Programme And Module Handbook
Course Details in 2021/22 Session

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Module Title LM Advanced Casting and Solidification
SchoolMetallurgy and Materials
Department Metallurgy & Materials
Module Code 04 32775
Module Lead Dr. W. D. Griffiths
Level Masters Level
Credits 10
Semester Semester 2
Restrictions None
Contact Hours Lecture-15 hours
Guided independent study-85 hours
Total: 100 hours
Description The module will build on previous general knowledge of nucleation, growth, solidification and casting methods, but now covering (i). typical casting methods, (ii). advanced casting methods, and (iii). advanced solidification theory.

The module will cover casting methods, to include investment casting and other specialised casting techniques, such as low pressure sand and low pressure die casting, high pressure die casting, squeeze casting, ablative casting and Lost Foam casting, including mould materials, mould surface treatments.

The module will then cover defects inherent in the casting process, such as oxide film entrainment, shrinkage and gas porosity, intermetallics and defects associated with mould design.

This will be followed by advances in nucleation theory and practice, and growth, including faceting, planar, cellular and dendritic morphologies, dendrite arm spacing, segregation during solidification, directional solidification and single crystal solidification, and formation of the macrostructure.

These link to the following topics in the 2017 QAA Materials Subject Benchmark Statement:
ii phase equilibria and phase transformations, multiphase materials, thermodynamic and kinetic aspects
iii structure on the nano, micro, meso and macro scales.
vii materials synthesis - vapour, liquid, colloidal, powder and solid-state deposition techniques
viii bulk processing, heat and mass transfer, and fluid mechanics
ix joining methods, surface treatment and the application of coatings
xi materials design - compositional variation and processing to achieve required microstructures, and hence properties
iv engineering principles: including design, manufacturing and processing
x an awareness of health and safety, sustainability and environmental issues, and of ethical considerations
Learning Outcomes By the end of the module students should be able to:
  • A. Correlate, in the case of typical casting processes, the formation of the microstructure and mechanical properties in common non-ferrous and ferrous alloys.
  • B. Understand how common casting defects occur and contribute to reduced mechanical properties.
  • C. Understand how advanced casting processes, (investment casting, Lost Foam casting, ablation casting, etc.), produce the required microstructure and macrostructure, and hence the required properties.
  • D. Describe the current theories of nucleation, by both homogeneous and heterogeneous means, in typical ferrous and non-ferrous alloys.
  • E. Understand the processes underlying the growth of the microstructure and macrostructure, following on from nucleation.
These relate to AHEP3 learning outcomes
  • Demonstrate knowledge and understanding of scientific principles and methodology necessary to underpin their education in their engineering discipline, to enable appreciation of its scientific and engineering context, and to support their understanding of relevant historical, current and future developments and technologies (SM1)
  • Demonstrate knowledge and understanding of mathematical and statistical methods necessary to underpin their education in their engineering discipline and to enable them to apply mathematical and statistical methods, tools and notations proficiently in the analysis and solution of engineering problems (SM2)
  • Understand engineering principles and the ability to apply them to analyse key engineering processes (EA1)
  • Investigate and define the problem, identifying any constraints including environmental and sustainability limitations; ethical, health, safety, security and risk issues; intellectual property; codes of practice and standards (D2)
  • Apply advanced problem-solving skills, technical knowledge and understanding, to establish rigorous and creative solutions that are fit for purpose for all aspects of the problem including production, operation, maintenance and disposal (D4)
  • Demonstrate knowledge and understanding of the commercial, economic and social context of engineering processes (ELSE2)
  • Understand the requirement for engineering activities to promote sustainable development and ability to apply quantitative techniques where appropriate (ELSE4)
  • Demonstrate awareness of relevant legal requirements governing engineering activities, including personnel, health & safety, contracts, intellectual property rights, product safety and liability issues (ELSE5)
  • Demonstrate knowledge and understanding of risk issues, including health & safety, environmental and commercial risk, and of risk assessment and risk management techniques (ELSE6)
  • Demonstrate knowledge of characteristics of particular materials, equipment, processes, or products (EP2)
  • Understand the use of technical literature and other information sources (EP4)
  • Understand appropriate codes of practice and industry standards (EP6)
  • Understand the key drivers for business success, including innovation, calculated commercial risks and customer satisfaction (ELSE7m)
  • Apply engineering techniques taking account of a range of commercial and industrial constraints (EP10m)
Assessment 32775-01 : Exam : Exam (Centrally Timetabled) - Open Book (100%)
Assessment Methods & Exceptions Two hour exam 50% Coursework 50%
Reading List