Course Title: Apply Basic Principles of Materials Science to Engineering Applications

Part B: Course Detail

Teaching Period: Term1 2011

Course Code: PROC5230

Course Title: Apply Basic Principles of Materials Science to Engineering Applications

School: 130T Vocational Engineering

Campus: City Campus

Program: C6069 - Advanced Diploma of Engineering Technology

Course Contact: Program Manager

Course Contact Phone: +61 3 9925 4468

Course Contact Email: engineering-tafe@rmit.edu.au


Name and Contact Details of All Other Relevant Staff

Nominal Hours: 40

Regardless of the mode of delivery, represent a guide to the relative teaching time and student effort required to successfully achieve a particular competency/module. This may include not only scheduled classes or workplace visits but also the amount of effort required to undertake, evaluate and complete all assessment requirements, including any non-classroom activities.

Pre-requisites and Co-requisites

None

Course Description

This unit of competency sets out the knowledge and skills required to apply basic principles of materials science to engineering problems applications. It involves testing of materials to evaluate the engineering properties of materials and includes the recognition of common materials used in engineering, the properties of materials and the factors that influence those properties.


National Codes, Titles, Elements and Performance Criteria

National Element Code & Title:

VBP263 Apply Basic Principles of Materials Science to Engineering Applications

Element:

Complete and document materials testing and evaluation task

Performance Criteria:

3.1 OH&S requirements for completing the work are followed.
3.2 Documentation associated with materials testing and evaluation task is prepared according to enterprise procedures.
3.3 Documentation associated with the materials testing and evaluation task is controlled and correct revision levels are assigned.
3.4 The completion of the materials testing and evaluation task is notified and outcomes are discussed with appropriate personnel.

Element:

Perform materials testing and evaluation task.

Performance Criteria:

OH&S requirements for carrying out the work are followed.
2.2 Safety hazards which have not previously been identified are documented and risk control measures devised and implemented in consultation with appropriate personnel.
2.3 The materials testing and evaluation is undertaken according to enterprise procedures.
2.4 The most appropriate materials testing and evaluation methodology is chosen for given task.
2.5 Decisions for dealing with unexpected situations are made from discussions with appropriate personnel, job specifications and enterprise procedures.
2.6 Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

Element:

Prepare for materials testing and evaluation task

Performance Criteria:

1.1 OH&S and environmental requirements for a given work area are obtained and understood.
1.2 Established OH&S requirements and risk control measures and procedures in preparation for the work area are followed.
1.3 Safety hazards which have not previously been identified are documented and risk control measures devised and implemented in consultation with appropriate personnel.
1.4 The materials testing and evaluation task requirements are determined through documentation, job sheets and through discussion with appropriate personnel.
1.5 Expert advice is sought with respect to the materials science task and according to enterprise procedures where appropriate.
1.6 Appropriate personnel are consulted to ensure the work is co-ordinated effectively with others involved at the work site.
1.7 Resources and equipment needed for the task are obtained in accordance with enterprise procedures and checked for correct operation and safety.


Learning Outcomes


Complete and document materials testing and evaluation task

Perform materials testing and evaluation task.

Prepare for materials testing and evaluation task


Details of Learning Activities

The total number of scheduled hours of teaching, learning and assessment involved in this course includes all planned activities


Teaching Schedule

 

 Session Topic Content Delivery
Including Learning activities
 Performance CriteriaAssessment
task
 1 Overview of Classification of Materials
• Review of Material Classes
• Metals and non-metals, ferrous and non-ferrous metals
• Thermosetting, thermoplastic and elastomeric polymers
• Composite materials
• Ceramic materials
• Biomaterials
• Advanced Materials

Solve problems Chapter 1 Introduction to Materials Science
 1 Test scheduled for session 11
 1 Determine Structure of Materials
• Solids, liquids and gases, atomic structure, periodic table, chemical bonding, crystal structures, development of grain structures
Solve problems Chapter 2 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 2 Determine Properties of Materials
• Physical Properties: Electrical conductivity/resistivity, specific gravity/density, thermal conductivity/ expansion, specific heat, melting/boiling points
• Mechanical Properties: Strength- yield, tensile, compressive, torsion, flexural, hardness, impact properties, elasticity, plasticity, ductility, malleability, fatigue, and creep.
Solve problems Chapter 3 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 3 Calculate Stress and Strain Behaviour of Materials
• Determine Stress: yield, proof, ultimate, breaking
• Determine Strain
• Determine Modulus of Elasticity

