Unit Description and General Aims

Mechanical engineers must have a sound knowledge of materials; their properties, how to work them and maintain them. Materials in the 21st century are not only metals but a large range of plastics, elastomers, ceramics but even types of wood.
The student will obtain a sound knowledge of the metallurgy of both ferrous and non-ferrous metals as well as working knowledge of alloys and eutectic systems. The principles of heat treatment, forming, joining metals by various means, surface treatments to enhance required properties or to provide corrosion protection will be discussed.
The uses of various types of engineering plastics will be explained; students will recognise their advantages and limitations. Composite materials (GRPs, for instance) and their repair in practice will be explained. The student will appreciate how materials are converted into useful artefacts by using 3D methods.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Evaluate how materials have shaped societies throughout history.
   • Bloom’s Level 5
2. Assess the origins of the most used materials and have an awareness of their social and environmental consequences
   • Bloom’s Level 5
3. Determine the physics of materials, and metals, including atomic, crystalline, and molecular structures.
   • Bloom’s Level 5
4. Formulate the method for the further working of materials, including alloying, to achieve desired engineering properties.
   • Bloom’s Level 6
5. Critique material testing and implement collaboration with others in undertaking tests and reaching conclusions.
   • Bloom’s Level 5
6. Synthesise material data sourcing and compare materials, by calculation where necessary. To decide, considering all factors especially engineering, social, environmental, and economic, which materials best meet the particular requirements
   • Bloom’s Level 6

Student assessment

Prescribed and Recommended readings

Required Textbook

• W. D. Callister, D. D. Rethwish, Materials Science and Engineering: An Introduction, 10th Edition. John Wily and Sons, Inc., 2018. ISBN: 978-1119405498
• R. W. Messler Jr., The Essence of Materials for Engineers. Jones and Bartlett Learning, 2010. ISBN: 978-0763778330

Reference Materials

• M. F. Ashby, Materials Selection in Mechanical Design, 5th Edition. Department of Engineering, Cambridge University, England, 2011 (available on the eLibrary)
• Materials handbook, 10th edition, ASM, Metals Park OH, 1990
• Martin Grayson (ed.), Encyclopaedia of composite materials and components, John Wiley and sons, NY, 1983
• Other texts, peer-reviewed journals and websites as advised during lectures.

Unit Content

One topic is delivered per contact week, except for part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Introduction

1. Introduction to Materials Engineering
2. Materials universe
3. Evolution of materials,
4. Classification of materials: metals, ceramics, and polymers.

Topic 2

Structure and Classification of Materials

1. Interatomic bonding,
2. Crystalline and non-crystalline materials,
3. Crystal structures,
4. Crystalline solids and hard sphere models, concept of unit cell,
5. Calculation of theoretical density,
6. Packing factor, defects in crystalline solids

Topic 3 

Mechanical Properties of Materials

1. Mechanical properties
2. Introduction to tensile test
3. Tensile properties, engineering and true values of stress and strain
4. Tensile strength and yield strength
5. Young’s Modulus, poison’s ratio
6. Hardness, hardness test
7. Introduction to plasticity of metals

Topic 4

Failure Mechanisms

1. Mechanical failure
2. Fracture and fracture mechanics
3. Flaw theory
4. Fatigue of engineering materials
5. Goodman’s theory
6. Creep and relaxation

Topic 5

Metals and Alloys

1. Metal alloys
2. Structure and properties of iron-based alloys
3. Stainless steel and cast irons
4. Carbon equivalence
5. Aluminium alloys
6. Copper alloys
7. Titanium and refractory materials

Topic 6

Phase Diagrams and Iron-Carbon System

1. Phase diagrams
2. Binary systems
3. Application of lever rule
4. Iron-carbon system
5. Time-temperature transformation

Topic 7

Strengthening of Metals

1. Strengthening of metals
2. Solid solution strengthening
3. Heat treatment and grain size reduction
4. Cold working
5. Precipitation hardening
6. Diffusion with case studies

Topic 8

Corrosion and Degradation

1. Corrosion and degradation of materials
2. Types and mechanisms of corrosion
3. Electrochemical corrosion and EMF series
4. Uniform corrosion
5. Galvanic corrosion
6. Crevice and pitting corrosion
7. Prevention against corrosion
8. Metallic and non-metallic coatings
9. Selection of materials
10. Catholic protection with case studies

Topic 9

Thermal and Electrical Properties of Materials

1. Thermal properties of materials
2. Thermal conductivity
3. Heat capacity, temperature effects of heat capacity
4. Thermal expansion
5. Electrical properties of materials
6. Conductivity, resistivity, temperature effects on electrical properties
7. Effect of composition on electrical properties
8. Effect of atomic structure and cold work

Topic 10

Ceramics

1. Ceramics
2. Structure of ceramics
3. Hard sphere model of ceramics and coordination number
4. Mechanical properties of ceramics
5. Modulus or rupture, flexural strength
6. Applications and modifications of ceramics with case studies

Topic 11  

Polymers

1. Classification of polymers
2. Common polymer molecules
3. Molecular weight (size), shape and architecture of common polymers
4. Crystallinity, mechanical properties of polymers
5. Deformation mechanism of semi-crystalline polymers
6. Deformation mechanism of elastomers
7. Application of polymers with case studies

Topic 12

Future Materials and Sustainability

1. Future engineering materials
2. Smart materials
3. Material economics
4. Design and selection
5. Development of new materials to reduce environmental effects and pollution
6. Biomaterials
7. Materials leading towards sustainability and case studies

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

 Software/Hardware Used

Software

• Software: N/A
• Version: N/A
• Instructions:  N/A
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback

• Assessment due dates were adjusted to decrease the overload in some weeks. 
• Assessment 1 was converted from a standalone assessment to weekly quiz format.