Course Title: Apply metallurgy principles
Part B: Course Detail
Teaching Period: Term2 2013
Course Code: PROC5279C
Course Title: Apply metallurgy principles
School: 130T Vocational Engineering
Campus: City Campus
Program: C6114 - Advanced Diploma of Engineering
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
Program Manager: Dr Bill Chau
Phone 9925 4661, bill.chau@rmit.edu.au
Program Coordinator: Leon Mattatia
Phone 9925 4668, leon.mattatia@rmit.edu.au
Teacher: George Zouev
Phone 9925 4935, george.zouev@rmit.edu.au
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 covers applying basic metallurgy principles related to selecting appropriate non-destructive testing techniques (NDT) and interpreting the results of NDT tests for metallurgical processes.
National Codes, Titles, Elements and Performance Criteria
National Element Code & Title: |
MEM24012C Apply metallurgy principles |
Element: |
1. Interpret and apply the principles of solidification and crystal structures in metals and alloys. |
Performance Criteria: |
1.1. Principles of solidification and crystal structures in metals and alloys are interpreted and applied in relation to NDT techniques. |
Element: |
2. Interpret equilibrium diagrams for metals and alloys. |
Performance Criteria: |
2.1. Equilibrium diagram for metal or alloy is correctly sourced 2.2. Equilibrium diagrams are correctly interpreted. |
Element: |
3. Interpret and apply the principles of fusion welding of metals and alloys. |
Performance Criteria: |
3.1 Principles and methods for fusion welding of metals and alloys are applied to NDT test selection. 3.2. Defects in weldments are identified and classified from NDT test results. |
Element: |
4. Interpret and apply the principles of the formation of castings. |
Performance Criteria: |
4.1. Principles and methods used to produce metal castings are applied to NDT test selection. 4.2. Defects in metal and alloy castings are identified and classified from NDT test results. |
Element: |
5. Interpret and apply the principles of steel forging. |
Performance Criteria: |
5.1. Principles and methods used to produce steel forgings are applied to NDT test selection. 5.2. Defects in steel forgings are identified and classified from NDT test results. |
Element: |
6. Interpret and apply the principles of mechanical testing. |
Performance Criteria: |
6.1. Principles of mechanical testing are applied to NDT test selection. 6.2. Defects in metal product are identified and classified from NDT test results |
Learning Outcomes
N/A.
Details of Learning Activities
Students will participate in a variety of teaching methods including: lectures, tutorials, practical demonstrations, class discussions, group/individual work on projects/assignments, and audio-visual presentations.
Teaching Schedule
Week 1:
Introduction and overview of this Course
Structure of Materials - Part 1
* Structure of Crystalline Solids
* Unit Cells
* Solidification
* Grain Boundaries
* Crystallography and Microstructures
* Microscopy
* Nucleation and Crystal Growth
* Amorphous Structures
* Metallic Crystal Structures
* Crystalline imperfection in solids
* Solid Solutions
Week 2:
Structure of Materials - Part 2
* Structure of Crystalline Solids
* Unit Cells
* Solidification
* Grain Boundaries
* Crystallography and Microstructures
* Microscopy
* Nucleation and Crystal Growth
* Amorphous Structures
* Metallic Crystal Structures
* Crystalline imperfection in solids
* Solid Solutions
Week 3:
Alloy Systems
* Eutectics
* Solid Solutions
* Intermetallic Compounds
* Equilibrium Diagrams
* Solubility
* Precipitation
Week 4:
Heat Treatment
* Steel Metallurgy
* Iron-Carbide Equilibrium Diagram
* Heat Treatment of Metals
* Strengthening Mechanisms
* Precipitation and Age Hardening
* Isothermal Transformation Diagrams
* Tempering of Martensite
* Thermal Processing of Metals Alloys
* Surface Hardening
* Surface Modification
Week 5:
Principles and methods for fusion welding of steel and alloys of the following methods:
• Manual metal-arc welding (MMAW)
• Submerged arc welding(SAW)
• Gas metal-arc welding (GMAW)
• Gas tungsten-arc welding (GTAW)
• Flux-cored arc welding (FCAW)
Week 6:
Principle methods used to produce metal castings and Powder Metallurgy
• Sand casting
• Shell moulding
• Core and core production
• Permanent metal mould casting
• Die casting
• Investment casting
• Centrifugal casting
Week 7:
Bulk forming plastic deformation processes
• Hot and Cold Rolling
• Recrystallisation
• Drop forging
• Press forging
• Upset forging
• Roll forging
Week 8:
Destructive Mechanical Testing Techniques
• Tensile testing
• Stress: yield, proof, ultimate, breaking
• Modulus of Elasticity
• behaviour of ductile and brittle materials to tensile forces
• Impact testing
• Hardness testing
• Rockwell
• Vicker’s
• Brinell
• Fatigue testing
Week 9:
Practical Lab – Recrystallisation of Work Hardenend Brass
Week 10:
Determine defects in Weldments, Casting and Forging processes
Defects in weldments are identified and classified:
• lack of fusion
• cracks
• porosity
• inclusions
• incorrect weld shape and size
Defects in steel forgings are identified and classified:
• Inclusions
• Porosity
• Cracking
• Cold Shuts
• Surface irregularities
• Distortion
• Grain flow irregularities
• Bursts
• Laps/Folds
• Seams
• Tears
Defects in metal castings are identified and classified:
• Inclusions
• Porosity (blow holes, pinholes)
• Cold Cracking
• Hot Cracking
• Cold Shuts
• Surface irregularities
• Distortion/Shrinkage
• Improper composition
Week 11:
Determine Microstructure of Metals when Influenced by Thermal Fabrication Processes
• Joining; soldering, brazing, welding
• Casting microstructures
• Wrought microstructures
• Difficulty in welding high carbon steels
Week 12
Specify Non-Destructive Testing of Materials Methods for Industrial Applications
• Visual
• X-Ray
• Ultrasonic
• Dye penetrant
• Magnetic particle
• Eddy current
Week 13: Unit Competency Test
Learning Resources
Prescribed Texts
Study notes are supplied and available from: Student network drives: S:\Mechanical and Manufacturing Students\PROC5279C Apply Metallurgy Principles\George Zouev |
References
Other Resources
Student network drives:
S:\Mechanical and Manufacturing Students\PROC5279C Apply Metallurgy Principles\George Zouev
Overview of Assessment
A person who demonstrates competency in this unit must be able to apply metallurgy principles to NDT test selection and interpretation. Competency in this unit cannot be claimed until all prerequisites have been satisfied.