Solve problems Chapter 4 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 3 Perform Tensile Testing of Materials
• Draw graph of results from Tensile Testing
• Calculate behaviour of ductile and brittle materials to tensile forces
• Perform Hardness and Impact testing

Solve problems Chapter 4 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 3 Research assignment 1, 2, 3 You will research and produce a typical engineering report regarding a specific material utilised in engineering manufacturing
 4 Perform Laboratory Practical #1, Mechanical testing and Heat Treatment of Steel 1, 2, 3 You will perform a laboratory practical investigation using heat treatment to alter the mechanical behaviour of carbon steels. You will then write a typical scientific report on your investigation, presenting results and discussing your analysis and conclusions
 5 Determine Chemical Properties of Materials
• Corrosion and Oxidation of metals
• Degradation of polymers

Solve problems Chapter 5 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 5 Specify Applications of Ferrous Metals to Industrial Applications
• Plain Carbon and Alloy Carbon steels
• Cast irons

Solve problems Chapter 6 Introduction to Materials Science


 1, 2, 3 Test scheduled for session 11
 6 Specify Applications of Non-Ferrous Metals to Industrial Applications
• Aluminium, Copper, Nickel, Zinc, Titanium, Magnesium, and their respective metals alloys
• Refractory metals
Solve problems Chapter 7 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 7 Specify Applications of Polymers to Industrial Applications
• Thermosetting ,Thermoplastic and Elastomeric polymers
• Polymerisation
• Manufacturing processes
• Applications

Solve problems Chapter 8 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 8 Specify Applications of Ceramic Materials to Industrial Applications
• Heavy clay products, Domestic ceramics, Electrical ceramics, Abrasives, Refractories, Glass, Glass Ceramics, Advanced ceramics
• Manufacturing processes and applications

Solve problems Chapter 9 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 8 Specify and Evaluate Mechanical and Physical Properties of Composite Materials to Industrial Applications
• Principles
• Laminar, Particulate and Fibre Composites
• Metal, Ceramic Matrix Composites
• Applications

Solve problems Chapter 10 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 9 Perform Laboratory Practical #2, Perform Annealing and Recrystallisation of Work Hardened Brass to Evaluate Mechanical Properties by Hardness Testing and Optical Microscopy 1, 2, 3 You will perform a laboratory practical investigation using heat treatment to alter the mechanical behaviour of work hardened brass. You will then write a typical scientific report on your investigation, presenting results and discussing your analysis and conclusions
 10 Determine Effects of Mechanical and Thermal Processes on the Properties of Materials
• Hot and cold work
• Grain growth
• Recrystallisation

Solve problems Chapter 11 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 10 Determine Microstructure of Metals when Influenced by Thermal Fabrication Processes
• Joining; soldering, brazing, welding
• Difficulty in welding high carbon steels

Solve problems Chapter 12 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 10 Specify Non-Destructive Testing of Materials Methods for Industrial Applications
• Visual
• X-Ray
• Ultrasonic
• Dye penetrant
• Magnetic particle
• Eddy current

Solve problems Chapter 13 Introduction to Materials Science
 1, 2, 3 Test scheduled for session 11
 11 Unit Competency Test 1, 2, 3 This is an closed book test


Learning Resources

Prescribed Texts

Workbook: PROC5230 (VBP263) Apply Basic Principles of Materials Science to Engineering Applications, available from RMIT Bookshop

Textbook: Materials Science and Engineering, an Introduction; 7th Edition. William D. Callister, Jr. John Wiley & Sons – Publisher, available from RMIT Bookshop


References


Other Resources

Student Network Drive ’S’-drive

S:\Mechanical and Manufacturing\PROC5230 Apply Basic Principles of Materials Science to Engineering Applications\George Zouev\


Overview of Assessment

2 x Practical laboratory reports  
1 x End of course exam


Assessment Tasks

Assessment 1 – Research Assignment

This assessment will focus on your ability to research and write a standard technical report focusing on the following criteria:

Locating (finding)


Once the purpose, scope and requirements of the assignment have been defined, the process of locating relevant resource material begins. This involves:
• identifying what to look for and where to find it
• determining search terms and research parameters
• consulting library catalogues, databases, bibliographies, search engines, recommended texts, knowledgeable experts
• considering a range of sources, including books, journals, websites, people, images
• collecting and managing resources
• recording all relevant bibliographical details.


