Short Title:Materials and Processes 2
Full Title:Materials and Processes 2
Module Code:MAPR H1003
Credits: 5
NFQ Level:6
Field of Study:Mechanics and metal work
Module Delivered in 6 programme(s)
Module Author:BRIAN O BRIEN
Module Description:This module provides the stdent with fundamental knowledge in materials and processes for materials. It will provide the student with the knowledge required to implement both materials and manufacturing process selection through the analysis of design requirements. It will provide students with an overview of relationship between structure & properties of materials and manufacturing processes. 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 Describe a range of ferrous and non ferrous systems in terms of phase diagrams, solubility, cooling curves, heat treatment mechanisms.
LO2 Distinguish between the process heat treatments that are carried out on plain carbon steels in a manufacturing environment.
LO3 Describe how metals can be shaped into a variety of forms,used in industry, e.g. rolling, extrusion and casting.
LO4 Describe polymer manufacturing processes, mould design. Moulding defects, shrinkage
LO5 Carry out labs in the following areas, e.g. heat treatment, welding, thermal expansion, casting, Deep Drawing & Injection Moulding
LO6 Undertake a manufacturing assignment and prepare report on an assignment & present and defend results.
LO7 Describe the welding process and typical industrial equipment used.
LO8 Select from a range of common engineering metals and polymers using grade or specification.
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) %
Solubility, Cooling Curves & Phase Diagrams
Metals - Ferrous and Non-Ferrous Systems , Binary Phase diagrams & phase equilibrium; Iron-carbon Diagram; Non-ferrous phase diagrams;
Heat Treatment of Metals
Ferrous Heat Treatment Systems. Normalising, Annealing, Quenching & Tempering
Polymer Processing
Injection Moulding, Extrusion, Blow Moulding, Tooling, Moulds and Shrinkage
Solidification, microstructure, Techniques and methods used in casting ferrous and non-ferrous metals. Permanent and non-permanent casting methods, Machinery and mould design
Bulk Forming
Rolling of industrial sections, Extrusion of metals, Hot & cold work structures, recrystallation & Grain growth, properties
Thermal Joining
Welding process, techniques and equipment, Brazing & Soldering
Material Selection
Overview of common metallic and polymeric engineering materials. Use of CES materials database. Consider grade, specification, composition and properties of common materials
Assessment Breakdown%
Course Work100.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Laboratory Materials Lab ((Individual, Report & Worksheets)Injection Moulding, Thermal Expansion, Heat treatment 1,2,5 15.00 Week 3
Laboratory Manufacturing Lab (Individual, Report), Welding, casting, Deep drawing 3,5 15.00 Week 5
Project Manufacturing of an engineering component- Individual or Group assignment – Presentation, poster & report 1,2,3,6 20.00 Week 7
Other In-Class examination 1,2 25.00 Week 6
Other In-Class Examination 3,4 25.00 Week 12
No End of Module Formal Examination
Reassessment Requirement
Repeat the module
The assessment of this module is inextricably linked to the delivery. The student must reattend the module in its entirety in order to be reassessed.

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
Lab No Description 1.33 Every Week 1.33
Directed Learning Materials Case Study. Analysing a consumer product; electing materials based on functional and ergonomic requirements 0.67 Every Week 0.67
Independent Learning Study and Assignment work 3.00 Every Week 3.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture As F/T 2.00 Every Week 2.00
Independent Learning Study and Assignment work 3.00 Every Week 3.00
Lab As F/T 1.33 Every Week 1.33
Directed Learning As F/T 0.67 Every Week 0.67
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00

Module Resources

Required Book Resources
  • Lecture Notes on Moodle
Recommended Book Resources
  • Groover, M.P., Fundamentals of Modern Manufacturing, Wiley
  • W. Bolton, Materials for Engineering,, Newnes
  • S. Kalpakjian, Steven Schmid, Manufacturing Engineering and Technology, Prentice Hall
  • Michael Ashby, Hugh Shercliff, David Cebon, Materials, engineering, science, processing and design, Butterworth-Heinemann
This module does not have any article/paper resources
Other Resources
  • CES Software – Materials and Processes Selector: Granta DesignsCES Software

Module Delivered in

Programme Code Programme Semester Delivery
TA_EBIOM_B B.Eng (Hons) in Biomedical Design 2 Mandatory
TA_EAMEC_B B.Eng(Hons) in Mechanical Engineering [Ab Initio] 2 Mandatory
TA_EBIOM_D Bachelor of Engineering in Biomedical Design 2 Mandatory
TA_EAMEC_D Bachelor of Engineering in Mechanical Engineering 2 Mandatory
TA_EAUTO_D Bachelor of Mechanical Engineering (Automation) 2 Mandatory
TA_EMECH_C Higher Certificate in Engineering in Mechanical Engineering 2 Mandatory