ENGINEERING TRIPOS PART IIA - 2012/2013

Module 3C1 - Materials Processing & Design

MANUFACTURING ENGINEERING TRIPOS PART I - 2011/2012

Module 3P1 - Materials into Products

Coursework:

Engineering IIA: Jominy end-quench test for hardenability
Full Technical Report: weldability of steels, and correlation with hardenability

AIMS

• To provide an understanding of materials processing technology for the manufacture of products;
• To consider the integrated nature of design, material and processing in the manufacture of products;
• To illustrate the processing factors that influence selection in design;
• To relate processing to microstructure evolution and product failure.

OBJECTIVES

By the end of the course, students should:

• Have a broad appreciation of the different materials processing methods used for metals, ceramics and polymers.
• Understand the main interactions between process and material in design and process selection, for each of the main classes of material.
• Understand the factors which control the microstructure of shaped castings, and their consequences for final properties and design of castings.
• Know the main classes of polymers and composites, and understand the processing and design considerations in selecting these for a given component.
• Know the main deformation processes for wrought alloys, and be able to conduct simple plastic analyses.
• Know the microstructural characteristics of wrought alloys, and the reasons for alloying and heat treatment, with examples from Al alloys and steels.
• Understand hardenability of steels, using CCT diagrams to select steels and heat treatments for a given component specification.
• Understand the processes and issues in the manufacture of powder metallurgy and ceramic products.
• Understand the importance of surface treatments and joining technologies, and know the main factors to consider in process selection.
• Be able to apply their knowledge of materials processing, microstructure evolution, and the mechanisms of material degradation to analyse failures and to improve product design.

SYLLABUS

1. Introduction (1L, H.R. Shercliff)

• Classification of manufacturing processes.
• Review of material and process selection.
• Coupled problems in design and manufacturing: the interaction between material, process and design parameters.

2. Metal Casting (2L, H.R. Shercliff)

• Ingot and shaped casting technology.
• Revision of phase diagrams and transformations applied to solidification: segregation, constitutional supercooling, casting alloys and microstructures.
• Casting defects and design of shaped castings.

3. Deformation Processing of Wrought Alloys, Heat treatment (5L, H.R.Shercliff)

• Wrought alloy processing and microstructure evolution.
• Simple modelling of plastic forming processes (stress analysis, and upper bound method).
• Application to rolling, forging, extrusion, machining of metals; case studies.
• Revision of phase transformations and TTT diagrams.
• CCT diagrams and hardenability for steels.

4. Processing of Polymers and Composites (2L, I.M. Hutchings)

• Polymer and composite processing technology.
• Design, material and process selection for polymers and composites.

5. Powder Processing, Surface Engineering, Welding and Joining (3L, I.M. Hutchings)

• Sintering, HIPing and other processing technologies for powder metals and ceramics.
• Surface engineering processes and their applications.
• Welding technology: fusion, friction, laser, ultrasonic.
• Other joining processes: diffusion bonding, brazing, soldering, adhesives.

6. Design against Failure (3L, I.M. Hutchings)

• Processing as the origin of defects and failures (microstructure, damage, residual stress).
• Environmental factors in failure of materials.
• Analysis and case studies of failures.

Examples Papers:

REFERENCES

Please see the Booklist for Part IIA Courses for references for this module.