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MECH6011 - Materials & Processes

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Title:Materials & Processes
Long Title:Eng Materials & Processes
Module Code:MECH6011
 
Duration:1 Semester
Credits: 5
NFQ Level:Fundamental
Field of Study: Mechanical Engineering
Valid From: Semester 1 - 2016/17 ( September 2016 )
Module Delivered in 6 programme(s)
Module Coordinator: GER KELLY
Module Author: LORRAINE HOWARD
Module Description: This module will introduce the student to a variety of machining and manufacturing processes. It will highlight the Health, Safety and Environmental aspects of Materials and Manufacturing Processes. It also covers the production/properties and associated heat treatment of ferrous and non-ferrous materials. (Contact: Dan O'Brien)
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Describe Health, Safety & Environment as applied to Materials and Manufacturing Processes.
LO2 Briefly describe the production/properties and associated heat treatment of ferrous and non ferrous materials.
LO3 Explain Machining, Casting and Shaping Processes.
LO4 Describe basic Destructive and Non-Destructive Tests.
Pre-requisite learning
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named CIT module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
No recommendations listed
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
No incompatible modules listed
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.

No requirements listed
Co-requisites
No Co Requisites listed
 

Module Content & Assessment

Indicative Content
Health Safety and Environment
Product life cycle and material selection. Working environment;hazard identification and risk assessment. Legal requirements.
Metal Cutting
Cutting tool geometry, standard and specialised cutting tool materials. Tool wear.
Cutting Fluids
Synthethic and semi-synthetic cutting fluids. Neat oil and soluble oils and their application.
Basic Applied Chemistry
Covalent, ionic and metallic bonding of atoms. Basic crystal structures and polymorphism. Dendrite growth. Insolidification. The influence of cooling rates on crystal size.
Casting Processes
Ingot casting and continuous casting. Descriptive treatment of sand casting and pressure and gravity die casting processes. Centrifugal casting, investment casting and the full mould process.
Mechanical Testing of Metals
Destructive and non-destructive tests; tensile and hardness. Impact, creep and fatigue tests. Penetrant, magnetic, x-ray, gamma-ray and ultra-sonic tests.
Mechanical Shaping of Metals
Hot and cold working processes, advantages and disadvantages. Forging, hot rolling and extrusion. Cold rolling, drawing, spinning, stretch forming, coining and embossing.
Alloys
Alloy structure types, eutectics, solid solutions and intermetallic compounds. Introduction to equilibrium diagrams. Micro and macro examination of specimens, selection, grinding, polishing, etching. The metallurgical microscope, its use and care.
Manufacture & Heat Treatment of Iron & Steel
Manufacture of iron, smelting process and blast furnace. Steel making, basic oxygen process, electric-arc steel making. The composition of plain carbon steels. Heat treatment: hardening, tempering, annealing and normalising techniques. Surface hardening of steel. Furnaces, control of atmosphere and temperature measurement
Cast Irons
Cast irons; effects of composition on structure, influence of cooling rate on structure. Grey, white, malleable, and spheroidal-graphite irons.
Copper and Alloys
Production and properties of copper and its alloys, brass, bronze, copper-nickel alloys.
Aluminium and its Alloys
Production and properties of aluminium and its alloys, wrought and cast heat treated and wrought and cast non heat treated.
Assessment Breakdown%
Course Work30.00%
End of Module Formal Examination70.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Short Answer Questions Class Test 1,2,3 16.0 Week 6
Written Report Material Properties & Selection using the CES Selector Application 2,3 7.0 Week 8
Written Report Destructive Testing & Material Testing Lab Demonstration 4 7.0 Week 10
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination 1,2,3,4 70.0 End-of-Semester
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

The institute reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Formal Lecture 4.0 Every Week 4.00
Independent & Directed Learning (Non-contact) Self Directed Study 3.0 Every Week 3.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Formal Lecture 3.0 Every Week 3.00
Independent & Directed Learning (Non-contact) Self Directed Learning 4.0 Every Week 4.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.00
 

Module Resources

Recommended Book Resources
  • R. Higgins, Bill Bolton, 2010, Materials for Engineers and Technicians, Fifth Edition, 5th Ed. Ed. [ISBN: 978-1-85617-769-6]
  • Bruce J Black 2005, Workshop Processes, Practices and Materials, 3rd Ed. Ed., Newnes [ISBN: 0750660732]
Supplementary Book Resources
  • Michael Ashby, DRH Jones 2005, Engineering Materials 1: An Introduction to Properties, Applications and Design, 3rd Ed Ed., Butterworth - Heinemann [ISBN: 0750663804]
  • William Callister 2002, Materials Science and Engineering, 6th Ed. Ed., Wiley [ISBN: 0471135763]
  • W. Bolton 2000, Newnes Engineering Materials Pocket Book, Newnes [ISBN: 0750649747]
  • Lawrence Smyth / Liam Hennessy, New Engineering Technology, The Educational Company of Ireland [ISBN: 0861674480]
This module does not have any article/paper resources
This module does not have any other resources
 

Module Delivered in

Programme Code Programme Semester Delivery
CR_EBIME_7 Bachelor of Engineering in Biomedical Engineering 1 Mandatory
CR_EMANF_7 Bachelor of Engineering in Manufacturing Engineering 1 Mandatory
CR_EMECH_7 Bachelor of Engineering in Mechanical Engineering 1 Mandatory
CR_EBIME_6 Higher Certificate in Engineering in Biomedical Engineering 1 Mandatory
CR_EMECH_6 Higher Certificate in Engineering in Mechanical Engineering 1 Mandatory
CR_EMECN_7 Parttime - Bachelor of Engineering in Mechanical Engineering 1 Group Elective 1

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