📖Program Curriculum
Course modules
Compulsory modules
All the modules in the following list need to be taken as part of this course.
Introduction to Manufacturing, Materials and Research Techniques
Aim
To provide an introduction to manufacturing technology and materials. Introduce you to the key skills required to write proposals and understand how to prepare the costs. To familiarise students with teamworking, ethics and concepts. To develop your personal skills in management and team working.
Syllabus
• Overview of the programme and course, project management, technical writing and communication presentations, environmental issues. Learning styles, group and team working and self-study.
• Manufacturing technology, introduction to engineering materials life cycles, health, safety and environment. Research techniques including writing proposals and resourcing.
Intended learning outcomes On successful completion of this module you should be able to:
1. Explain the need and commitment to address professional and ethical responsibilities and a respect for diversity.
2. Critically assess manufacturing technology examples; such as explaining how a part is made, what it is made from and compare properties of the manufacturing process.
3. Demonstrate how to work effectively as a member of a technical team.
4. Prepare a proposal, estimating the project costs and resources, taking into account commercial and industrial constraints.
Lean Product Development
Aim
As a Master level course this module has to develop knowledge, critical scientific thinking and hands-on experiences for developing a product. A scholarly approach of product development, project management and evolution, as well as the use of the most suitable material and technology, are expected. Research appropriately into customer and market requirements and their analysis to translate the requirements into product specification.
Syllabus
· Introduction to Product Development (PD)
· Concurrent Engineering · PD Tools and Methods
· Lean Product Development · Set-Based Concurrent Engineering (SBCE)
· SBCE Industrial Case Studies
· PD in Knowledge-based Environment
· Trade-Off Curves to enable SBCE
· Tutorial PD Project
Intended learning outcomes
On successful completion of this module you should be able to:
1. Assess the application of product development process in lean environment and addressing global collaboration.
2. Design a process of product development based on the principles of set-based concurrent engineering.
3. Formulate the process of selection of materials and manufacturing processes.
4. Appraise the application of tools and techniques to support product development such as QFD, DFM, DFA, and FMEA.
5. Create and manage product development knowledge to solving product design and development problems and to enable trade-off between design solutions.
General Management
Aim
To give you an introduction to some of the key general management, personal management and project management skills needed to influence and implement change.
Syllabus
Management Accounting Principles and Systems.
Personal style and team contribution, interpersonal dynamics, leadership, human and cultural diversity.
Project Management: structure and tools for project management.
Introduction to standards: awareness of standards, relevant standards (quality, environment and H&S), value of using standards, management of the standard and audit.
Intended learning outcomes
On successful completion of this module you will be able to:
1. Interpret and organize the objectives, principles, terminology, and systems of management accounting.
2. Assess the inter-relationships between functional responsibilities in a company.
3. Assess and select among the different management styles, team roles, different cultures, and how the management of human diversity can impact organisational performance.
4. Interpret and analyse the structure, aspects, and tools for project management.
5. Critically assess the ethical and social responsibilities within an engineering context.
Elective modules
A selection of modules from the following list need to be taken as part of this course
Composites Manufacturing for High Performance Structures
Aim
To provide a detailed awareness of current and emerging manufacturing technology for high performance composite components and structures and an understanding of materials selection and the design process for effective parts manufacturing.
Syllabus
• Background to thermosetting and thermoplastic polymer matrix composites.
• Practical demonstrations – lab work.
• Overview of established manufacturing processes, developing processes, automation and machining.
• Introduction to emerging process developments; automation, textile preforming, through thickness reinforcement.
• Design for manufacture, assembly techniques and manufacturing cost.
• Case studies from aerospace, automotive, motorsport, marine and energy sectors.
• DVD demonstrations of all processing routes.
Intended learning outcomes On successful completion of this module you should be able to:
1. Describe a range of modern manufacturing techniques for thermoset and thermoplastic type composites.
2. Select appropriate manufacturing techniques for a given composite structure/ application and describe current areas of technology development for composites processing.
3. Demonstrate or describe practical handling of prepregs and a range of fibre forms and resins.
4. Use the design process for high performance composite structures and appraise the influence on design to the manufacturing process.
