Manufacturing Processes I

Code:

L.EM024

Acronym:

PF I

Keywords
Classification	Keyword
OFICIAL	Drawing, Design and Manufacture

Instance: 2022/2023 - 1S

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

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
L.EM	200	Syllabus	3	-	6	52	162

Teaching language

Portuguese

Objectives

The essential objective of this UC is to provide students with the fundamental concepts:

• of the welding and brazing bonding processes used in the manufacture of carbon steel and carbon/manganese steel structures. - Concept of weldability.


• of the techniques of bonding materials with structural adhesives.


• of the casting processes of parts in ferrous and non-ferrous alloys.


• of additive manufacturing processes using metals and plastics.

Learning outcomes and competences

With this curricular unit, students are expected to be able to:

• describe the main phases of the casting, welding and adhesive bonding processes;


• identify the critical phases of these processes;


• explain the relationships between structure and defects and operating conditions in the different phases of the processes:


• identify the main conditions and parameters that must be controlled in order to reduce or avoid defects and promote the desired metallurgical structure and mechanical properties;


• apply this knowledge to produce sketches and critique the design of parts to be obtained by these technologies;


• analyze and criticize given manufacturing processes, in the areas of casting, welding and adhesion;


• learn more on your own and develop your scientific and technical skills in these areas.

It is also expected that when they complete the binding process block, students will also have:

• knowledge of the main welding and brazing bonding techniques used in the manufacture of carbon steel and carbon/manganese steel structures.


• In particular, it is intended that the student will have a knowledge of: - Main welding technologies used in the national industry and the most significant parameters that control them; - Technology-specific limitations in relation to other alternative methods; - Concept of weldability of a material and the main connection difficulties; - Need to design a part bearing in mind that it will be welded. - Have a general knowledge of the techniques of bonding materials with structural adhesives.

Working in groups and acquiring greater competence in communication strategies (written and oral) and motivation

Working method

Presencial

Pre-requirements (prior knowledge) and co-requirements (common knowledge)

Science of materials
Metallic materials
Non-Metallic Materials
Mechanics of solids

Program

ADDITIVE MANUFACTURING AND FOUNDRY In theoretical classes: 1. Main casting alloys and their technological characteristics. 2. Interfaces. 3. Germination and growth of new phases and crystals. Casting of cast iron. 4. Melting and reactions between the liquid refractory metals and the atmosphere. 5. Solidification, solidification mechanisms and resulting structures in different alloys. 6. Fast fusion and solidification in welding. 7. Classes of additive manufacturing processes and main processes used industrially In laboratory practices: 1. Drawing rules and their relationship to defects in castings. 2. Conventional casting processes. 3. Design for obtaining castings. 4. Laboratory wax casting and additive manufacturing. JOINING PROCESSES 1 - Properties and classifications of connection processes. 2 - Manual welding with coated electrodes. 3 - Submerged arc welding. 4 - TIG Welding. 5 - MIG / MAG Welding. 6 - Resistance welding. 7 - Brazing.

Mandatory literature

Peter Beeley; Foundry technology. ISBN: 0-7506-4567-9
Fernando Jorge Lino Alves; Protoclick. ISBN: 972-95376-1-5
A. Barbedo de Magalhães; Interfaces e germinação. A Fusão dos metais.
Fernandes, A. A., Figueiredo, M.; Processos de Ligação de Metais, 2005
Phillips, D.; Welding Engineering, Wiley, 2016
Eduardo. A. S. Marques, Ricardo. J. C. Carbas, A. Francisco G. Tenreiro, Lucas. F. M. da Silva; Introdução às ligações adesivas estruturais, 2021. ISBN: 9789899017856
Lucas Filipe Martins da Silva, Ricardo Carbas, Eduardo Marques; Problemas e Trabalhos Práticos de Juntas Adesivas Estruturais. ISBN: 9789897232237

Teaching methods and learning activities

Teaching methodologies:
Weekly load - 2h T and 2h PL
Scheduled total hours - 52h
Out-of-class laboratory work - 12h
Reporting - 28h
Exam preparation - 70h Attendance to students (time to be indicated by each teacher).

Evaluation Type

Distributed evaluation without final exam

Assessment Components

Designation	Weight (%)
Teste	70,00
Trabalho prático ou de projeto	30,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Elaboração de relatório/dissertação/tese	28,00
Estudo autónomo	70,00
Frequência das aulas	52,00
Trabalho laboratorial	12,00
Total:	162,00

Eligibility for exams

Article 4 of the General Evaluation Rules.

Calculation formula of final grade

Final grade calculation formula:
CF=A*0.3+B*0.4+C*0.2+D*0.1
CF-Final classification
A- Casting test classification and additive manufacturing
B - Binding Process Test Classification
C- Classification of group work (report + presentation) of foundry and additive manufacturing
D- Classification of group work (report + presentation) of welding and adhesive joints

All the components (A-D) have a minimum rating of 7 values.

Examinations or Special Assignments

It does not apply, except in special cases provided for in FEUP's regulations. In these cases, the evaluation should be based on an examination (30%+40%=70%) and two bibliographic research reports, one on casting and the other on metal bonding. The evaluation of the foundry work will take into account the quality of the respective reports (5%), the digital and face-to-face presentations (5%) and the discussion (10%). The work of binding processes will have a weight of 10%.

Internship work/project

Not applicable.

Special assessment (TE, DA, ...)

It does not apply, except in special cases provided for in FEUP's regulations. In these cases, the evaluation should be based on an examination and two bibliographic research reports, one on casting and the other on metal bonding, their presentation and discussion, as specified above.

Classification improvement

To improve the classification, students must take a final recourse exam. The student may take an exam in one or both blocks. The weights are indicated in the calculation of the curricular unit's classification.