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Name of Course: Code: Credits:


Learning and Support Time: Lecture : Tutorial: Laboratory: 39 Hours 8 Hours 13 Hours

Independent Study : 2 -3 Hours/Week for every Hour spent in Class


Aims/Description: The aim of this unit is to complement Science for Technicians and Mechanical Principles, which are in part concerned with the strength of engineering materials. It also has strong links with Communications and Life Skills for Technicians and underpins those units concerned with production and process technology.

Course Text Materials Science and Engineering: An Introduction, 7th Edition, 2007 William D. Callister, Jr. 1/9/2013 Page 1 of 8

John Wiley ISBN: 978-0-471-73696-7

Reference Text: Higgins, R A Properties of Engineering Materials (Butterworth-Heinemann,1994) Ramsden, E A-Level Chemistry: Material Science (Nelson Thornes,1995) MODULE # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 TOPIC Metals Polymers Ceramics Composites Mechanical properties Thermal properties Electrical and magnetic properties Durability Tests Design considerations Costs Forms of supply Information sources Ductile and brittle fracture Material fatigue Material creep Degradation HOURS 1 3 3 4 2 5 5 4 4 4 4 4 4 4 4 4 4


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Evaluation: This course consists of two (2) components: Course Work Component = 50% Examination Component = 50%

The pass mark for each component is 50%; students are required to pass both components. Failure of any component of the course even if the overall mark were above 50% would be considered a failure of the course. Evaluation Components Quiz Assignment Project & Presentation Lab Percent 10 10 15 15 50 100

Final Examination Total

Resources: The concepts underlying this course are intended for classroom and Laboratory delivery. And this may be enhanced by inclusion of valid practical demonstrations. The classification of materials and their properties is investigated together with available data sources. The selection and processing of materials is also investigated together with the modes of failure that may be encountered. This unit presents opportunities to demonstrate key skills in communication. Course Content

Course Work


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Structure and Classification of Engineering Materials (10%)

At the end of the course students should be able to

1.1 1.2 1.3 Identify the four broad classification of engineering material
Describe the five types of bonding that occur in materials and their characteristics. Define the following terms:

a. Crystal structure b. Body-centered cubic structure c. Face-centered cubic structure d. Hexagonal close-packed structure 1.4 1.5 1.6 1.7
State the three lattice-type structures in metals. Distinguish between the three most common types of crystalline structures. Identify the crystalline structure possessed by a metal. Define the following terms:

a. Grain b. Grain structure c. Grain boundary d. Creep 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17
Define the term polymorphism.

Identify a brief list of non ferrous metals and a brief description of their properties.
Define the term alloy. Describe an alloy as to the three possible microstructures and the two general

characteristics as compared to pure metals.

Identify the three types of microscopic imperfections found in crystalline

State how slip occurs in crystals. Identify the four types of bulk defects.

Identify the three classifications of polymers. Distinguish between the three types of polymers Distinguish between man-made and natural polymers.


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1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26

Describe a typical polymer molecule in terms of its chain structure. Describe the crystalline state in polymeric materials Define ceramic as an engineering material. Identify the basic structure of ceramics. List some of the modern ceramic materials. Define composites as an engineering material. Cite the distinguishing features of each of the three type of composite material. State the three common fiber reinforcement used in polymer-matrix composites. Cite both desirable characteristics and limitations of each of the fibers used in polymer matrix composites.

Properties and Effects of Processing (15%)

At the end of the course students should be able to

1.27 Define the following mechanical properties density, tensile strength, shear and compressive strength, hardness, toughness, ductility, malleability, elasticity, brittleness. 1.28
Describe the effects on the mechanical properties of engineering materials caused

by: a. Forming processes i) Cold working ii) Hot working iii) Forging iv) Rolling v) Extrusion vi) Drawing b. Heat treatment 1.29 Describe the following thermal properties a. Heat capacity


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b. Thermal expansion c. Thermal conductivity 1.30 Describe the following electrical and magnetic properties a. Resistivity b. Permeability c. Permittivity 1.31 Describe durability as it is related to a. Corrosion resistance b. Solvent resistance c. Protection processes 1.32 1.33 1.34 Describe the two types of testing (destructive and non-destructive) Describe the different types of destructive testing (tensile, hardness, impact, compression and bend). Describe the different types of non destructive testing.

Material Selection Criteria (15%)

At the end of the course student should be able to

1.35 List the different property classifications of material that determine their applicability. (mechanical, thermal, suitability for method of manufacture, electrical properties, magnetic properties, optical, others ) 1.36 1.37 1.38 Describe the design process. Identify some of the design consideration in the design process (strength, wear resistance, impact resistance, surface finish, service environment, processability). Identify some of the cost consideration in the design/production process (raw material costs, processing costs, storage costs; availability, quantity and regularity of purchasing ) 1.39 Describe the effects of the various cost factors on material selection


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Identify the various forms of material supply (eg. sheet and plate, barstock, pipe and tube, rolled sections, extrusions, ingots, castings and mouldings, forgings and pressings, granules and powders, chemical liquids )

1.41 1.42

Describe how the manufacturing process affects the form of the material supply. Identify the various sources of information available to design engineers (eg. British Standards specifications (BS), International Standards specifications (ISO), manufacturers and stockholders catalogues and websites, trade directories, disc and network databases )

Modes of Failure (20%)

At the end of the course student should be able to

1.43 1.44 Describe the different types of loading (tensile, compressive, shear, and torsion) Explain the following a. Ductile failure b. Brittle fracture 1.45 Describe how material deform or break (gradual and impact loading, effects of grain 1.46 1.47 size, effects of temperature, transition temperature, appearance of fracture surfaces ) Describe material fatigue Define the following a. Fatigue strength b. Endurance limit c. Crack formation d. Fatigue notch sensitivity 1.48 1.49 1.50 1.51 1.52 Describe the effect cyclic loading, stress concentration have on material fatigue Sketch stress v loading cycles curves Explain various stress v loading cycles curves Describe material creep Describe the various type of material creep (primary, secondary and tertiary creep)


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1.53 1.54 1.55 1.56

Define degradation in engineering material Describe stress corrosion in metals Describe solvent attack, radiation damage and ageing of polymers Describe deterioration of ceramics due to thermal shocks and sustained high temperatures

Laboratory Sessions: Week 5 6 7 Laboratory Session Tensile Testing Hardness Testing Impact Testing

The practical activities should emphasize the development of key inquiry learning skills such as:

Observation, Reporting and Recording

2. Manipulation and Measurement 3. Analysis and Interpretation 4. Planning and Design


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