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1 MODULE DESCRIPTOR TITLE MATERIALS PROCESSIG SI MODULE CODE CREDITS 20 LEVEL 6 JACS CODE J510 SUBJECT GROUP Materials Engineering DEPARTMET Engineering and Mathematics MODULE LEADER Dr Antonio Feteira OTIOAL STUDY HOURS BY TYPE Tutor-led Tutordirected Selfdirected Total Hours MODULE AIM(S) To introduce students to the principles and practice of iron and steel making processes. To analyse and evaluate iron and steel making processes in terms of chemical thermodynamic and kinetic parameters. To analyse and evaluate the main processes for the production of metallic, polymeric, ceramic and electronic materials. To analyse shaping and forming processes in terms of both their mechanics and the associated changes in material properties and structure. To develop mathematical models which can describe and predict process and material behaviour in mechanical shaping and forming processes. MODULE LEARIG OUTCOMES By engaging successfully with this module a student will be able to (i) (ii) (iii) (iv) (v) Describe the principles and practical details of the processing routes for the production of liquid iron, steel, ceramics and electronic materials. Quantitatively analyse the plant requirements for a range of mechanical shaping, forming and heat treatment processes. Evaluate, assess and correctly employ analytical models to simulate plastic deformation in mechanical shaping and forming processes. Characterise the flow characteristics of metallic and ceramic powders and their compaction in a die. Understand and evaluate sintering mechanisms in relation to metallic and modern ceramic materials to produce high quality powder components.

2 IDICATIVE COTET Iron Making in the Blast Furnace Iron ores and their reduction characteristics. Iron blast - furnace design, construction and operation. Burden preparation - Agglomeration processes. Chemical and physical processes within the blast furnace. Process analysis and control of production in the blast furnace. Primary Steel Making Processes Thermodynamic principles of red-ox refining; slag-metal reactions; ionic slag models; slag basicity; Temkin and Flood models. Basic oxygen converter steel making: Design of plant; vessel and refractory practice; design of lance and nozzles for super-sonic flow, jet characteristics; process control; foams and emulsions; tapping and deoxidisation practice. Electric arc furnace steel making: Charge materials; heat balance for melting in the arc furnace; enhanced meltdown procedures; oxygen lancing in the arc furnace; processing reactions and slag-metal control; tapping and deoxidation practice. Secondary Steel making Processes Refining and heating strategies in the ladle and secondary refining vessels. Process control and practice - recarburisation, deoxidation, sulphur and phosphorus content, alloying elements, temperature control. Origin of hydrogen, nitrogen and oxygen in steel and behaviour at reduced pressure; Sievert's Law; Commercial vacuum degassing processes. Chromium in steels. Chromium-carbon relationship. AOD and VOD processes. Vacuum-arc-remelting and electroslag refining. Mechanical Shaping and Forming Processes Process modelling and analysis of plastic flow in mechanical deformation processes; hot and cold work; friction and lubrication in working processes; heterogeneous deformation and redundant work; stress systems and workability. Heat Treatment Types of heat treatment furnaces and media; analysis of heat transfer; controlled atmospheres. Surface treatment of steel; carburising; nitriding; transient diffusion models; error function. Quenching; types of quenchants; heat transfer and cooling curves; Quenching Power (H); residual stresses; hardenability, critical diameters and the Jominy Test. Powder Processing Characteristics of powders; analysis of powder flow and consolidation in a die; effects of die shape, size, lubricant and temperature; isostatic pressing. Sintering; analysis of liquid phase and reaction sintering mechanisms; hot pressing. Analysis of examples of metallic, ceramic and composite powder products. Electronic and Photonic Materials Processing Photonic Materials - Principles of fibre optic systems; mono-mode, multi-mode and graded index fibres; microstructural profiles and property requirements; production and processing methods; principles of optical information storage systems; production and processing requirements.

