Course Details in 2017/18 Session
|Module Title ||Fundamentals of Materials Science: Shaping|
|School||Metallurgy and Materials|
|Department || Metallurgy & Materials|
|Module Code || 04 17034 |
|Module Lead ||Prof Attallah|
|Level || Certificate Level |
|Credits || 10 |
|Semester|| Semester 2|
|Restrictions || None |
Guided independent study-74 hours
Practical Classes and workshops-4 hours
Total: 100 hours
|Exclusions || |
|Description || The module will introduce the following aspects of the shaping of materials:|
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.
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)
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)
17034-01 : Module mark : Mixed (100%)
|Assessment Methods & Exceptions || Written examination (70%); Continuous assessment (30%) |
|Other || None|