Short Title:Materials and Processes 1
Full Title:Materials and Processes 1
Module Code:MAPR H1002
Credits: 5
NFQ Level:6
Field of Study:Engineering, Manufacturing and Construction
Module Delivered in no programmes
Module Author:BRIAN O BRIEN
Module 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.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Identify a material according to it’s material structure and properties [POa, POb ]
LO2 Explain how a material’s properties are influenced by the manufacturing route. [POa , POc]
LO3 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 ]
LO4 Describe how metals can be shaped into a variety of forms used in industry; rolling, extrusion, casting, machining. [POa, POb, POc, POe]
LO5 Describe how polymers can be shaped into a variety of forms using differentmanufacturing processes; thermo-forming, injection moulding, extrusion. [POa, POc,]
LO6 Identify the different joining methods that can be used for metals and polymers. [POa, POc, POe]
LO7 Describe the different machining processes. [POa, POc,]
LO8 Analyse the manufacturing process for a product which is relevant for each discipline including recycling & environmental aspects. [POa, POc, POd, POe, POf]
LO9 Prepare report on an assignment & present and defend results. [POb,POc POd Pof,POg]
Pre-requisite learning
Co-requisite Modules
No Co-requisite modules listed

Module Content & Assessment

Content (The percentage workload breakdown is inidcative and subject to change) %
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
Issues in manufacturing, materails, recycling
Assessment Breakdown%
Course Work40.00%
End of Module Formal Examination60.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Laboratory Materials Properties; Tensile, impact & hardness testing(Individual Worksheets)   15.00 Week 3
Laboratory Manufacturing Processes, Turning, Milling & Polymer Identification. (Individual Worksheet)   15.00 Week 5
Project Mechanical, Manufacturing & ElectroMech Analysis of a consumer product relevant to discipline. Individual assignment & report.   10.00 Week 7
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination   60.00 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.

IT Tallaght 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 No Description 2.00 Every Week 2.00
Laboratories No Description 2.00 Every Week 2.00
Total Weekly Learner Workload 4.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Independent Learning Study and Project work 4.33 Every Week 4.33
Total Weekly Learner Workload 4.33
Total Weekly Contact Hours 0.00

Module Resources

Recommended Book Resources
  • 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
This module does not have any article/paper resources
This module does not have any other resources