5. Evaluate performance-cost balance implications of materials and process choice.
Nano Materials and Advanced Composites
Aim
This module will carry out a critical analysis of how nano materials are used for the significant enhancement of traditional composites for improving structural and functional properties for advanced engineering applications; The module will help you to formulate/construct with necessary knowledge to synthesis new multifunctional composites to fulfil the unmet industrial challenges.
Syllabus
• Basics understanding of nanotechnology and nano materials.
• Manufacturing high purity nano materials.
• Nanomaterials Safety and handling.
• Integration of nano materials in traditional glass/carbon fibre composites.
• Improving fracture toughness and impact resistance of composites with nano materials.
• High performance carbon nanotube fibres as potential replacement of carbon fibres.
• Nano materials for improving the surface and functional properties of composites.
• Case studies for nano materials reinforced for multiscale composites for aerospace, automotive and marine applications.
Intended learning outcomes On successful completion of this module you should be able to:
1. Understand, analyse and appraise the different types of manufacturing processes for nano materials.
2. Evaluate the properties, processing of polymer matrix based nanocomposites.
3. Evaluate and recommend the manufacturing route for testing of nano material
4. Formulate the manufacturing and testing process for nano reinforced carbon/glass fibre based multi-scale composites for superior functional and structural properties for advanced engineering sectors.
Composites Joining, Repair and Serviceability
Aim
This course will provide you with an industrially useful knowledge on joining and repair of high-performance composite structures. This knowledge will be critical for the through life maintenance of composite components used in range engineering application such as wind turbine blades, aircraft wings and fuselage etc. The course will explore non-destructive testing methods used to detect the damage in composite components which are essential to decide if the repair is needed.
Syllabus
• Introduction to composite structural integrity.
• Best practices in bonding, bolting and assembly approaches.
• Process-induced defects in composite fastening and bonding.
• Mechanical fastening options for carbon fibre composites- some selection guidance.
• Adhesive bond damage tolerance and failure assessment.
• Tailored composite bonded repair.
• Self-healing bonding applications.
• Aerospace composite repair - regulatory perspective.
• Automated machining and surface preparation for composite repair.
• Thermoplastic welding.
• Laboratory exercise on composite impact damage, NDI and bonded repair.
• Visit composite manufacturing and NDI facilities.
Intended learning outcomes On successful completion of this module you should be able to:
1. Evaluate and analyse the need and requirement for composite integration, repair and joining.
2. Evaluate and recommend a variety of integration, repair and joining procedures in composite structures from fastening, thermoset adhesive bonding to thermoplastic welding.
3. Analyse a range of adhesive bond damage tolerance and failure assessment procedures.
Introduction to Materials Engineering
Aim
The aim of this module is to enable you to analyse the structure and properties of materials, to relate fabrication processes with structure and properties, and assess how this determines materials properties, and apply this knowledge to materials in applications.
Syllabus
• Introduction to materials: Atomic structure, crystal structure, imperfections, diffusion, mechanical properties, dislocations and strengthening mechanisms, phase diagrams, phase transformations, solidification, corrosion.
• Basic and alloy steels, tensile behaviour of metals, work and precipitation hardening, recovery and recrystallisation.
• Structural steels - C-Mn ferrite-pearlite structural steels, specifications and influence of composition, heat treatment and microstructure on mechanical properties. Fracture, weldability and the influence of welding on mechanical properties.
• Corrosion Resistant Materials - Stainless steels - austenitic, ferritic, martensitic and duplex stainless steels- compositions, microstructures, properties.
• Welding and joining processes, weld metal, heat affected zones and weld cracking.
• Non-metallic Materials - Polymers and composites manufacturing issues, physical properties and mechanical behaviour. Structure and properties and applications of ceramics.
• Principles underlying electrical and magnetic properties of materials.
Intended learning outcomes
On successful completion of this module you should be able to:
1. Analyse material structures on a micro and macro scale, and correlate micro structure to mechanical performance.
2. Relate the chemical composition, microstructure and processing route for steels and non-ferrous alloys with the resulting mechanical properties.
3. Compare and contrast fracture, corrosion and welding behaviour for a variety of alloys.
4. Describe and evaluate a range of manufacturing processes for composites and ceramics and explain important properties of these classes of material with respect to typical applications.
