Materials Engineering.

Materials Engineering.LinksSuccessful completion of Unit 8: Engineering Design and this unit would enable learners to meet, in part, the Engineering Technician (Eng Tech) and Incorporated Engineer (IEng) requirements laid down in the UK Engineering Council Standard for Professional Engineering Competence (UK-SPEC) Competence B2, Identify, organise and use resources effectively to complete tasks, with consideration for cost, quality, safety and environmental impact.Essential requirementsLearner access to suitable materials testing equipment, specimens and test instrumentation is required. The range of tests chosen will depend on the learners working environment and particular needs but will need to include, as a minimum, tests that involve metals and polymers. Sample materials from each of the four categories for inspection, as well as products/structures produced from these categories of material, are also required.Employer engagement and vocational contextsLiaison with employers would prove of benefit to centres, especially if they are able to offer help with the provision of a suitable materials testing and/or processing/fabrication environment.LO
Learning outcome
(LO) AC In this assessment you will have the opportunity to present evidence that shows you are able to: Task no.
Evidence
(Page no)
LO1 Be able to determine the properties and selection criteria of materials from test and data sources
1.1 Detail the appropriate material properties and criteria for the selection of a metallic, ceramic, polymer and composite
1.2 Explain the particular characteristics related to the
microstructure and macroscopic behaviour of the four
categories of engineering materials
1.3 Generate and process test data to assess material
properties for two categories of material
1.4 Investigate and assess the quality of suitable data from
three different sourcesLO2 Understand the relationships between manufacturing process and material behaviour
2.1 Explain how one heat treatment process and two other
treatment processes affect the structure, properties and
behaviour of the parent material
2.2 Explain how one liquid processing method and two
mechanical processing methods affect the structure,
properties and behaviour of the parent material
2.3 Investigate how the composition and structure of metal
alloys, polymers and polymer matrix composites
influence the properties of the parent material
LO3 Be able to select suitable materials and processing method for a specific product
3.1 Analyse the function/s of a product in terms of the materials constraints on its design
3.2 Identify the required properties for the product and
select the most appropriate materials and processing
methods
3.3 Identify and explain the possible limitations on the
product imposed by the processing and by the need to
safeguard the environment and minimise costs
LO4
Understand the in-service causes of failure of engineering materials
4.1 Explain the common causes of in-service failure for
products or structures produced from each or a
combination of the four categories of engineering
materials
4.2 For one product or material structure, identify and
explain the in-service conditions that may contribute to
early failure
4.3 Explain the methods for investigating materials failure
and for estimating product service life, when a product
is subject to creep and fatigue loading
4.4 Determine and make recommendations for
remedial/preventive measures for a given product or
Materials structure, that will help improve its service life.Assignment title Materials Unit 21 assignmentPurpose of this assignment
This assignment will give you the opportunity to show your knowledge of basic engineering problems involving the strength of materials. The selection of the most appropriate materials for an engineered product and their processing is of prime importance if the product is to be fit for purpose. Engineers must thus be aware of the range of materials at their disposal. Knowledge of the structure of materials and the way in which this affects their properties is also desirable. Material properties may be determined or verified by testing and engineers should be aware of the range of standard tests and test equipment that is used and be able to interpret the test data. Materials generally need to be formed to shape, fabricated or processed in some other way, to make engineering components. The properties of the raw material can affect the choice of process and in some cases the choice of process can affect the final properties of a component. Materials also, for a variety of reasons, sometimes fail in service and engineers need to be aware of the modes and causes of such failure, as well as the preventative methods that may be used, to prolong their service life.This unit will thus provide learners with the necessary background knowledge and understanding of the properties, testing, treatments, processing, selection, failure modes and prevention of a variety of engineering materials. In addition, this unit offers learners the opportunity to consider environmental issues related to increased productivity and sustainability that lead to less waste and to the more efficient use of energy and resources when selecting materials for particular applications.
Scenario
You are going to spend five months of practice as a Mechanical Engineer in First Testing Company, one of the biggest Machine Elements Laboratories in the United Kingdom. You will be required to attend an interview and in preparation for this your potential supervisor asks you to solve the following tasks in order to assess your level of knowledge and understanding.Task 1 : (LO 1: 1.1, 1.2, 1.3,1.4 and D1) Research 1:For the diagram below define the terms1. Proportional limit
2. Yield stress
3. Ultimate stress
4. FractureAnd explain what is happening in the following regions.1. Elastic region
2. Yielding region
3. Strain hardening region
4. Necking regionTask Graph in Excel, as above, the relevant data for the selection of a metallic, ceramic, polymer and composite.
