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TA201A: MANUFACTURING PROCESSES I

Course Description

  • To discuss and demonstrate fundamental manufacturing processes:
    • Casting/ solidification
    • Metal working/ metal forming
    • Welding and heat treatment
    • Powder metallurgical processes
    • Plastic injection moulding

Course Content

Topics (Lecture No.)

Introduction to Manufacturing: (1/2)

Classification; Historical Perspective

 

Engineering Materials: (2/ 3/ 4)

Engineering Materials – Classification

Structure of Materials

Types of Materials

Properties of Materials

Microstructure-property inter-relationship

 

Casting / Solidification: (5/ 6)

Classifications of casting processes

Patterns, core making,

Sprue and Riser design, Fluidity, Shrinkage

Casting defects

Other types of casting

 

Joining Processes: (7/ 8)

Fusion welding: Arc (MMAW, SAW, SMAW), Gas welding and resistance welding, Other fusion welding techniques

Fusion zone, Heat affected zone (HAZ)

Brazing and Soldering

Adhesive joining

Mechanical fastening

 

Metal Forming: (9/ 10)

Bulk deformation, Sheet metalworking

Strain and flow stress

Temperature in metal forming, Effect of strain-rate

Rolling – classification, roll camber, defects

Forging (open and closed-die), Extrusion

Defects

Shearing, blanking, punching

 

Various Topics: (11)

Powder Metallurgy

Plastic Injection Moulding

Outcomes of this Course

  • At the end of the course, whenever your look at a component, you should be able to answer questions like:
    • What are the primary techniques used in the manufacture of this component
    • What material was used for this product
    • What process was used
  • Get hands-on experience on manufacturing processes
  • Utilize your Craftsmanship and creativity to fabricate a part