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MEM30007A

MEM30007A Select Common Engineering Materials (36 hr)

Nominal Hours: 36 | Diploma/Adv Dip: Elective (Group 1 - Compulsory) | Competency Based
Assessment Plan A: (One Semester: 9 weeks)
Updated Feb 2017

Task Topic Description and Link to Notes Quiz # Practice
iTester
Assess
Moodle
Lesson
schedule
Assess schedule Work Load% Must Pass
1

Mechanical Properties of Materials

10101 1 3 10 Y
2 Classification, Properties and Structure 10102 2 4 10 Y
4

Polymers

10104 3 5 15 Y
5 Steels and Heat Treatment 10105 4 6 15 Y
6 Non-Ferrous Metals 10106 5 7 10 Y
7 Processing 10107 6 8 15 Y
3 Testing of Materials 10103 7 9 10 Y
8 Product Study: Materials/Processing Hand-in - - 8 10 15 Y
9   Written / Unseen Question Test Exam - - - 9* - -
- TOTAL - - - - - 100 -

Quiz = Computer Based Testing: Typically consists of practice mode (iTester) and assessment mode (Moodle).
Exam = Written test submitted on paper, all working shown neatly.

*Where applicable.

 

Download Videos from the Server

There is a collection of videos that can be downloaded from the server (in the location shown below). There are a few extra videos here, but most of them are needed to cover this subject.

Note: This is several gigabytes altogether, so you will need a large USB memory stick or a portable drive.

 

ASSESSMENT

(CAUTION: This subject contains most of MEM30006A Stresses, so you should do both together) Assessment is a combination of multiple choice tests, written tests, and submitted reports (print/email).

  • Lab Reports: Specification for lab reports. (Including error analysis where required)
  • Project Reports: Specification for project reports.
  • TESTER tasks: Computer based learning and assessment using the TESTER program.
    Procedures and rules. For most computer-based assessments, homework must be presented before Tester (exam mode) can be attempted.  In some cases, certain programs (e.g. Excel) are excluded from running with Tester during an exam. 

When you have completed this unit of competency you will have developed the knowledge and skills to determine the resultant and equilibrant of systems of forces, in one plane, then determine nominal sizes for a simple horizontal beam subject to a combination of uniform and point loadings.


Textbook/s (Optional)
Sheedy, P.A.; Materials Their Properties, Testing and Selection; Technical Secretarial Services, Forestville, NSW, 1994

Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann.  ISBN: 9781856177696

Additional references:

  • Culley, Ron Fitting and Machining, TAFE Publication (Victoria), 1988.
  • Riley, J R Material and Processes, TAFE Publication (Victoria), 1980.
  • Street, A and Alexander, W Metals in the Service of Man, Penguin, London, 1989.
  • Halmshaw, R Non Destructive Testing, Edward Arnald Publication, London, 1987.
  • Oberg, Erik Machinery's Hand Book, Industrial Press, New York, 1984.
  • Steel Institute of Australia Inc. Code of Practice for Colour Coding of Steel Products, Sydney, 1992.

ENMAT101A: Engineering Materials and Processes

WEEK LECTURES / EXAMINATIONS (2hrs) Lab QUIZ

Wk 1

Ch 1: Properties and Classification
Ch 2: Properties of materials

Lab 1 (2 hrs): Hardness test

10101

Wk 2

Ch 3: Mechanical testing
Ch 4: The crystal structure of metals

Lab 2 (2 hrs): Tensile Test


10102, 10103

Wk 3

Ch 5: Casting processes
Ch 6: Mechanical deformation of metals
Ch 7: The mechanical shaping of metals

Lab 3 (2 hrs): Metal Casting

10107

Wk 4

Ch 8: Alloys
Ch 9: Equilibrium diagrams
Ch 10: Practical microscopy

Lab 4 (2 hrs): Microscopy, Weld samples

10106

 

Wk 5

  Ch 11: Iron and steel
Ch 12: The heat-treatment of plain-carbon steels

Lab 5 (2 hrs): Torsion, Bending Tests

10105

Wk 6

Ch 13: Alloy steels
Ch 14: The surface hardening of steels
Ch 15: Cast iron

Lab 6 (2 hrs): Heat Treatment

10105 (cont)

Wk 7

Examination Wk A:  Assessment 1: Short answer test on content from weeks 1 to 5 – (Ch1 to Ch15) 15%

Lab Reports  1, 2, 3, 4 - 15%

 

Wk 8

Ch 16: Copper and its alloys
Ch 17: Aluminium and its alloys
Ch 18: Other non-ferrous metals and their alloys

Lab  7 (2 hrs): Polymer tensile test,

10106 (cont)

Wk 9

Ch 19: Plastics materials and rubbers
Ch 20: Properties of plastics

Site Visit: e.g. Rolling Mill, Materials process/testing  

10104

Wk 10

Ch 21: Ceramics
Ch 22: Glasses
Ch 23: Composite materials

Demo: Epoxy FRC, thermoforming

10106 (cont)

