Module Delivered in
| Short Title: | Materials and Processes 2 |
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| Full Title: | Materials and Processes 2 |
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| Reviewed By: | FIONA CRANLEY |
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| Description: | This module provides a more in-depth knowledge of materials and associated 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 module demonstrates how simple analytical and experimental models can be used to predict process characteristics for both metals and polymers. 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 | - Describe a range of ferrous and non ferrous systems in terms of phase diagrams, solubility, cooling curves, heat treatment mechanisms. [POa,POb,POc]
- Distinguish the process heat treatments that are carried out on a range of metals in a manufacturing environment. [POa,POc,POe]
- Identify the different joining methods that can be used for metals. [POa,POc]
- Describe the effects of temperature on the mechanical properties of different polymeric materials. [POa]
- Describe the effects that the injection moulding processes have on polymeric materials. [POa,POb,POc]
- State the standard Machining Fundamentals regarding single-point & multi-point machining. [POa, POb,POc POe]
- Describe the different machining processes including machinability. [POa, POb,POc]
- Describe the testing of a selection of polymers and creep testing of metals. [POa, POb]
- 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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Solubility & cooling curves Metals - Ferrous and Non-Ferrous Systems , Binary Phase diagrams & phase equilibrium; Iron-carbon Diagram; Non-ferrous phase diagrams; Metals, Manufacturing & Processing Heat Treatment Systems. Process Ferrous heat treatments, Precipitation Hardening - natural & artificial ageing. Powder Metallurgy, Polymer Polymeric Materials. Thermoplastics, Elastomers, Thermosets, Transition temperatures, Tg, Tm & Td. Crystallinity & models. Relationship between polymerization, structure and properties. Mechanical Properties of polymeric materials. Polymer Processing Effect of injection moulding processes on polymeric materials; Controlling the Injection moulding process. Crystallinity & shrinkage. Machining Machining Metals & surface finish requirements; Machining Fundamentals, a simple model; single-point & multi-point, machinability.- Types of chip; cutting forces; temperature & tool life. Machining fluids & environmental issues Material Testing Creep, fatigue Additional Masnufacturing Processes Electronic Chip Production, Pharma Processing
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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 Lab ((Individual, Report & Worksheets) | | 15 | Week 3 | | Laboratory | Manufacturing Lab (Individual, Report) | | 15 | Week 5 | | Project | Manufacturing of an engineering component- Group assignment – Presentation, poster & 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 | | Lab | No Description | 1.330000042915 | Every Week | 1.33 | | Assignment | Materials Case Study. Analysing a consumer product; electing materials based on functional and ergonomic requirements | 0.670000016689 | Every Week | 0.67 | | Total Weekly Learner Workload | 4.00 | | Total Weekly Contact Hours | 3.33 |
| Workload | Part-time mode |
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| Type | Description | Hours | Frequency | Average Weekly Learner Workload |
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| Independent Learning | Study and Assignment 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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| Required Book Resources |
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- Lecture Notes & CES Software – Materials and Processes Selector.
| | Recommended Book Resources |
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- Groover, M.P. 2010, Fundamentals of Modern Manufacturing, 4 Ed., Wiley
- W. Bolton 2000, Materials for Engineering,, Second Ed., Newnes
- S. Kalpakjian, Steven Schmid 2010, Manufacturing Engineering and Technology, Sixth Edition Ed., Prentice Hall
- Michael Ashby, Hugh Shercliff, David Cebon 2007, Materials, engineering, science, processing and design, Butterworth-Heinemann
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