3 Electronic Materials - Microstructural profiles and property requirements of semiconductor materials; processing of base semi-conductor material; purification; crystal growth; epitaxial growth; fabrication of devices and integrated circuits. LEARIG AD TEACHIG METHODS Students will be supported in their learning, to achieve the above outcomes, in the following ways Formal lectures will be used to establish the practical context and underlying theoretical principles. Tutorials will serve to reinforce the formal lecture content. These will be student centred, often with an analytical content and will provide the opportunity for formative assessment and feedback. Further directed study will be supported by printed notes and guided reading using a Blackboard site. ASSESSMET STRATEGY AD METHODS Tas k o. TASK DESCRIPTIO SI Code % Weighting of overall module mark Word Count / Duration Inmodule retrieval available 1 Examination EX 80% 3 hours 40% 2 Assignment CW 20% 40% ASSESSMET CRITERIA The learning outcomes will be assessed as follows: Summative coursework assignments will contribute 20% of the module mark with an end of module examination providing 80%. Assessment by examination will be based on both performing of numerical calculations, critical reflection on engineering problems and explanation of fundamental principles of materials processing. A pass mark of 40% will be needed. For the coursework, a typical assessment will be based mainly on performing of numerical calculations. Percentage Pass Mark or Pass/Fail Coursework Merit (60%+) Calculations and equations used are error free and clearly understandable by the reader. Pass (40%+) Demonstration that a robust engineering analysis has been performed at a level sufficient 3 rd year engineering degree, however calculations can be difficult to follow by reader. Fail (<40%) Calculations or equations contain errors. Answers produced may be unrealistic.

4 FEEDBACK Students will receive feedback on their performance in the following ways: All summative assessment on this module, except for the examination, is also formative, with full feedback provided. Other formative feedback will be provided in tutorials and laboratories Feedback will be given by the unit tutor, in writing, on completion of each of the laboratory reports. Immediate feedback (following Blackboard based assessment) will be given electronically via the Blackboard facility. Verbal feedback will be given by the unit tutor throughout the tutorials and practical laboratory sessions LEARIG RESOURCES (ICLUDIG READIG LISTS) Lecture and tutorial notes will be available on the university's virtual learning environment system (Blackboard). Students should also take their own notes in lectures and tutorials and are encouraged to develop their understanding of the subject by reading recommended texts that will be available from the University library. A. Ghosh and A. Chatterjee "Ironmaking and Steelmaking, Theory and Practice", Prentice-Hall of India Pvt.Ltd (2012) H. Tschaetsch "Metal Forming Practise" Springer, (2006) M. Kaviany "Essentials of heat transfer: principles, materials and applications" Cambridge University Press (2011) M.. Rahaman "Ceramic Processing and Sintering", CRC Press; 2 edition, (2003) REVISIOS Date Sept 2012 August 2013 Reason Confirmed in Prof Eng Re/approval Model B Approved in 12/13 Assessment Review

5 SECTIO 2 'MODEL B' MODULE (IFORMATIO FOR STAFF OLY) MODULE DELIVERY AD ASSESSMET MAAGEMET IFORMATIO MODULE STATUS - IDICATE IF AY CHAGES BEIG MADE EW MODULE EXISTIG MODULE - O CHAGE Y Title Change Level Change Credit Change Assessment Pattern Change Change to Delivery Pattern Date the changes (or new module) will be implemented 09/2013 MODULE DELIVERY PATTER - Give details of the module delivery pattern. If the course has more than one intake, for example, September and January, please give details of the module start and end dates for each intake. Module Begins Module Ends Course Intake 1 01/09/ /2015 Course Intake 2 DD/MM/YYYY DD/MM/YYYY Course Intake 3 DD/MM/YYYY DD/MM/YYYY Is timetabled contact time required for this module? Are any staff teaching on this module non-shu employees? If yes, please give details of the employer institution(s) below Y What proportion of the module is taught by these non-shu staff, expressed as a percentage? MODULE ASSESSMET IFORMATIO FIAL TASK According to the Assessment Strategy shown in the Module Descriptor, which task will be the LAST TASK to be taken or handed-in? (Give task number as shown in the Assessment Strategy) Task o. 1 MODULE REFERRAL STRATEGY B: Model B modules always apply a Task for Task referral strategy (as shown for initial assessment strategy) O-STADARD ASSESSMET PATTERS MARK 'X' I BOX IF MODULE ASSESSMET PATTER IS O STADARD, eg MODEL B, ALL TASKS MUST BE PASSED AT 40%. X B: on-standard assessment patterns are subject to faculty agreement and approval by Registry Services - see guidance. notes.

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