1 Semester

60 Hours

Hawthorn, Sarawak

HES1230 Materials and Processes

Nil

Credit Points: 12.5 Credit Points

Related Course/s:

Aims & Objectives:

• Provide a basic understanding of engineering materials and manufacturing processes emphasising their applications and importance in an engineering context
• Demonstrate and explore through the use of practical laboratory experience the manufacturing processes in relations of materials and their effect on performance
• Make students aware of failure in materials and thereby develop an understanding of the principles of materials selection
• Make students aware that many materials are derived from non-renewable sources and suffer from degradation in many forms in their application
• Inform students in the knowledge that advances in modern manufacturing are playing critical roles in many new technologies

After successfully completing this unit, students should be able to:

• Demonstrate an understanding of a variety of engineering materials (ferrous and non-ferrous) by familiarise with material microstructure and property in a heat treatment laboratory experiment
• Evaluate the failure of materials by analysis of known failure case studies by completing a series of tutorial exercises relating to failure of materials
• Identify a series of materials removal processes and to relate how a product is manufactured by calculating the force and friction involved in the process
• Apply knowledge of quality and measurement by completing a series of laboratory practicals using measuring techniques similar to those used in industry
  

Teaching Methods:

Assessment:

Generic Skills Outcomes:

• Ability to apply knowledge of basic science and engineering fundamentals
• Ability to communicate effectively, not only with engineers but also with the community at large
• Ability to undertake problem identification, formulation and solution
• Ability to utilize a systems approach to design and operational performance
• Ability to function effectively as an individual and in a multi-disciplinary and multi-cultural teams, with the capacity to be a leader or manager as well as an effective team member
• Understanding of the social, cultural, global and environmental responsibilities of the professional engineer, and the need for sustainable development
• Understanding of the principles of sustainable design and development.
• Understanding of professional and ethical responsibilities and commitment to them
• Expectation of the need to undertake lifelong learning, and capacity to do so

Content:

Ferrous, Non-ferrous Metals and Ceramics: Production of cast iron/steel, blast furnace, basic oxygen steel making, electric arc, Fe-Fe3C phase diagram, plain carbon steel, cast irons, Microstructural phase constituents, structure/property relations, Isothermal transformation diagrams, principles of heat treatment, Alloy steels, modern thermal processing methods, HSLA, tool steel heat treatment, Joining of metals, soldering, brazing, welding, Aluminium alloys, modes of strengthening, heat treatment, microstructure property relations.               

Surface Engineering: Infusion processing, thermal hardening, thermo-chemical treatment. Surface coatings, dip processing, electroplating, thermal spraying, vapour deposition.

Material Removal Processes: Chip forming processes, machine, grinding, Tool wear, Taylor tool life, tool wear mechanisms, Tool materials, HSS, carbide, Surface coating, Surface integrity, economics, Non-traditional material removal processes.

Manufacturing automation: Numerical control, fundamentals of CNC programming, role of robotics in increasing efficiency, CAD/CAM.

Textbooks:

References: