REFERENCE NO.: E12 - EMAT 1. COURSE NAME: Engineering Materials 2.

COURSE DESCRIPTION: The course includes the Properties and Uses, Process, Basic Metallurgy Metals and Processes, Non-Metallic Materials, Materials Underload and Vibrations 3. NUMBER OF UNITS FOR LECTURE AND LABORATORY: 3 LECTURE, 0 LABORATORY = 3 UNITS 4. NUMBER OF CONTACT HOURS: 3 LECTURE; 0 LABORATORY = 3 HOURS 5. PREREQUISITES: NONE 6. COURSE OBJECTIVES The student shall be able to select suitable materials for repairs and/or fabrication of various parts normally needed on board and the students will also be able to apply the properties of materials generally used on board under varying conditions. FUNCTION: F1- Marine Engineering at the Operational Level F3- Maintenance and Repair at the Operational Level 7. COURSE OUTLINE: LEARNING OBJECTIVES/OUTCOMES: The student shall be able to... Materials for Construction and Repair 7.1. Properties and Uses 7.1.1 explain in simple terms what influences the choice of material for a marine engineering component 7.1.2 describe in simple terms what is meant by the following mechanical properties: 7.1.2.1 elasticity 7.1.2.2 brittleness 7.1.2.3 hardness 7.1.2.4 strength 7.1.2.5 toughness 7.1.2.6 ductility 7.1.2.7 malleability 7.1.2.8 plasticity 7.1.3 explain what is meant by low-, medium- and high-carbon steels 7.1.4 compare the tensile strength, ductility and hardness of low-, medium- and high-carbon steels
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7.1.5 state the uses of low-, medium- and high-carbon steels 7.1.6 describe the properties of cast iron and gives examples of its use 7.1.7 define an alloy 7.1.8 state the uses of aluminum, copper, zinc, lead, tin and antimony 7.1.9 state the component metals of brass, bronze and white metal 7.1.10 state the uses of the above alloys 7.1.11 explain why the above alloys are suitable for the uses in the above objective 7.1.12 identify samples of metals described in the above objectives 7.2. Process 7.2.1 describe, in basic terms, the following heat-treatment processes: 7.2.1.1 tempering 7.2.1.2 annealing 7.2.1.3 normalizing 7.2.1.4 hardening 7.2.2 explain, indicate why the processes in the above objective are used 7.2.3 state how low-carbon steels can be given a hard case 7.2.4 state why low-carbon steels are sometimes given a hard case 7.2.5 describe in basic terms a suitable heat-treatment process for common carbon steels, given the properties required

Processes for Fabrication and Repair 7.3. Basic Metallurgy, Metals and Processes 7.3.1 describe in simple terms the production of pig iron from iron ore 7.3.2 describe the principles of the open-hearth, the Bessemer and more modern processes used in the production of steel from pig iron 7.3.3 explain the principal differences between sand casting, die casting, centrifugal casting, forgings, cold working and hot-rolled plate, bars and other sections 7.3.4 state the normal range of carbon content in mild steel, tool steel, cast steel and cast iron 7.3.5 describe the principle difference between ferrous and non-ferrous metals 7.3.6 give examples of applications of non-ferrous metals in marine engineering 7.3.7 state the purpose of the alloying elements nickel, chromium and molybdenum in steels used in marine engineering 7.3.8 identify the metals used in non-ferrous alloys commonly employed in marine engineering 7.4. Non-Metallic Materials 7.4.1 explain the reasons for using the following fillers in polymers: 7.4.1.1 glass fibre 7.4.1.2 asbestos 7.4.1.3 mica 7.4.2 state that polymers can be plastic, rigid, semi rigid or elastomeric 7.4.3 state the properties and limitations of polymers 7.4.4 lists polymers and other non-metallic materials in common use
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7.4.5 state applications of polymers and other non-metallic materials on board ship 7.5 Materials Under Load 7.5.1 define stress as the internal resistance per unit area of a material to an externally applied load 7.5.2 define strain as the deformation produced in a material by an externally applied load 7.5.3 describe three types of loading as: 7.5.3.1 tensile 7.5.3.2 compressive 7.5.3.3 shear 7.5.4 illustrate with the aid of simple sketches, a material under each of the applied loadings given in the above objective, using arrows to indicate load and stress and dotted lines to indicate deformation 7.5.5 explain how stress and strain can be calculated in terms of loading and material dimensions, for the cases in the above objectives 7.5.6 define, for an elastic material subjected to a tensile load: 7.5.6.1 elastic limit 7.5.6.2 yield point 7.5.6.3 ultimate strength 7.5.6.4 breaking strength 7.5.7 state that, within the elastic limit, Hookes law will apply 7.5.8 define Hookes law as: stress = a constant strain 7.5.9 define the constant contain in Hookes law as the elastic modulus 7.5.10 apply the above objectives to simple numerical calculations 7.5.11 show, on a sketched graph of load to a base of corresponding extension values, the behavior of an elastic material under tensile loading and indicates the condition points listed above 7.5.12 state the significance in engineering practice of the four physical properties in the above objectives 7.6 Vibration 7.6.1 state that vibration is caused by the effect of a single force or a succession of forces applied suddenly to elastic materials 7.6.2 state the forces causing vibration in a ship usually result from an imbalance in the machinery 7.6.3 describe the main sources of ship vibration as: 7.6.3.1 machinery with reciprocating components (e.g. pistons etc.) 7.6.3.2 ships propeller blades rotating through water of varying pressure and velocity 7.6.3.3 rotating machinery which has not been balanced (e.g. some crankshafts) 7.6.3.4 rotating machinery becoming unbalanced through damage, erosion, corrosion or deposits (e.g. dirt, scale, etc.) 7.6.3.5 unbalanced powers in the cylinders of a diesel engine 7.6.3.6 worn bearings in rotating machinery
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7.6.4 state that a ships structure and machinery are constructed largely of materials which are elastic 7.6.5 state that vibrations are transmitted from one elastic material or component to another 7.6.6 state the anti-vibration materials are sometimes placed between connecting parts in order to reduce vibration 7.6.7 state that if a component is vibrating then a reversing stress is present in the material 7.6.8 state that in normal working conditions the stresses due to vibrations are well within limits allowed for in the design 7.6.9 state that vibrations in a component may be from different sources, which can synchronize and magnify the effect 7.6.10 state that if vibrations become excessive the stresses induced can cause permanent damage 7.6.11 state that excessive vibration should not be allowed to continue 7.6.12 state that when varying the rotational speed of machinery, stages may be encountered where vibrations become excessive 7.6.13 explain that the condition described in the above objective is normally due to a synchronization of vibrations which occurs at what is known as critical speeds 7.6.14 state the excessive vibration within machinery is not always apparent 7.6.15 state that critical speeds are predictable and should be clearly marked on controls and known to engineer officers 7.6.16 state the machinery should not be allowed to operate either at or close to a critical speed 7.6.17 state the critical speed ranges should passed through as quickly as possible 7.6.18 state that in addition to including stress, vibration may cause securing devices to work loose 7.6.19 explain how vibration may be reduced 8. EQUIPMENT, MATERIALS, CHEMICALS, TEACHING AIDS: The equipment, materials, chemicals, teaching aids needed in this course is listed in the attached APPENDIX 1. 9. REFERENCES: 9.1 9.2 9.3 9.4 9.5 Alimen. Engineering Materials. 2001 Dalaguete, Felicito. Machine Shop Practice. 1999 Elkanvil. Process and Design for Manufacture 1989. Singer. Strength of Materials 3rd ed./1980. Popoy, Ed., Mechanics of Materials 1976.

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