Wk 11

Ch 24: Fibre-reinforced composite materials
Ch 25: Methods of joining materials

Lab  8: Dye, Mag, Ultrasound

10104 (cont)

Wk 12

Ch 26: Causes of failure; NDT; Material Standards

Lab 9: Product Study

10103 (cont)

Wk 13

Ch 27 Choice of Materials and Processes;  Design. Economic, Environmental, Social Issues

Ass 3 due: Collaborative Report (Product Study) 20%

10108

Wk 14

Study Wk

 

 

Wk 15

Examination Wk B:
Assessment 4: Written examination: 35%

Assessment 2 due: Portfolio of Lab Reports  5, 6, 7, 8, 9 - 15%

 

 

Exam A

15%

Exam B

30%

Labs 1-4

15%

Labs 5-9

15%

Report

15%

Quizzes 1-8

10%

(Total)

100%

 


UNIT MEM30007A: Select Common Engineering Materials

  • Identify common engineering materials by their principal properties
  • Select materials for specific applications
  • Verify selected materials as fit for purpose.
 

1. Identify common engineering materials by their principal properties   

1.1
 

The principal properties of ferrous and non-ferrous metals are identified.

 

 

1.2
 

The principal properties of thermosetting and thermoplastic polymers are identified.
 

 

 

1.3
 

The principal properties of ceramics and composite materials are identified.
 

 

 

1.4
 

The effects of different types of bonding in materials are identified.
 

 

 

1.5  

The effects of mechanical and thermal processes on the principal properties of materials are identified.
 

2. Select materials for specific applications
 

2.1  

The engineering requirement for the specific application is determined in consultation with others.
 

 

 

2.2
 

Material is selected based on the requirement and consideration of principal properties and further processing.
 

 

 

2.3
 

Selection is confirmed according to standard operating procedures.
 

3. Verify selected material as fit for purpose
 

3.1  

Appropriate tests for the required properties are identified.

 

 

3.2
 

Tests are conducted as required in accordance with standard operating procedures.  

 

 

3.3
 

Test results are recorded and analysed and material choices are confirmed or modified as appropriate.
 

Required Knowledge (Content)

1. Classification of materials

  • metals and non-metals
  • ferrous and non-ferrous metals
  • polymers (thermoplastics, thermosetting and elastomers)
  • ceramics
  • composite materials

2. Structure of materials
3. Physical properties of materials

  • electrical conductivity/resistivity
  • specific gravity/density
  • thermal conductivity/expansion
  • specific heat
  • melting/boiling points

4. Magnetic properties
5. Optical properties
6. Mechanical properties:

  • strength – yield, tensile, compressive
  • stress/strain data
  • hardness
  • toughness (impact and slow strain)
  • elasticity
  • plasticity
  • ductility
  • malleability
  • fatigue
  • creep

7. Chemical properties:

  • corrosion of metals, corrosion processes, mechanisms
  • degradation of polymers

8. Materials testing methods – destructive testing and applications:

  • tensile
  • compressive
  • shear
  • torsion
  • hardness
  • impact
  • fatigue
  • creep
  • visual
  • corrosion testing

9. Engineering materials
10. Engineering applications of ferrous metals:

  • cast irons
  • carbon and alloy steels
  • stainless steels

11. Engineering applications of non-ferrous metals:

  • aluminium and its alloys
  • copper, brass and bronze
  • nickel alloys, zinc, titanium
  • magnesium
  • refractory metals

12. Engineering applications of polymers:

  • thermosetting polymers
  • thermoplastic polymers

13. Ceramics and glasses
14. Effects of mechanical and thermal processes on the properties of materials:

  • casting
  • forging, rolling and extrusion
  • cold forming
  • powder processes
  • heat treatment
  • joining – fasteners
  • soldering
  • brazing
  • welding
  • adhesives
  • finishing – coatings, metallic and non-metallic

15. Hazards and control measure associated with selecting common engineering materials: 

  • housekeeping
  • safe work practices and procedures

Schedule:

1. Principal properties

  • Classification 
  • Ferrous and non-ferrous 
  • Thermosetting and thermoplastic polymers 
  • Ceramics and composite materials
  • Types of bonding 
  • Mechanical and thermal processes  

2. Specific applications

  • Engineering requirements
  • Principal properties/processes
  • Further processing
  • Standard operating procedures

3. Fit for purpose

  • Tests identified
  • Testing conducted
  • Analysis
  • Confirmation/modification  

Teaching and Learning Resources

TAFE library catalogue is available online: TAFE NSW Library Network Catalogue
Useful reference materials/learning resources are:
Sheedy, P.A.; Materials Their Properties, Testing and Selection; Technical Secretarial Services, Forestville, NSW, 1994


External Links:

http://www.virginia.edu/bohr/mse209/class.htm