Manufacturing Processes II

Code:

EM0035

Acronym:

PF II

Keywords
Classification	Keyword
OFICIAL	Materials

Instance: 2011/2012 - 1S

Active?	Yes
Responsible unit:	Materials and Technological Processes Group
Course/CS Responsible:	Master in Mechanical Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
MIEM	125	Syllabus since 2006/2007	4	-	6	56	160

Teaching language

Portuguese

Objectives

BACKGROUD

In two of the four main manufacturing processes (foundry and fusion welding) the material of the component to be produced is totally or partially in the liquid state during part of the process. The phenomena occurring in the liquid state, in melting and solidification and the reactions between the liquid and the refractories and other solid phases temporary in contact and between the liquid and the atmosphere have an enormous influence in the structure and properties of the parts produced. This is way it is so important, in the Mechanical Engineering integrated Master course, to learn and understand what happens in the liquid state and in the transition processes from liquid to solid and during the following cooling until the ambient temperature.
Many of the future mechanical engineers, even if they do not work in foundry, will need to design and use castings. This is why it is so important for them to know the enormous potentialities of foundry technologies and also their limitations and the consequent design rules.

SPECIFIC AIMS

To promote the students acquisition of the basic knowledge on the metallurgical and mechanical processes occurring during fusion, in the liquid state, in contact with refractories and with the atmosphere, during solidification and in the cooling process in the solid state until ambient temperature.
To promote the learning about how metallurgical and mechanical defects can easily be produced and how to reduce or avoid them to appear in those processes.

To promote students knowledge and understanding of those processes in order to apply them to foundry welding and bonding processes and applications.

In the foundry component one specific aim is also to develop the technical knowledge of foundry technology processes.

Joining of materials module:

The course has as its main objectives to introduce the techniques of welding and brazing/soldering and adhesive bonding.


PREVIOUS KNOWLEDGE

In the first year of the MIEM course students visited two foundries and a very short introduction to foundry and welding technologies has been done, in the discipline of Introduction to Production Technologies and Design. Meanwhile, in other disciplines they have been introduced and developed their knowledge in materials science, metallurgy and other related matters.

PERCENTUAL DISTRIBUTION

40% Scientific component;

60% Technological component.

LEARNING OUTCOMES

Upon completion of the course the student should:
- be able to describe the main phases of the foundry, welding and adhesive bonding processes;
- identify the critical phases in those processes;
- explain the relation between structure, defects and the conditions in the different phases of the manufacturing processes;
- identify the main conditions and parameters to be controlled in order to reduce or avoid defects and promote the desired metallurgical structure and mechanical properties;
- apply this knowledge to establish the manufacturing parameters to produce specific parts with the recommended technology;
- analyse and criticise given foundry, welding and bonding procedures;
- to learn more by themselves and develop their scientific and technical competencies in the fields of foundry, welding and bonding.
Upon completion of the course the student should also:

- Have a basic knowledge of the most important welding technologies and the main parameters that control them.
- Be aware of the main constraints of the joining techniques studied in comparison with other alternative methods.
- Understand the weldability concept and main difficulties associated to these techniques.
- Know how to design structure/components for manufacturing by welding
- Have a general knowledge of the structural adhesives available in the market, its field of application, advantages and limitations

Program

Foundry Technology:

Theoretical classes:

1. Main foundry alloys and their technological characteristics.
2. Interfaces;
3. Nucleation and growth of new phases and crystals;
4. Melting and reactions between the liquid metals the refractories and the atmosphere;
5. Solidification, solidification mechanisms and resulting structures in different alloys;
6. Fast melting and solidification in welding and defects; how to avoid them.

Practical classes:
In the practical classes students will do exercises of design of castings and will be introduced to

a. Main casting design rules.
b. Conventional foundry technologies (sand casting, die casting and injection moulding);
c. Unconventional foundry technologies (investment, counter-gravity and vacuum casting for reactive alloys);
d. Differences between casting parts and molds;
e. Foundry defects, finishing, inspection and control techniques.


Joining of materials block:

1 - Properties and classification of welding processes;
2 - Shielded metal arc welding;
3 - Submerged arc welding;
4 – Gas tungsten arc welding (TIG- tungsten inert gas);
5 - MIG/MAG welding (gas metal arc welding);
6 - Electric resistance welding;
7 - Soldering and brazing;
8 - Introduction to structural adhesive bonding;
9 - Weldability of C and C/Mn steels;
10 - Postweld heat treatments;
11 - Welding distorsion;
12 - Welding procedure qualification;
13 - Joint preparation;
14 - Welding economics;
15 - Weld defects and non destructive testing.

