WM105-15 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 manufacture can consistently deliver new products to the market in a controlled and safe manner. Today, with increasing amounts of environmental legislation and competition, the engineer is tasked with using progressively fewer 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. The next level of importance is due to the in homogeneous nature of materials.
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 Design Module (WM101). 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.
Bulk materials. Engineered materials. Fabricated products. Servicing of products. Recycling/disposal. The materials cycle relates directly to all streams of engineering and examples from civil, electronic and mechanical/manufacturing will be used for each area.
Nature and family of materials with an emphasis on understanding the structure/property relationship.
Metallic. Ceramics. Polymers. Composites. Electronic materials.
Atomic structure. Molecular structure and bonding. Structure of solid materials. Crystal systems. Crystal imperfections. Substitutional solid solutions. Interstitial solid solutions.
Properties of materials: Mechanical properties. Electrical properties. Dielectric properties. Magnetic properties. Optical properties. Manufacturing properties. Thermal properties. Electrochemistry- electrolysis, corrosion and its prevention. Testing standards.
Learning outcomes
By the end of the module, students should be able to:
- Understand the nature of materials, information and systems and be able to select appropriate materials for engineering use
- Understand 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 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
Indicative reading list
- Manufacturing Processes for Engineering Materials. Kalpakjian and Schmid
- Manufacturing Engineering Technology: Kalpajian and Schmid
- Materials Science for Engineers, James F Shackelford. ISBN 0-13-127619-0
- Callister W.D., Materials Science and Engineering
- Ashby, M.F, Materials Selection in Mechanical Design
- Askeland, D.R. The science of engineering materials
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 | 24 sessions of 1 hour (16%) |
| Seminars | (0%) |
| Tutorials | 6 sessions of 1 hour (4%) |
| Other activity | 10 hours (7%) |
| Private study | 35 hours (23%) |
| Assessment | 75 hours (50%) |
| Total | 150 hours |
Private study description
Review of content, practice using voluntary online Moodle quizzes to do self-assessment of learning.
Research using online textbooks, towards a more detailed understanding of subject areas close to the student's work or towards the delivery of assessments.
Other activity description
Distance learning support - via Teams, Skype, Email depending on the type of interaction required by the student. Typically this activity is associated with assessments.
Costs
No further costs have been identified for this module.
You must pass all assessment components to pass the module.
Assessment group C
| Weighting | Study time | Eligible for self-certification | |
|---|---|---|---|
Assessment component |
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| MMP Coursework | 50% | 20 hours | Yes (extension) |
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A written report based on laboratory testing. The lab is an Impact Toughness lab, and during it they need to test different materials. |
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Reassessment component is the same |
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Assessment component |
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| MMP Exam | 50% | 55 hours | No |
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Examination of learning outcomes not elsewhere covered |
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Reassessment component is the same |
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Feedback on assessment
Written individual feedback on all individual assessments.
Cohort feedback for the exam.
Courses
This module is Core for:
- Year 1 of UWMS-H7B1 Undergraduate Applied Engineering