Module Delivered in
| Short Title: | Materials and Processes 1 |
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| Full Title: | Materials and Processes 1 |
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| Reviewed By: | FIONA CRANLEY |
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| Description: | 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. |
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| Learning Outcomes: |
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| On successful completion of this module the learner will be able to | - Identify a material according to it’s material structure and properties [POa, POb ]
- Explain how a material’s properties are influenced by the manufacturing route. [POa , POc]
- Describe the different types of materials testing that can be carried out to determine the materials behaviour under different application environments. Typical tests include tensile testing, impact strength, fatigue and hardness. [POa, POb, POc, POd, POe, POf ]
- Describe how metals can be shaped into a variety of forms used in industry; rolling, extrusion, casting, machining. [POa, POb, POc, POe]
- Describe how polymers can be shaped into a variety of forms using differentmanufacturing processes; thermo-forming, injection moulding, extrusion. [POa, POc,]
- Identify the different joining methods that can be used for metals and polymers. [POa, POc, POe]
- Describe the different machining processes. [POa, POc,]
- Analyse the manufacturing process for a product which is relevant for each discipline including recycling & environmental aspects. [POa, POc, POd, POe, POf]
- Prepare report on an assignment & present and defend results. [POb,POc POd Pof,POg]
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Module Content & Assessment| Content |
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Classification and Properties of Materials. Classification and Identification of Metals Properties of materials: mechanical properties, physical properties, Thermal properties, electrical properties and chemical properties Structure of Metals Arrangement of atoms, bonding, Macro and microstructure, grains Crystalline and Imperfections in crystal structure. Alloys & Solid Solutions in Metals. Solidification mechanisms Structure of Polymers Macro-molecules (polymer chains) Amorphous and Crystalline, linear, branched cross-linked & network. Thermo-plastic and Thermo-setting, Polymerization. Materials Testing Tensile testing, compressive, impact, hardness, fatigue Detailed discussion on tensile testing including lab. Failures, ductile & brittle, DBT re impact. Manufacturing Processes of Metals: Bulk forming processes, Casting processes, Machining processes, cutting speeds & feeds & calculations. Environmental issues Manufacturing Processes of Polymers: Thermo-forming, extrusion, injection moulding, rotational moulding and blow moulding, Compression moulding. Associated Environmental issues Joining Processes of Metals: Welding of metals & associated Environmental issues Environment Issues in manufacturing, materails, recycling
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| Assessment Breakdown | % |
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| Course Work | 40% | | End of Semester Formal Examination | 60% |
| | Outcome addressed | % of total | Assessment Date |
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| Formal End-of-Semester Examination | None | 60% | Semester End |
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| Coursework Breakdown |
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| Type | Description | Outcome addressed | % of total | Assessment Date |
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| Laboratory | Materials Properties; Tensile, impact & hardness testing(Individual Worksheets) | | 15 | Week 3 | | Laboratory | Manufacturing Processes, Turning, Milling & Polymer Identification. (Individual Worksheet) | | 15 | Week 5 | | Project | Mechanical, Manufacturing & ElectroMech Analysis of a consumer product relevant to discipline. Individual assignment & report. | | 10 | Week 7 |
| Reassessment Requirement |
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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. |
IT Tallaght reserves the right to alter the nature and timings of assessment Module Workload & Resources| Workload | Full-time |
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| Type | Description | Hours | Frequency | Average Weekly Learner Workload |
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| Lecture | No Description | 2 | Every Week | 2.00 | | Laboratories | No Description | 2 | Every Week | 2.00 | | Total Weekly Learner Workload | 4.00 | | Total Weekly Contact Hours | 4.00 |
| Workload | Part-time mode |
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| Type | Description | Hours | Frequency | Average Weekly Learner Workload |
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| Independent Learning | Study and Project work | 4.329999923706 | Every Week | 4.33 | | Part-Time Total Weekly Learner Workload | 4.33 | | Part-Time Total Weekly Contact Hours | 0.00 |
| Resources |
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| Recommended Book Resources |
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- Lecture Notes & CES Software – Materials and Processes Selector.
- W. Bolton, 2000, Materials for Engineering, Second Ed., Newnes
- Donal Askeland 1994, The science and engineering of materials, Third Ed., PWS Publishing Company
- Michael Ashby, Hugh Shercliff, David Cebon 2007, Materials, engineering, science, processing and design, Butterworth-Heinemann
- Groover, M.P. 2010, Fundamentals of Modern Manufacturing, 4 Ed., Wiley
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