The module will introduce the following aspects of the shaping of materials: Metals:
Solidification behaviour of metals; zones in ingot casting; segregation, constitutional undercooling and porosity; grain size control (inoculation and vibration); shaped casting – sand, die and investment; Casting defects – inclusions, hot tearing.
Characteristics of hot and cold forming; directionality and grain size; forging; rolling; extrusion and cold drawing
Fusion welding of metallic components; welding processes – MMA, MIG, TIG, SAW, power beam, resistance and friction; welding defects. Polymers:
Calendaring of sheet polymers (differences from sheet metal forming);thermoforming of polymeric sheets; injection moulding of polymers; modifications of injection moulding for ceramics
Extrusion of polymers (differences from metals) Ceramics:
Modifications for extrusion of ceramics; ceramic powder preparation – colloids and gels; cold and hot uniaxial pressing; isostatic processes; Slip casting
Material and process selection examples for polymers, metals and ceramics.
Learning Outcomes
By the end of the module the student should be able to:
describe processes to shape metals using casting and solid processing
detail structures and properties of cast and wrought metallic alloys
suggest likely defects resulting from a range of processing routes for metals, ceramics and polymers
describe the process of thermoforming including stress analysis of extensional flow, thinning analysis and product properties
describe injection moulding indicating events in a cycle.
discuss the role of flow ratio, solidification time, shrinkage and die design for easy ejection in injection moulding
describe the process of polymer extrusion highlighting differences from extrusion of metallic alloys and ceramic powders
describe the production of ceramic powders using colloids and the use of sols to control particle size
detail the processes of cold and hot pressing both uniaxially and isostatically, describing process parameters and materials properties
indicate the use of slip casting and detail the features of that process
select suitable processes for fabricating shapes and structures from metals, polymers and ceramics.
(UK-Spec Learning Outcomes:- US1, E1, P1, P2)
Assessment
17034-01 : Module mark : Mixed (100%)
Assessment Methods & Exceptions
Written examination (70%); Continuous assessment (30%)