Engineering and design

Materials and Manufacturing Processes

Module code: H7106
Level 4
15 credits in autumn semester
Teaching method: Laboratory, Lecture, Practical, Workshop
Assessment modes: Coursework, Unseen examination

This module will cover topics including:

  • approaching engineering problems from first principles
  • the practice of formulating and modelling a problem and applying relevant concepts to describe and study system behaviour
  • critical evaluation of solutions to engineering and design problems
  • introduction to materials and material science: principal characteristics and applications of plastics, metals, composites, ceramics and natural materials
  • historical and recent developments in material science with respect to design and engineering applications
  • introduction to atomic and macroscopic level properties of materials
  • key chemical, electrical, mechanical, thermal, environmental and manufacturing properties of materials
  • how material properties arise from atomic level interactions
  • atomic bonding
  • the basic force/separation curve and the development of the stress/strain relationship
  • introduction to behaviour of materials under load, introduction to forces and basic types of loading cases
  • stress and strain curves
  • mechanics of materials under axial tensile and compressive forces
  • stress concentrations
  • introduction to design stresses and factors of safety
  • selection of materials: basic methods of material selection, use of software in material selection
  • engineering failures: typical failure mechanisms of materials such as fatigue, creep, crack growth, and corrosion
  • case studies of engineering failures with respect to material selection and design
  • introduction to manufacturing processes: casting, moulding, forming, machining, joining, rapid manufacturing and 3D printing
  • correct machine shop working practice and related health and safety considerations
  • practical lathe or milling exercise to understand feeds and speeds, operation, parting off, surface finish, tool selection, and cutting fluids/coolants
  • engineering tolerances
  • cost of manufacture and materials, and related design considerations.

Module learning outcomes

  • Demonstrate understanding of the underlying principles and concepts of the relation between material properties and design.
  • Demonstrate the evaluation of material behaviour for different loading cases.
  • Apply the principles of selection of materials, and analyse the failure modes of materials.
  • Have knowledge and experience of the basic principles of manufacturing processes.