Mandatory literature

American Welding Society; Welding Handbook
American Welding Society; Welding Handbook
Silva, Lucas Filipe Martins da; Juntas adesivas estruturais. ISBN: 978-972-8953-21-8
Código ASME XIX
ASM 400; Nondestructive inspection and quality control
Prof. António Barbedo de Magalhães; Apontamentos sobre Interfaces e germinação, Fusão e Solidificação de Ligas Metálicas
Prof. António Augusto Fernandes; Processos de Ligação de Metais. Manuscrito , 2005
Beeley, Peter; Foundry technology. ISBN: 0-7506-4567-9

Complementary Bibliography

Petrie, Edward M.; Handbook of adhesives and sealants. ISBN: 978-0-07-147916-5
Peter Beley; Foundry Technology, Bytterworth heinemann, 2001. ISBN: 0 7506 4567 9
Adams, R. D. 340; Adhesive bonding. ISBN: 1-85573-741-8
Lucas Filipe Martins da Silva, Andreas Öchsner; Modeling of adhesively bonded joints, Springer, 2008. ISBN: 978-3-540-79055-6
Silva, Lucas F. M. da; Öchsner, Andreas; Adams, Robert D. (Eds.); Handbook of Adhesion Technology, Springer, 2011. ISBN: 978-3-642-01168-9

Teaching methods and learning activities

Foundry module:

Presentation of the theoretical concepts and knowledge with PowerPoint, transparencies and explanations in the blackboard;

Production, presentation and discussion of a team bibliographic work by each small group of students on one specific cast piece or foundry technology or about an ambient or hygiene and security problem related to foundry.

Students exercises of critical analysis of casting parts design and design of sketches cast pieces and of moulds and cores to produce proposed foundry pieces;


Joining of materials Module:

Formal lectures, both of a practical nature and theory, supported by slides and videos. Students will perform lab/project work in teams up to 5 members, covering topics taught during the classes. Each team will submit a report of the work done which will be marked.

Evaluation Type

Distributed evaluation without final exam

Assessment Components

Description	Type	Time (hours)	Weight (%)	End date
Attendance (estimated)	Participação presencial	52,00
Elaboration of reports	Trabalho escrito	45,00		2011-12-16
	Total:	-	0,00

Amount of time allocated to each course unit

Description	Type	Time (hours)	End date
Study	Estudo autónomo	65	2011-12-16
	Total:	65,00

Eligibility for exams

To attain frequency, the student must attend at least 75% of the theoretical-practical and practical classes planned (FEUP rules).

Students exempt to frequent the classes have to do, present and debate two reports of bibliographic research, one on foundry and another on joining technologies.

Calculation formula of final grade

Foundry module:

Foundry module:

The students will perform one test (30%) and one team project, team work with the weight of other 15% and 5% for the active participation of each student in the classes. The classification of the team work depends on the quality of the report (5%), of the digital and the presential presentation (5%) and of the discussion on it (5%).

This first 50% will be aided of other 50% for the welding and bonding module

Joining of materials:

The students will perform one test and two team projects. The test will be marked with 8 points ( represents 40% of the final mark); the project/lab work is marked with 2 points (represents 10% of the final mark)

Examinations or Special Assignments

NA , excepted the cases specified in the faculty regulations for working students and other special cases.

In such cases the evaluation will be based on an exam (30%+40%=70%) and two reports, including their digital and presential presentations and debate. Those reports will be based on bibliographic research, one on foundry and the other on welding or adhesive bonding technologies. The evaluation of the foundry work depends on the quality of the report (5%), of the digital and presential presentations (5%) and of the debate (10%). The work on welding or bonding technologies will have a global weight of 10%.

Special assessment (TE, DA, ...)

The special evaluation of students exempt from attending classes will be done as described above, unless if they prefer to do the distributed evaluation as the other students.

Classification improvement

To improve the classification, the students must submit themselves to a final exam

Observations

Bibliography:

Notes by Professor Barbedo de Magalhães on interfaces, nucleation and growth of cristals, melting, reactions with the atmosphere and the refractories during the melting process, and solidification process.

JOINING OF MATERIALS Module
Código ASME XIX
ASM 400;Nondestructive inspection and quality control
American Welding Society;Welding Handbook
Prof. António Augusto Fernandes;Processos de Ligação de Metais. Manuscrito , 2005
Adams, R. D.;Structural Adhesive Joints in Engineering. ISBN: 0-412-70920-1
Edward M. Petrie;Handbook of adhesives and sealants, 2000. ISBN: 0-07-049888-1
Adhesive bonding: Science, technology and applications, R D Adams, 2005. ISBN: 1 85573 741 8
Kinloch, A. J.;Adhesion and adhesives. ISBN: 0-412-27440-X