WM171-15 Materials and Manufacturing Processes
Introductory description
In any engineering activity the performance of materials needs to be understood to ensure that the processes of design and manufacturing can consistently deliver new products to the market. Today, with increasing environmental legislation and greater competition, the engineer is tasked with using novel materials, which in turn means they have to be proportionately more reliable and their properties even better controlled. Many aspects affect material properties. At the most basic level the arrangement of the individual atoms within the structure is important. Other factors include the effects of inhomogeneities that are caused by the manufacturing processes used to form the material into the component's shape.
Module aims
This module will outline the main materials and processes used to manufacture products and will align as closely as possible with aspects of the DFMA module. Students need to understand the relationship between the properties of these materials, the processes and product design. The module will cover the main classes of metals, polymers, ceramics, electronic materials and composites with an emphasis on understanding structure property relationships and the resulting constraints on manufacturing process. The module will cover the main primary (shaping and joining) processes as well as some secondary manufacturing processes used in the design and creation of commercial products from these materials.
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.
- Atomic structure. Molecular structure and bonding. Structure of solid materials. Crystal systems. Crystal imperfections. Substitutional solid solutions. Interstitial solid solutions. Structure/Properties relationship
- Thermal Treatments and Strengthening mechanisms.
- Properties of materials: Mechanical Electrical Magnetic Physical properties.
- Testing Standards.
- Metallic. Ceramics. Polymers. Composites. Electronic materials.
- Bulk materials. Engineered materials. Fabricated products. Servicing of products. Recycling/disposal. Manufacturing Technologies.
- Material Selection using Granta Edupack.
Learning outcomes
By the end of the module, students should be able to:
- Explain the nature of materials, information and systems and be able to select appropriate materials for engineering use, whilst considering sustainability.
- Explain and be able to describe how to exploit the structure property relationship in order to enhance the utility of engineering materials in use and in manufacture
- Appreciate the available range and limitations of manufacturing processes and sustainability and propose suitable processes for simple products
- Appreciate the basic concepts and the terminology of materials science as applied in all major branches of engineering so that they are sufficiently able to hold discussions with specialists in a multi-disciplinary team
- Describe the purpose and benefits provided by thermal treatments including the associated processes.
Indicative reading list
- Manufacturing Processes for Engineering Materials. Kalpakjian and Schmid ISBN 9789810679538
- Manufacturing Engineering Technology: Kalpajian and Schmid ISBN 9789810694067
- Materials Science for Engineers, James F Shackelford. ISBN 0-13-127619-0
- Callister W.D., Materials Science and Engineering ISBN 9781119453918
- Ashby, M.F, Materials Selection in Mechanical Design ISBN 9780081005996
- Askeland, D.R. The science of engineering materials ISBN 9781305077102
- Principles of Modern Manufacturing - Materials Processed and Systems, MikellP. Groover ISBN 978-1-119-24912-2
View reading list on Talis Aspire
Subject specific skills
Domain knowledge
Interpreting phase diagrams, isothermal tranformation diagrams, stress-strain curves
Calculating composite stiffnesses and densities using theory of composites
Developing Performance Indices for Materials Selection
Materials selection processes
Granta Edupack software
Transferable skills
Technical writing
Communication
Team working
Leadership
Study time
| Type | Required |
|---|---|
| Lectures | 7 sessions of 3 hours (14%) |
| Seminars | (0%) |
| Tutorials | 6 sessions of 1 hour (4%) |
| Practical classes | 1 session of 3 hours (2%) |
| Online learning (scheduled sessions) | 6 sessions of 1 hour (4%) |
| Online learning (independent) | 2 sessions of 1 hour (1%) |
| Other activity | 10 hours (7%) |
| Private study | 42 hours (28%) |
| Assessment | 60 hours (40%) |
| Total | 150 hours |
Private study description
Review of content, practice using voluntary online Moodle quizzes. Research using online textbooks.
Other activity description
Distance learning support
Costs
No further costs have been identified for this module.
You must pass all assessment components to pass the module.
Assessment group D1
| Weighting | Study time | Eligible for self-certification | |
|---|---|---|---|
| WM171 Coursework - Group report | 30% | 24 hours | No |
|
The learners need to write a lab report discussing the experimental results. The lab is an Impact Toughness lab, and during it they need to test different materials at different temperatures and discuss the effect of temperature on properties. |
|||
| MMP Exam | 70% | 36 hours | No |
|
Online examination (3 hrs) will be conducted to cover the appropriate learning outcomes. |
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Feedback on assessment
Written individual feedback on all individual assessments.
Cohort feedback for the exam.
Pre-requisites
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There is currently no information about the courses for which this module is core or optional.