ES4E6-15 Automotive Materials and Processes
Introductory description
ES4E6-15 Automotive Materials and Processes
Module aims
This automotive related module advances the known key aspects of materials selection for body-in-white parts as well as for view parts and powertrain application. A range of selected processes to manufacture and combine different materials will be evaluated, according to their suitability for automotive manufacture and in order to improve performance of the vehicle in terms of mechanical strength, weight reduction, overall costs and environmental impact. Highly specialised parts such as coatings, catalysts and brakes will also be introduced to the audience.
Outline syllabus
This is an indicative module outline only to give an indication of the sort of topics that may be covered. Actual sessions held may differ.
Lightweight materials: High strength steels, Aluminium and Magnesium Alloys, Plastics and Composites
Processes: Pressing and Forming, Joining, Composite manufacture
Specialist applications: Coatings, Catalysts and Brakes
Design for light-weighting
Learning outcomes
By the end of the module, students should be able to:
- Demonstrate an advanced understanding and evaluate the production processes of metallic materials, used for automotive fabrication.
- Demonstrate advanced knowledge on where to use certain materials in the chassis, for panels and powertrain application as well as applying this to evaluate reasonable design of a “real” vehicle in the coursework.
- Evaluate current techniques for joining the different materials, mentioned above and apply this knowledge to the design of a “real” vehicle in the coursework.
- Assess the importance of the use of different materials in terms of mechanical stability, lightweight application, environmental impact and costs. Advance this knowledge to the complex design in automotive applications.
Indicative reading list
- Chang-Soo Kim, Charles Randow, Tomoko Sano “Hybrid and Hierarchical Composite Materials” Springer International Publishing (2015).
- Vadim V. Silberschmidt, Valery P. Matveenko “Mechanics of Advanced Materials – Analysis of Properties and Performance” Springer International Publishing (2015).
- Jörg Vetter “Chapter - Surface Treatments for Automotive Applications” from “Coating Technology for Vehicle Applications” Springer International Publishing (2015).
- Andre Hieke, Val. Lieberman, G.J. van der Kolk “Chapter – Hard Coatings and Coating Processes for the Automotive Industry” from “Coating Technology for Vehicle Applications” Springer International Publishing (2015).
Subject specific skills
Ability to conceive, make and realise a component, product, system or process
Ability to be pragmatic, taking a systematic approach and the logical and practical steps necessary for, often complex, concepts to become reality
Ability to seek to achieve sustainable solutions to problems and have strategies for being creative and innovative
Transferable skills
Apply problem solving skills, information retrieval, and the effective use of general IT facilities
Communicate (written and oral; to technical and non-technical audiences) and work with others
Exercise initiative and personal responsibility, including time management, which may be as a team member or leader
Appreciation of the global dimensions of engineering, commerce and communication
Be professional in their outlook, be capable of team working, be effective communicators, and be able to exercise responsibility and sound management approaches.
Study time
| Type | Required |
|---|---|
| Lectures | 30 sessions of 1 hour (20%) |
| Project supervision | 1 session of 3 hours (2%) |
| Other activity | 1 hour (1%) |
| Private study | 116 hours (77%) |
| Total | 150 hours |
Private study description
116 hrs guided independent learning
Other activity description
1 x 1 hr revision class
(1 x 3 hr hands-on session where people can have a look to the vehicles that are shown either in a workshop or at Warwick to evaluate and interpret which materials are appropriate and are being used and where they are used.)
Costs
No further costs have been identified for this module.
You must pass all assessment components to pass the module.
Assessment group A
| Weighting | Study time | |
|---|---|---|
| Workshop-based Report | 40% | |
|
Workshop-based Report (3000 words) |
||
| assignment | 60% | |
|
assignment |
||
Feedback on assessment
- Model solutions to past papers.
- Support through advice and feedback hours.
- Written feedback on assignment.
- Cohort-level feedback on final exam.
Courses
This module is Option list A for:
- Year 4 of UESA-H336 MEng Automotive Engineering
- Year 4 of UESA-H114 MEng Engineering
- Year 4 of UESA-HH76 MEng Manufacturing and Mechanical Engineering
- Year 5 of UESA-HH38 MEng Manufacturing and Mechanical Engineering with Intercalated Year