ENGINEERING TRIPOS PART IIA - 2012/2013
Module 3C1 - Materials Processing & Design
MANUFACTURING ENGINEERING TRIPOS PART I - 2011/2012
Module 3P1 - Materials into Products
Dr H.R. Shercliff (IIA)
Prof I.M. Hutchings (MET I)
Engineering IIA: Jominy end-quench test for hardenability
Full Technical Report: weldability of steels, and correlation with hardenability
- To provide an understanding of materials processing technology for the manufacture of
- 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.
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.
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.
0. (Revision from IA and IB): phase diagrams, phase transformations, solidification, TTT diagrams, plasticity (week 1)
1. Casting of metals (week 1)
2. Deformation processing of wrought alloys (week 2)
3. Wrought alloy microstructure and heat treatment of steels (week 4)
4. Polymers and composites, powder processing, surface engineering, welding and joining (week 5)
5. Design against failure (week 7)
Please see the Booklist for Part IIA Courses for references for this module.
Last updated: June 2012