit will be next week
66
4th task - prepare for industry visit
by finding out as much as possible about problem
Other things to do - check email to
see when industry visit will be next week
Go through all 310 materials on website