1.1 Detail on graph the appropriate material properties and criteria for the selection of a metallic, ceramic, polymer and composite.
1.2 Explain on graph the particular characteristics related to the microstructure and macroscopic behaviour of the four
Categories of engineering materials (metallic, ceramic, polymer and composite).
1.3 Generate and process test data (on graph) to assess material properties for two categories of material
1.4 Investigate and assess the quality of suitable data from three different sourcesTask 2 (LO 2) Research 2:For the Brinell hardness testing find and record:-1. The advantages.
2. The limitations.2.1 Explain how one heat treatment process and two other treatment processes affect the structure, properties and
behaviour of the parent material
2.2 Explain how one liquid processing method and two mechanical processing methods affect the structure,
properties and behaviour of the parent material
2.3 Investigate how the composition and structure of metal alloys, polymers and polymer matrix composites influence the properties of the parent material
Task 3 (LO3 and M1) Research 3:
For each of the 6 methods of NDT Visual, Liquid penetration, Magnetic, Ultrasonic, Eddy current and X-ray
a. Find one additional example for each within the engineering industry, with a description of the application
b. Describe for each the reasons the particular method was used over the alternative methods
3.1 Analyse the functions of a product in terms of the materials constraints on its design
3.2 Identify the required properties for the product and select the most appropriate materials and processing
methods
3.3 Identify and explain the possible limitations on the product imposed by the processing and by the need to
safeguard the environment and minimise costs
Task 4 (LO 4, M2 and M3) Research 4:For the five forms of steel Martensitic, Austenite, Cementite, Perlite Course and Perlite fine, Discuss
a. How each is formed and the requirements for their formation
b. The different properties of each. E.g. Hardness, toughness etc.Task 5 (LO 4 and D2) Research 5:You have been approached by a manufacturer of an Aircraft Undercarriage and asked to design a new Retracting Lever for their new model. (see image below)For both of these components:
a. Give an example of the material that could be used to make them.
b. The properties that the materials require to perform their function safely and efficiently.
c. Describe any treatments that the materials may need. i.e. hardening etc. and how this can be performed.
d. Describe a process by which the body of the part can be formed.
e. Describe 2 different surface processes that could be used on the retracting level to protect it from corrosion.
4.1 Explain the common causes of in-service failure for products or structures produced from each or a combination of the four categories of engineering materials. Try to predict what would happen if you redesigned the lever with either each or a combination of the categories of material.
4.2 For the retracting lever, identify and explain the in-service conditions that may contribute to early failure.
4.3 Explain the methods for investigating materials failure and for estimating product service life, when a retracting lever is subject to creep and fatigue loading
4.4 Determine and make recommendations for remedial/preventive measures for a retracting lever that will help improve its service life.Evidence checklist Summary of evidence required by student Evidence presented
Tasks 1, 2, 3, 4 and 5 A report written in a formal style, including a contents page indicating the different report chapters and sections. Attach your Assignment 1 report and witness statement to your results for Task 1 to 5. This must be submitted electronically A bibliography with references must be supplied using the Harvard System of referencing. An electronic copy of your reports submitted electronically on moodle.Achievement SummaryQualification Pearson BTEC HND Diploma in Mechanical Engineering
Assessor name
Ed StricklandUnit Number and title Unit 21 Materials
Student nameCriteria Reference To achieve the criteria the evidence must show that the student is able to: Achieved?
(tick)
LO 1 Be able to determine the properties and selection criteria of materials from test and data sourcesLO 2 Understand the relationships between manufacturing process and material behaviourLO 3 Be able to select suitable materials and processing method for a specific productLO 4 Understand the in-service causes of failure of engineering materialsHigher Grade achievements (where applicable)Grade descriptorAchieved?
(tick)
Grade descriptor
Achieved?
(tick)M1: Identify and apply strategies to find appropriate solutionsD1: Use critical reflection to evaluate own work and justify valid conclusionsM2: Select / design and apply appropriate methods / techniques
D2: Take responsibility for managing and organising activitiesM3: Present and communicate appropriate findings
D3: Demonstrate convergent/lateral/creative thinking