5. Relate magnetic and electrical behaviour of materials to specific materials.
Advanced Welding Processes
Aim
The aim of this module is to provide you with an understanding of the principles behind the most recent developments in welding processes. There is a strong emphasis on laser welding, as well as recent developments in arc, friction and resistance welding. The module will cover the operating principles, characteristics and practical applications of each process.
Syllabus
• Fundamentals of lasers, optics and fibre optics
• Laser welding including micro-welding and hybrid processes
• Introduction to laser processing
• Laser material interactions
• Laser powder melting
• Laser wire melting
• Laser sources, optics and fibre optics
• Advanced arc welding processes
• Solid state welding processes
• Friction welding
• Additive manufacture
• Advanced resistance welding
• Dissimilar material welding
• Remote underwater welding
• Weld metal engineering
• Electron beam welding
• Process monitoring
• Other laser processes (e.g. laser peening)
• Material characteristics and response to laser
• Weld metal engineering
• Laser safety
Intended learning outcomes On successful completion of this module a student should be able to:
1. Evaluate and compare the physical principles behind the operation of the advanced welding and processing methods e.g. laser, advanced gas metal arc processes, friction based techniques etc.
2. Select the most appropriate welding system for a particular application and analyse the economic benefits.
3. Examine physical and engineering principles behind selective applications for welding processes and critique methods for maximising process efficiency.
4. Appraise recent developments in welding technology and identify where these new processes can be used.
Additive and Subtractive Manufacturing Technologies
Aim
To provide you with an understanding of the principles behind some of the most recent developments in the processing of high value added components. There is a strong emphasis on high efficiency and reduced cost in the manufacture of high volume and/or high value added parts using the latest technology based around advanced fabrication, machining processes and additive techniques. The module will cover the physical principles, operating characteristics and practical aspects related to these key technologies.
Syllabus
• Metal cutting processes and practice.
• Abrasive machining processes and practice
• Non-conventional machining including photochemical machining and associated metal removal and addition processes.
• Micro machining and micro moulding.
• Machine tool components and machine-materials interactions, metrology.
Intended learning outcomes
On successful completion of this module you should be able to:
1. Critically review recent developments in machining and fabrication processes for the production of engineering components and identify their main areas of application and limitations.
2. Describe and apply the relationships between material properties, processing conditions, metrology and component service performance.
3. Analyse how the physical principles behind the operation of these processes can be used to monitor process capability and performance.
4. Apply design rules and fabrication techniques to manufacture micro components.
5. Assess different routes for the high volume manufacture of micro components.
Surface Science and Engineering
Aim
To provide you with an understanding of the role that surfaces play in materials behaviour; concentrating on corrosion and wear processes. To introduce the concepts of surface engineering and how surface engineering may be used to optimise a component’s performance. To introduce suitable analytical techniques used to evaluate and characterise surfaces and thin samples.
Syllabus
• Philosophy of surface engineering, general applications and requirements.
• Basic principles of electrochemistry and aqueous corrosion processes; corrosion problems in the aerospace industry; general corrosion, pitting corrosion, crevice corrosion, influence of deposits and anaerobic conditions; exfoliation corrosion; corrosion control; high temperature oxidation and hot corrosion; corrosion/mechanical property interactions.
• Friction and Wear: Abrasive, erosive and sliding wear. The interaction between wear and corrosion.
• Analytical Techniques: X-ray diffraction, TEM, SEM and EDX, WDX analysis, surface analysis by AES, XPS and SIMS.
• Surface engineering as part of a manufacturing process.
• Integrating coating systems into the design process.
• Coating manufacturing processes.
• Electro deposition, flame spraying, plasma spray, sol-gel.
• Physical vapour deposition, chemical vapour deposition, ion beam.
• Coating systems for corrosion and wear protection.
• Coating systems for gas turbines.
• New coating concepts including multi-layer structures, functionally gradient materials, intermetallic barrier coatings and thermal barrier coatings.
Intended learning outcomes
On successful completion of this module you should be able to:
1. Demonstrate a practical understanding of surface engineering as part of the manufacturing process.
2. Critically appraise new coating concepts. Describe and select appropriate coating manufacturing processes, giving examples of their applications.