Selecting (sifting/choosing)


The information collated during the location stage may generate a redefinition or refocusing of the research project. Selection and evaluation of resources takes place to a certain extent during the location stage, but it is often better to collect more information than you need, at least initially. Careful evaluation of the assembled resources is necessary to ensure they are appropriate, authoritative and relevant. Selecting resources involves:
• identifying the source of the information
• focusing on the assignment topic to determine the objectivity, accuracy, currency, suitability and academic merit of the information
• skimming and scanning resources to sort information into categories
• taking brief notes and observing how different sources may relate to one another
• identifying questions or areas which may require further research
• establishing which are your principal and supplementary resource materials.


Organising (sorting/structuring)


This step of the research process requires a more detailed reading of the resource material and the development of a structure for the assignment. Here, the skills of notetaking and arranging information are necessary, as is:
• keeping your notes focused on the topic
• writing in your own words
• sorting information into categories
• considering how various elements of the topic connect to one another
• establishing a detailed plan or outline of the assignment
• developing an argument
• integrating sources and quotations effectively.


Presenting (synthesising/communicating)


Following the plan established in the organising stage, the task now is to write the assignment. Presentation of the research entails:
• pulling all the information together
• checking that information relates to the original question
• considering the sequence in which the information is arranged
• drafting and editing the assignment
• considering the purpose and audience for the assignment
• writing concisely, clearly and accurately
• proofreading
• following all appropriate academic conventions.

Evaluating (reflecting)


Although many people consider the research process to be over as soon as the assignment is submitted, it is important to reflect on what has taken place, in order to consider what has been learnt and improve next time. The evaluation stage involves:
• thinking about performance at each step of the process
• analysing how research skills or techniques could be improved
• reflecting on knowledge gained
• considering how this knowledge may be applied in other contexts.
The process of researching is iterative: this means that what you find will help determine what more you need to do. You will find that you collect information, think about it, return to it, discard it, add to it in the process of developing your response to an assignment topic. This process involves organising your approach.

This component will have a weighting of 10% of the final overall assessment mark.


Assessment 2 – Laboratory Practical 1: Mechanical Testing and the Heat Treatment of Steel.

This assessment will focus on your ability to perform experimental work, record resultant data, observe outcomes, perform calculation and produce a report. This will involve the following criteria:

• Always take the view that you are writing it for people other than yourself and so make it simple, attractive, and readable by others.
• Your report must be concise and in your own words.

Typical elements of a good report are:
1. Objective, purpose, or goal of the experiment or activity – a title!
2. Equipment used. Name and identify what you will need or use to accomplish your goal.
3. Brief outline of procedure to be followed in your own words.
4. Collect data and display either in tabular or graphical form. You may attach your raw data separately to your report but your final table or graph must be in a clean form to be seen by others.
5. Analyze data. What do those numbers mean? How to interpret the graph(s)?
6. Calculations. Show your calculations clearly. Be mindful of the accuracy – significant figures, percent error etc.
7. Conclusions. What have you learned from this experiment or activity? How well was the goal met? How reliable is your result? What further predictions can you make based on your findings? How do you account for any inaccuracies and how do you propose to remedy these if possible?

This laboratory practical will have a weighting of 10% of the final overall assessment mark.


Assessment 3 – Laboratory Practical 2: Annealing and Recrystallisation of Work Hardened Brass

As per assessment 2.

This laboratory practical will have a weighting of 10% of the final overall assessment mark.


Assessment 4 – Final Test (closed book)

This assessment will focus on your ability to:

1. Prepare for materials testing and evaluation task, 2. Perform materials testing and evaluation task and
3. Complete and document materials testing and evaluation task.

It will require you utilise the underpinning skills and knowledge that has been demonstrated in the previous 10 sessions in your classroom and laboratory. You will be required to identify appropriate materials suitable for engineering applications, describe the classification of materials, describe the properties of materials and describe the factors that influence those properties to adequately demonstrate this competency’s elements.

The test consists of short answer questions and you will be required to perform calculations applicable to determining the strength of materials and be able to draw and identify graphs applicable in the determination of the strength of materials.

This test will have a weighting of 70% of the final overall assessment mark.



Assessment Matrix

Competency / ModuleAssessment 1
10%
Assessment 2
10%
Assessment 3
10%
Assessment 4
70%
Performance Criteria 1YesYesYesYes
Performance Criteria 2YesYesYesYes
Performance Criteria 3YesYesYesYes

Course Overview: Access Course Overview