Programme And Module Handbook
Course Details in 2017/18 Session

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Module Title Fundamentals of Materials Science: Shaping
SchoolMetallurgy and Materials
Department Metallurgy & Materials
Module Code 04 17034
Module Lead Prof Attallah
Level Certificate Level
Credits 10
Semester Semester 2
Restrictions None
Contact Hours Guided independent study-74 hours
Practical Classes and workshops-4 hours
Lecture-22 hours
Total: 100 hours
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)

Assessment 17034-01 : Module mark : Mixed (100%)
Assessment Methods & Exceptions Written examination (70%); Continuous assessment (30%)
Other None
Reading List