3. Describe oxidation and corrosion processes, including the factors that control the rates of corrosion. Critically discuss types of corrosion damage, the conditions under which they occur and methods of corrosion control.
4. Predict the behaviour of friction and wear, including abrasive, erosive and sliding wear. Design for wear resistance, including the selection of suitable coating systems.
5. Select and recommend techniques to characterise surfaces and describe analytical principles.
Finite Element Analysis
Aim
The course is aimed at giving potential Finite Element USERS basic understanding of the inner workings of the method.
The objective is to introduce users to the terminology, basic numerical and mathematical aspects of the method. This should help students to avoid some of the more common and important user errors, many of which stem from a "black box" approach to this technique. Some basic guidelines are also given on how to approach the modelling of structures using the Finite Element Method.
Syllabus
• Background to Finite Element Methods (FEM) and its application.
• Introduction to FE modelling: Idealisation, Discretisation, Meshing and Post Processing.
• Tracking and controlling errors in a finite element analysis. ‘Do’s and don’ts’ of modelling.
• Illustration of basics of FEM using the Direct Stiffness method to define both terminology and theoretical approach.
• Problems of large systems of equations for FE, and solution methods.
• Damage modelling and its validation process.
• Digitalisation of materials and analysis for design optimisation.
• NASTRAN application sessions.
Intended learning outcomes
On successful completion of this module you should be able to:
Appraise the underlying principles and key aspects of practical application of FEA to structural problems.
Calculate the main mathematical and numerical aspects of the element formulations for 1D, 2D and 3D elements.
Construct and analyse finite element models based on structural and continuum elements with proper understanding of limitations of the FEM.
Evaluate results of the analyses and assess error levels.
Critically evaluate the constraints and implications imposed by the finite element method.
Operations Management
Aim
To introduce you to core factors of managing operations.
Syllabus
An introduction to manufacturing and service activities.
Capacity, demand and load; identifying key capacity determinant; order-size mix problem; coping with changes in demand.
Standard times, and how to calculate them; process analysis and supporting tools; process simplification.
What quality is; standards and frameworks; quality tools; quality in the supply chain.
Scheduling rules; scheduling and nested set-ups.
Roles of inventory; dependent and independent demand; Economic Order Quantity; uncertain demand; inventory management systems and measures.
Information systems – at operational, managerial, and strategic levels; bills of material; MRP, MPRll and ERP systems.
Ohno’s 7 wastes; Just-in-Time systems (including the Toyota Production System, and Kanbans).
Class discussion of cases, exercises, and videos to support this syllabus.
Intended learning outcomes On successful completion of this module you will be able to:
1. Assess the key capacity determinant in an operation, and carry out an analysis to develop the most appropriate approach in response to changes in demand.
2. Select and apply appropriate approaches and tools to determine standards and improve processes.
3. Determine the information needed to support businesses, in particular manufacturing operations.
4. Assess and select appropriate Just-in-Time (JIT) tools to improve operations.
5. Develop appropriate quality systems for the whole of their supply chain – from supplier, through operations to customers – and ensure these systems are sustained and a culture of continuous improvement prevails.
Operations Analysis
Aim
To develop your rigorous and logical application of tools and techniques for the design and control of operational systems.
Syllabus
• Six Sigma, Process capability, common and special cause variability, control charts, acceptance sampling. Improvement procedures. Design of experiments.
• Lean Manufacturing elements such as Value Stream Mapping and Waste identification.
• Analysis of systems. Systems thinking.
• P-FMEA. Business process fundamentals and the process review.
• Performance measurement. Responding to and improving reliability.
Intended learning outcomes On successful completion of this module you should be able to:
1. Combine tools for assessing, controlling and improving processes, and their strengths and limitations.
2. Analyse the relationship between work-in-process, lead-time and output in a production system and the impact of variability.
3. Decide the appropriate Six Sigma, Statistical Process Control tools and techniques and lean manufacturing approaches for different manufacturing cases.
4. Develop a ‘systems view’ of manufacturing and servicing operations.
5. Critically appraise unreliability and maintenance techniques.
Manufacturing
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