Module Specifications..
Current Academic Year 2023 - 2024
Please note that this information is subject to change.
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None Students will be afforded the opportunity to repeat the terminal exam in a resit examination. Learning outcomes associated with continuous assessment and project work may be repeated through the completion of a repeat assignment. |
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Description This module is focused on the development of theoretical understandings in relation to engineering materials and practical skill development for the processing of a wide range of materials. The students’ appreciation and understanding of material science will be developed through theoretical treatment of the subject, whilst reinforcing and developing this understanding through the practical processing of a range of materials. This integrated approach will provide the foundations for mastery of craft and design related competencies. Links between the theoretical content and the practical experience will be reinforced, where students will be required to make informed choices in relation to the processes they employ and the machining parameters (feeds, speeds etc.) that they will select as a result of reflecting on the material properties of the work piece that they are processing. This foundational understanding of materials and associated practical skill development will be dealt with throughout the completion of a technological project that will contain an introductory technological design challenge. Students will be required to complete and provide a rationale for the material selection of each component of the project, where initial material selection will be confirmed through the use of a systematic material selection process. Foundational appreciation, skills and knowledge development in relation to material selection and processing techniques and technology will act as the building blocks to making informed design choices on aspects such as sustainability in future modules. Students will operate within a workshop based, practical learning environment with a keen awareness of best practice and a complete adherence and dedication to standard operating procedures and safe practice. This module will be delivered through classroom tutorials and engineering workshop sessions. Classroom tutorials will deliver theoretical content whilst being interactive and engaging students, providing time for exploration of the theoretical content and problem-solving through pair work, small group discussions, and consideration of fundamental concepts such as; material properties, material selection, sustainability, material processing techniques, process planning, engineering graphical standards, the production and reading of working drawings, and technological design considerations. Tutorials will also provide the opportunity for students to develop skills associated with manual drafting and the production of working drawings which will be subsequently manufactured in practical labs. Computer software will be utilised where appropriate to produce working drawings, conduct material selection procedures, produce project reports and conduct research to inform design and manufacture decisions. Practical engineering workshop labs will see students develop processing skills with a range of engineering materials. Emphasis will be placed on handcraft, bench working skills and basic machining processes with a focus on measurement, manufacturing sequences and safe practices. | |||||||||||||||||||||||||||||||||||||||||
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Learning Outcomes 1. Emphasise and employ standard operating procedures and appropriate health and safety considerations and value the importance of a commitment of safe practice when working in a practical environment. 2. Appreciate the role that health and safety, fundamental knowledge and skills associated with materials processing play in the development of further technological capabilities. 3. Appreciate the environmental and sustainability implications of consuming materials for the realisation of engineering components products and systems. 4. Value high quality work and appreciate the importance of craftsmanship, accuracy and aesthetics. 5. Describe sourcing and primary production techniques and the solidification of metals and the typical microstructures that are present in a range of metallic materials. 6. Carry out a range of destructive and non-destructive material tests to determine, characterise and outline the mechanical properties of a range of material samples. 7. Outline and employ the stages of a systematic material selection process for specific technical applications. 8. Process materials using common hand tools while demonstrating best practices and appropriate health and safety considerations. 9. Conduct risk assessments and select appropriate cutting tools, machine parameters and appropriate work holding techniques for the machining (Pillar drill, lathes, milling machine) of a range of work piece materials. 10. Describe permanent (e.g. riveting, thermal joining processes and adhesives) and non-permanent (mechanical fasteners) methods of joining materials. | |||||||||||||||||||||||||||||||||||||||||
All module information is indicative and subject to change. For further information,students are advised to refer to the University's Marks and Standards and Programme Specific Regulations at: http://www.dcu.ie/registry/examinations/index.shtml |
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Indicative Content and Learning Activities
Structures of Metals:Types of Atomic Bonds, Crystal structures of metals, Grains and Grain Boundaries, Plastic deformation of Polycrystalline metals, recrustallisation and Grain Growth, Cold and Hot working of metals.Material Properties and Materials Testing:Tension, Compression, Torsion, Bending, Hardness, Fatigue, Creep, Impact, Toughness, Malleability, Tensile strength, and how to test and characterise different materials using appropriate material tests (Brinell, Vickers and Rockwell hardness numbers, Izod and Charpy impact testing, Tensile testing (Extensometer) and the derived material properties from load vs extension graph; i.e Stress/Strain, Young’s Modulus of Elasticity, Yield points, Ultimate tensile strength.)Metals:Classifications and Origins of Metals; Structures of Metals; Iron and Steel; Non-Ferrous Metals; Heat Treatment of Metals; Corrosion of Metals; Materials Testing.Plastics:Classification and Sources of polymeric materials; Physical Structure of polymer materials; Manufacture and Processing of plastics; Properties and uses of common thermoplastics and thermoset plastics; Additives in Plastics, Elastomers, Intro to Polymer Processing — Injection Moulding, Extrusion, Blow Moulding and Vacuum Forming.Material Selection:Students will be required to rationalise the material selection for each component of the project, where material selection will be confirmed through the use of a systematic material selection process. Students will rank suitable materials for particular applications using material indices within the CES Granta material selection software.Primary processing of materials (woods, metals and plastics):Primary processing (extraction, mining, refining, harvesting, conversion, seasoning), material availability and sustainability.Secondary processing of material:Measurement (datum surfaces, accuracy and equipment), marking out strategies and procedures. Hand tool processing procedures and best practices, Correct and accurate use of hand tools for material removal and finishing including; Work holding, Hacksawing, Filing, Cold Chiselling, Folding, Bending, Forming etc. material joining, health and safety.Processing of Metals:Casting, Forming, Introduction to machining procedures and best practices, machine setup, cutting tools, cutting fluids. Basic construction and standard operating procedures of pillar drill, lathe, milling machine. This will include developing and demonstrating an awareness of correct machine care and maintenance.Engineering Graphics:Emphasis on reading working drawings and relevant standards and conventions; (Line types, symbols and hatching, dimensioning, annotations, standards associated with sectional and exploded views). Selecting the most appropriate views including section views and detail views as a means of aiding in the communication of a working drawing for manufacture. Directly related to the content of Graphics 1 module through the application of orthographic projection for working drawings.Drawing standards and conventions:Line types, symbols and hatching, dimensioning, annotations, standards associated with sectional and exploded views, working drawings.Design:Nature of design briefs (open-ended, closed-ended, ill-defined, well-defined), introduction to design portfolios (authenticity of design journeys and structured communication), design based on material considerations and personal competencies, introduction to assessment of design.Project Work:Time management, commitment to quality of finish, planning for logistics and sequencing of processes. Record and reflect upon efficiencies of manufacturing sequences. Working with a commitment to health and safety practices in a practical workshop environment. Report on possible risks and develop an awareness of caring for themselves, others and the working environment. Consider and report upon the benefits of project work in technological education for forming deeper understanding of abstract concepts through concrete experimentation and realisation of a technological artefact or system. | |||||||||||||||||||||||||||||||||||||||||
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Indicative Reading List
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Other Resources 58993, Online Resource:, 0, https://www.nature.com/articles/nmat1314.pdf, | |||||||||||||||||||||||||||||||||||||||||
Programme or List of Programmes
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