This module provides the student with fundamental knowledge in materials and manufacturing processes for both metals and plastics. It will provide students with an overview of the relationship between the structure and properties of materials and their influences on manufacturing processes. It will provide the student with the knowledge required to implement both materials and manufacturing process selection through the analysis of design requirements. The student will expand their knowledge of the environmental aspects of manufacturing processes.
Classification and Properties of Materials: Classification and Identification of Materials, Properties of materials: mechanical properties, physical properties, Thermal properties, electrical properties and chemical properties, Selection
Internal Structure of Materials: Atomic structure and arrangement, atomic bonding, Periodic Table of the elements, Macro and microstructure, grains, Crystalline and Imperfections in crystal structure
Polymers: Macro-molecules (polymer chains)Amorphous and Crystalline Thermo-plastic and Thermo-setting. Relationship between polymerization. Structure and properties of common polymers.
Materials Testing: Tensile testing, impact, hardness, fatigue & creep. Detailed discussion on tensile testing, impact & hardness including lab. Describe failure modes including fatigue, creep & testing of materials.
Machining Processes: Machining Process Fundamentals, e.g. cutting speeds, feed rates, machining time, cutting tools, types of chips.
Environmental Issues in Manufacturing & Materials Usage: Classification, Recycling of Materials in Assignment
Joining: Use of Fasteners and adhesives, Typical equipment used
Coating: Techniques and methods used in coating engineering materials.