The assessment is conducted in both theoretical and practical aspects of the course according to the performance criteria set in the National Training Package. Assessment may incorporate a variety of methods including written/oral activities and demonstration of practical skills to the relevant industry standards.
Participants are advised that they are likely to be asked to personally demonstrate their assessment activities to their teacher/assessor.
Feedback will be provided throughout the course. To successfully complete this course you will be required to demonstrate competency in each assessment task detailed under Assessment Tasks section of Course Guide Part B.
Assessment Tasks
You are required to complete the following two assessment tasks:
1. Practical Lab - Week 9 - 30% weighting
2. Closed book Test - Week 13 - 70% weighting
The assessment is conducted in both theoretical and practical aspects of the course according to the performance criteria set
in the National Training Package. The students are required to undertake summative assessments that bring together knowledge
and skills.
To successfully complete this course you will be required to demonstrate competency in each assessment tasks detailed
under Assessment Task Section.
Your assessment for this course will be marked using the following table:
CHD Competent with High Distinction
CDI Competent with Distinction
CC Competent with Credit
CAG Competency Achieved – Graded
NYC Not Yet Competent
DNS Did Not Submit for assessment
All assessment tasks need to be successfully completed to demonstrate competence.
Late submission:
If you require an Extension of Submittable Work (assignments, reports or project work etc.) for 7 calendar days or less (from the original due date) and have valid reasons, you must complete and
lodge an Application for Extension of Submittable Work (7 Calendar Days or less) form and lodge it with the Senior Educator/ Program Manager.
The application must be lodged no later than one working day before the official due date. You will be notified within
no more than 2 working days of the date of lodgement as to whether the extension has been granted.
If you seek an Extension of Submittable Work for more than 7 calendar days (from the original due date) must lodge an Application for Special
Consideration form under the provisions of the Special Consideration Policy, preferably prior to, but no later than 2 working days
after the official due date.
Assessment Matrix
Assessment Task Element
Practical Lab Element 1,2,3,4,5,6
Exam Element 1,2,3,4,5,6
Other Information
Study and learning Support:
Study and Learning Centre (SLC) provides free learning and academic development advice to you.
Services offered by SLC to support your numeracy and literacy skills are:
assignment writing, thesis writing and study skills advice
maths and science developmental support and advice
English language development
Please Refer http://www.rmit.edu.au/studyandlearningcentre to find more information about Study and learning Support
Disability Liaison Unit:
If you are suffering from long-term medical condition or disability, you should contact Disability Liaison Unit to seek advice and
support to complete your studies.
Please Refer http://www.rmit.edu.au/disability to find more information about services offered by Disability Liaison Unit
Late submission:
If you require an Extension of Submittable Work (assignments, reports or project work etc.) for 7 calendar days or less (from the original due date) and have valid reasons, you must complete and lodge an Application for Extension of Submittable Work (7 Calendar Days or less) form and lodge it with the Senior Educator/ Program Manager.
The application must be lodged no later than one working day before the official due date. You will be notified within
no more than 2 working days of the date of lodgment as to whether the extension has been granted.
If you seek an Extension of Submittable Work for more than 7 calendar days (from the original due date) must lodge an Application for Special Consideration form under the provisions of the Special Consideration Policy, preferably prior to, but no later than 2 working days after the official due date.
Submittable Work (assignments, reports or project work etc.) submitted late without approval of an extension will not be accepted or marked.
Special consideration:
Please Refer http://www.rmit.edu.au/browse;ID=riderwtscifm (unresolved) to find more information about special consideration
Plagiarism:
Plagiarism is a form of cheating and it is very serious academic offence that may lead to expulsion from the University.
Please Refer: www.rmit.edu.au/academicintegrity to find more information about plagiarism.
Other Information:
All email communications will be sent to your RMIT email address and you must regularly check your RMIT emails.
Course Overview: Access Course Overview