Teaching

week.

Week commencing

9/29/2014

10/6/2014

10/13/2014

10/20/2014

10/27/2014

11/3/2014

11/10/2014

11/17/2014

11/24/2014

10

12/1/2014

10

12/1/2014

11

12/8/2014

S
S
S

12/15/2014
12/22/2014
12/29/2014

12

1/5/2015

13

1/12/2014

14

1/19/2015

15

1/26/2015

16

2/2/2015

16

2/2/2015

17

2/9/2015

18

2/16/2015

19

2/23/2015

20

3/2/2015

21

3/9/2015

22

3/16/2015
3/23/2015
3/30/2015

4/6/2015

23

4/13/2015

24

4/20/2015

Session1 Tuesday 1300-1400 EC1-02

Session 2 Tuesday 1700-1800 ECG-24

Introduction to Engineering materials:

classification, structure & properties

Engineering materials: Fundamental

material properties (mechanical & thermal)

Material & process selection using CES 1

Material & process selection using CES 2

Material Testing Methods

Metals: Crystals, Melting and Solidification,

Alloys, Solid Solutions, Dislocations &
Plastic Deformation, Crystal Defects

Polymers 1 (materials)+ introduction to

processingStructure and Bonding,
Classification and Characteristics,
Thermoplastics-Tg, Tm and Crystallinity,
Mechanical Behaviour of Thermoplastics,
Thermosets, Rubbers

Powder Metallurgy & Engineering

Ceramics:Why used, Powder Manufacture,
Press & Sintering, Post Sintering
Processes, Impregnation &
InfiltrationStructure, Properties, Defects,
Glasses, Mechanical Testing of Ceramics,
Fibre reinforcement, Manufacturing

Composite Materials 1Classification of

Engineering Composites, Fibre
Reinforcement of Polymers, Anisotropy,
Particle Reinforcement

Metal Casting Processes 1 Sand Casting,

Investment Casting, Shell Moulding,

Metal Casting Processes 1 Sand Casting,

Investment Casting, Shell Moulding,

Metal Casting Processes 2 Die Casting,

Casting Design Issues, Casting Quality &
Defects

XMAS
XMAS
XMAS

Strengthening metals & alloys 1 Work

hardening, Re-crystallisation

Strengthening metals & alloys 2 Heat

treatment of Al alloys and steels

Polymer Processing 1: Properties of

polymer melts, extrusion, injection moulding

Polymers 2 Processing Injection Moulding

Compression moulding, Blow moulding
rotational moulding, Thermoforming

Welding & Joining 1 Welding Processes

MMA, Oxy-Flame, MIG/GMA, TIG/GTA,
PTA

Welding & Joining 1 Welding Processes

MMA, Oxy-Flame, MIG/GMA, TIG/GTA,
PTA

Welding & Joining 2 Welding & Brazing

Processes Laser, Electron beam welding
Adhesives, Mechanical Fastening Brazing,

Composite materials 2 (manufacture)

Compression moulding, Pre-preg, SMC,
Vacuum bagging, Pultrusion, Filament
winding, RTM

Failure of Materials/ Fracture modes

Overview of Ductile, Brittle, Creep Fatigue
failure modes

Surface Issues & TreatmentsProtective

treatments for Fatigue, Corrosion & Wear

Metal forming 1: Rolling, forging, extrusion.

Plastic deformation in forming operations.
Hot and cold forging, hot and cold rolling.
Metal forming 2: Presswork, extrusion,
continuous casting
EASTER
EASTER

EASTER

Machining: Turning, Milling Drilling,

Introduction to non-conventional machining
processes

Rapid Prototyping

Session 1 Friday 1300-1400 ASG31

Session 2 Friday 1400-1500 ASG31

Assessments

Tut 1: Formative test on materials & props

ONLINE TUTORIAL

Tut 2: Material Properties

ONLINE TUTORIAL

Tut 3: CES, material selection

Tut 4: CES material & process selection

Tut 5: Mechanical testing Calculations of

mechanical properties from loadextension based on test graphs/data
supplied

Tut 6 : Online exercise Introduction to

phase diagrams

On-Line Test 1

Tut 7: Plastic processing DVDs

CSWK 1: hand out

Tut 8: Ceramics calculations

On-Line Test 2

CSWK Surgery

Tut 9: Composite calculations

Tut 9: Composite calculations

Tut 11: Casting DVDs and discussion of

casting defects.

CSWK 1: Submission via link

on 102EMM Moodle On-Line
Test 3

Tut 12: Strengthening & recrystallisation of

alloys

CSWK 2: hand out

Tut 13: Phase diagrams, Alloy structures

vs. properties

On-Line Test 4

Tut 14: Plastics processing DVD and

discussion on injection moulding tooling &
defects)

Tut 15: Polymer processing

Tut 16: Welding and Joining DVD

Tut 16: Welding and Joining DVD

Tut 17: Welding and Joining DVD /

Calculations of mechanical characteristics
of welded & bonded joints based on test
data

On-Line Test 5

Tut 18: Composite materials &

manufacturing. Composites processing
DVD

Tut 19: Failure of engineering materials.

Fatigue artefacts/case studies discussion

Tut 20: Surface issues/ corrosion

Tut 21: Forging, rolling, extrusion DVD

Tut 22: Pressworking questions

On-Line Test 6

CSWK Surgery

Tut 24: Examination of a RP component

CSWK 2: Submission via link

on 102EMM Moodle

Component
Coursework 1
(CSWK1)
Coursework 2
(CSWK2)
Online tests

Percentage of
Module Mark

Notes

30

Submission via Turnitin

50

Submission via Turnitin

20

Six tests to be completed during

the course. The best five marks
will be averaged

Author(s)

Title

Groover M. P.

Principles of modern manufacturing

Ashby M.F, Shercliff

H & Cebon D

Materials, engineering, science,

processing & design

Publisher

ISBN

John Wiley and Sons

978-1118474204

ButterworthHeinemann

978-1856178952