Materials Processing

MATS23401 Materials Processing 10 Semester 1 Undergraduate Level 5 Chamil Abeykoon Unit coordinator Department of Materials 1 FHEQ level (Framework for Higher Education Qualifications) ' Middle part of Bachelors ' European Credit Transfer & Accumulation System Rating : 5.0 The unit provides comprehensive coverage of the main technologies for the production of artifacts from metals, ceramics, and polymers, and of the theory which underlies materials processing operations.  The unit provides comprehensive coverage of the main technologies for the production of artifacts from metals, ceramics, and polymers, and of the theory which underlies materials processing operations. Lecture topics include:<ul> <li>Introduction; overview of materials processing showing the basic unit operations common to many processes;</li> <li>Heat transfer and fluid flow behaviour;</li> <li>Processing of metals (i.e. casting, extrusion, forging, rolling, wire drawing,);</li> <li>Processing of ceramics and powder processing (i.e. powder preparation, forming and sintering).</li> <li>Processing of ceramic fibre and ceramic matrix composites;</li> <li>Processing of polymers (extrusion, injection moulding, compresion moulding, blow moulding, rotational moulding);</li></ul> The unit aims to allow students to: <ul> <li>select the common processing technologies for polymeric, metallic, ceramic and ceramic composite materials;</li> <li>describe the underpinning physical principles of processing including; heat transfer, fluid flow and kinetic theory;</li> <li>be able to give examples of how processing can affect the structure, and hence properties, of materials;</li></ul>  A greater depth of the learning outcomes will be covered in the following sections: <ul> <li> Knowledge and understanding</li> <li> Intellectual skills</li> <li> Practical skills</li> <li> Transferable skills and personal qualities</li> </ul> <ul> <li> Describe the range and application of generic material shaping processes (processing of polymers, metals, ceramics).   </li> <li> Explain the principles and theory of fluid flow, heat transfer and rheology underlying the processing of materials.   </li> <li> Solve basic fluid flow, heat transfer and rheological problems in materials processing theoretically.   </li> <li> Describe the processing mechanism of single screw polymer extrusion.  </li> <li> Explain the process of cooling in injection moulding.   </li> <li> Explain the  operating prinicples in casting and thermomechanical processing of metals.   </li> <li> Explain the principles and mechanisms of ceramic processing from powder and chemical routes.  </li> <li> To be able to identify the appropraite thchnologies for the production of given artefacts.</li></ul><div>  </div> <ul> <li> Show improved logical reasoning, problem solving and ability in applied mathematics.  </li> <li> Apply simple models to the flow of heat during processing or in application. </li></ul> <ul> <li> Use appropriate software packages to solve basic fluid flow, heat transfer and rheological problems.  </li> <li> Develop awareness of practical aspects associated with operating equipment and performing experiments/tests.  </li> <li> Be able to analyse the data obtained from materials processing experiments/tests.   </li> <li> Understand principles of experimental techniques with virtual learning (e.g. microscope).</li></ul> <ul> <li> Solve subject related problems utilising appropriate methods.  </li> <li> Analyse the related results critically.  </li> <li> Explain the results reliably and effectively.  </li> <li> Work effectively in a group to solve problems.  </li> <li> Compose simple technical/scientific reports on laboratory tests.  </li> <li> Data anlysis with software pakages such as ABAQUS  </li> <li> Presentation of data/results.  </li> <li> Ability to work in a team (group work).</li></ul><div>  </div> <div>This unit is delivered using a blended learning approach, which integrates technology and digital media with traditional classroom activities. A variety of learning and teaching processes will be used including: lectures, discussions, group activities and independent study. Canvas will be used to present online study materials, including videos, lecture notes, guided reading, articles and other information. Canvas will also be used for the submission of assessments.   </div>  1 Written exam 70% 2 Written assignment (inc essay) 15% 3 Report 15% Written and verbal N <ul> <li> “Materials Science and Engineering - An Introduction”, W. D. Callister, D. G. Rethwisch, Pub. Wiley, 2010.</li> <li> “Physics of Plastics” AW Birley, B Haworth, J Batchelor, Hanser, 1991.</li> <li> “Plastics Engineering” RJ Crawford, 3rd Ed., B-H, 1998.</li> <li> “Principles of Ceramic Processing”, S. Reed, Wiley Interscience, 1995.</li> <li> “Materials Science of Thin Films", M. Ohring, 2002 – available as an e-book form University library.</li> <li> ‘’Polymer Extrusion’’, C. Rauwendaal, Hanser, 2001.</li> <li> ‘’Polymer Processing and Structure development’’, A. N. Wilkinson and A. J. Ryan, Kluwer, 1999.</li> <li> ‘’Polymer Extrusion: A Study on Thermal Monitoring Techniques and Melting Issues’’, C. Abeykoon, Lap Lambert, 2012.</li></ul>  Lectures 22 0 78