Short Title:Materials & Processes1
Full Title:Materials & Processes1
Module Code:MAPR H1006
 
Credits: 5
NFQ Level:6
Field of Study:Mechanics and metal work
Module Delivered in 3 programme(s)
Reviewed By:FIONA CRANLEY
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 from its physical and mechanical properties
LO2 Explain how a material’s properties are influenced by the manufacturing method.
LO3 Describe the tensile testing of a materials to determine the material’s properties.
LO4 Describe the hardness testing of a materials to determine the material’s properties. Use hardness testing equipment
LO5 Explain how material structure influences manufacturing processing and the application of the material
LO6 Describe the Impact testing of a materials to determine the material’s properties. Use an impact test machine
LO7 Describe the failure modes including fatigue, creep & testing of materials to determine these material properties.
LO8 Describe how metals can be shaped into a variety of forms by machining processes, Describe the major machining processes; turning, milling, drilling.
LO9 Describe how metals can be processed into a variety of forms by casting, Describe the major casting processes.
LO10 Describe how meterials can be joined and welded. Describe the major methods and processes used.
LO11 Analyse the manufacturing process and materials of a product including concepts of reusing and recycling.
LO12 Work as part of a team to complete a technical assignment with written and oral reporting
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 Materials, Properties of materials: mechanical properties, physical properties, Thermal properties, electrical properties and chemical properties, Selection
10.00%
Structure of Metals
Arrangement of atoms, bonding Macro and microstructure, grains Crystalline and Imperfections in crystal structure
10.00%
Structure of Polymers
Macro-molecules (polymer chains) Amorphous and Crystalline Thermo-plastic and Thermo-setting Relationship between polymerization, structure and properties,
10.00%
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.
15.00%
Manufacturing Processes of Metals
Machining Process Fundamentals, e.g. cutting speeds,feed rates, machining time, cutting tools, types of chips.
15.00%
Environmental Issues in Manufacturing & Materials Usage
Classification, Reclying of Materials in Assignment
10.00%
Joining and Welding
Use of Fasteners and adhesives, Methods of Soldering, Brazing and Welding. Typical equipment used
15.00%
Casting
Techniques and methods used in casting ferrous and non-ferrous metals. Sand, die and investment processes.
15.00%
Assessment Breakdown%
Course Work50.00%
End of Module Formal Examination50.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Practical/Skills Evaluation Materials Properties & Processes Labs (6) Individual Reports & Worksheets. Tensile Test, Hardness Test, Impact test, Milling, Turning & Drilling related Exercise. Submit a worksheet at the end of the laboratory session 1,3,4,6,7,8 30.00 Week 7
Project Work as part of a team to Reverse Engineer a component or product. Deliver a presentation and poster display. 1,2,3,4,5,6,7,8,11,12 20.00 Ongoing
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination 1,2,3,4,5,6,7,8 50.00 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 Classwork 2.00 Every Week 2.00
Laboratories Practical Laboratory work 1.50 Every Week 1.50
Assignment Group Assignment on Module Content 0.50 Every Week 0.50
Independent Learning Work outside of class 3.00 Every Week 3.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.50
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Classwork 2.00 Every Week 2.00
Laboratories Practical Laboratory Work 1.33 Every Week 1.33
Assignment Group Assignment on Module Content 0.67 Every Week 0.67
Independent Learning Work outside of Class 3.00 Every Week 3.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.33
 

Module Resources

Required Book Resources
  • Lecture Notes - J Dwan, n/a
Recommended Book Resources
  • William D. Callister 2010, Materials Science and Engineering: An Introduction, 8th ed Ed., Wiley
  • Mikell P. Groover 2007, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 3rd ed Ed., Wiley
  • Bruce J. Black, Newnes 2005, Workshop Processes, Practices and Materials, 3rd ed Ed.
  • W. Bolton, Newnes 2000, Materials for Engineering, 2nd ed Ed.
Required Article/Paper Resources
  • Class Notes handed out in Class - Very Important n/a
  • Lab Handout Sheets - to be submitted in Lab n/a
Other Resources
  • CES Software Materials Lab: n/a
 

Module Delivered in

Programme Code Programme Semester Delivery
TA_EAMEC_B B.Eng(Hons) in Mechanical Engineering [Ab Initio] 1 Mandatory
TA_EAMEC_D Bachelor of Engineering in Mechanical Engineering 1 Mandatory
TA_EMECH_C Higher Certificate in Engineering in Mechanical Engineering 1 Mandatory