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The textbook by WD Callister,
Jr: Materials Science and Engineering, 5th
Edition will be used.
Dr A. Ruys will
give lectures 1 to 16 and an end-of-term examination will be based on these lectures which counts for 50% of the written
examination.
Professor MV Swain will present lectures 17
to 24 and an end-of-term examination will be based on these
lectures which counts for 50% of the written examination.
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Marking schemes:
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Written examination
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60%
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Laboratory reports
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20%
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Tutorials and assignments
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20%
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Lecturers
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Dr A. Ruys (ME Bldg Rm
521)
a.ruys@aeromech.usyd.edu.au
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Professor MV Swain (ME Bldg Rm
332) mswain@aeromech.usyd.edu.au
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Tutors / Demonstrators
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Ms E. Kolos (ME Bldg Rm
342)
elizabeth.kolos@aeromech.usyd.edu.au
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Mr P. Boughton
(ME Bldg Rm
342)
boughton@aeromech.usyd.edu.au
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Lecture
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Description
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1
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Objectives, structure and assessment of the course.
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2
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General introduction to materials (Chapter 1)
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3
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Structure of crystalline solids (Chapter 3)
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4
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Imperfections in solids (Chapter 4)
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5
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Imperfections in solids (Cont'd Chapter 4)
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6
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Diffusion in solids and engineering applications (Chapter
5)
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Assignment #1 due
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7
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Mechanical properties of metals (Chapter 6)
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8
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Dislocation and strengthening mechanisms (Chapter 7)
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9
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Dislocation and strengthening mechanisms (Cont'd Chapter
7)
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10
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Failure of solids (Chapter 8)
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11
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Failure of solids (Cont'd Chapter 8)
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12
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Failure of solids (Cont'd Chapter 8)
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Assignment #2 due
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13
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Phase diagrams (Chapter 9)
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14
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Phase diagrams (Cont'd Chapter 9)
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15
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Annealing and heat treatment (Chapter 11)
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16
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Precipitation hardening (Cont'd Chapter 11)
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17
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TBA
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18
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Assignment #3 due
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(Mid Semester
Break)
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19
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(Prof Swain to provide contents of Lectures 17 - 24
based on Callister's book: Chapters 18, 19, 20,
21 and 22)
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20
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21
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22
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23
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24
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Assignment #4 due
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Attendance in tutorial classes is compulsory
and will be recorded by the tutors. Marks (up to a maximum of 5) will be
deducted from the final marks for tutorials/assignments. Tutorials have been
timetabled for Tuesday and Thursdays as per listed below. These will commence
in week 2.
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Tuesdays 11:00 to 12:00
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MT3 (Tutor: P. Boughton)
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EE614 (Tutor: E. Kolos)
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Wednesdays 11:00 to 12:00
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MT3 (Tutor: P. Boughton)
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MT2 (Tutor: E. Kolos)
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Thursdays 9:00 -10:00
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MT3 (Tutor: P. Boughton)
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MT4 (Tutor: E. Kolos)
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Thursdays 10:00 -11:00
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MT3 (Tutor: P. Boughton)
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MT4 (Tutor: E. Kolos)
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MT3 - Mechanical Engineering Tutorial Rm 3; EE614 - Electrical Engineering Tutorial Rm 614 etc
You should have the schedule for the tutorial
classes and the deadline for the submission of assignments from the
department already. Submit your assignment to your tutor who will
mark them and return to you in two weeks.
The four tutorials 1, 2, 3, and 4 are all taken
from the Callister Jr
book: Materials Science and Engineering. Generally, you are
given about three weeks to solve all the questions in each tutorial
and you should attempt to finish them in class. Tutorial questions
will not be marked but attendance is compulsory. Marks will be deducted for
non-attendance. You will be given separate assignments A1, A2, A3
and A4 and you should hand them in to the respective tutors according to the assignment
schedule. It is not always possible to arrange tutorials in phase
with lectures and students will be told about reading materials before they
come to the tutorial classes.
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Start: 10 July
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Finish: 28 July
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Calister:
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Chapter 3
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Q3.4, Q3.6
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Chapter 4
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Q4.5, Q4.30
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Read Chapters 3 and 4.
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Dut date: Friday 10 July
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Calister:
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Chapter 3
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Q3.8, Q3.18
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Chapter 4
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Q4.21, Q4.31
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Start: 31 July
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Finish: 18 August
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Calister:
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Chapter 5
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Q5.7
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Chapter 6
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Q6.27
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Chapter 7
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Q7.20, 7.25
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Read Chapters 5, 6 and 7.
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Dut date: TBA
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Calister:
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Chapter 6
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Q6.22, Q6.43
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Chapter 7
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Q7.18, Q7.32
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Start: 21 August
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Finish: 1 September
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Calister:
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Chapter 8
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Q 8.5, Q8.32
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Chapter 9
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Q9.5, Q9.7
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Read Chapters 8, 9 and 11.
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Dut date: TBA
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Calister:
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Chapter 8
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Q 8.4, Q8.14
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Chapter 9
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Q9.21, Q9.22
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(Professor Swain will set Tutorial #4 and Assignment A4)
There are two laboratory experiments for each
student, M1 and M2. You will be given a schedule of all these experiments
when they are finalised. Each experiment will
normally take one 3-hour afternoon. If additional time is required, arrangements
can be made with the demonstrators. P. Boughton
(M1) and E. Kolos (M2)
will be your demonstrators. They will be responsible to show you how
to conduct the experiments and mark your laboratory reports
which you have to hand in within 2 weeks after the experiments
have been completed. Always observe safety rules in the laboratory as the
testing machines and other facilities may cause bodily harm to you if not
careful. Laboratory attendance is compulsory. Non-attendance will
result in marks being deducted from the final score.
Materials Laboratory
M1: Mechanical Properties of Engineering Materials
Venue: Materials Laboratory, Mechanical Engineering Building Room 163
Purposes of Experiment:
The main aims are:
(a) to help the students to have hands-on experience of standard
mechanical testing machines to measure typical mechanical properties of
materials;
(b) to understand why metals behave differently to polymers; and
(c) to determine and appreciate the significance of the ductile-brittle
transition phenomenon in metals and polymers.
Materials for the Experiment:
Each group will choose one metal and one
polymer for the experiment. The metals can be either a low
carbon steel or an aluminium alloy. The polymers
may be chosen from PVC, PMMA and Nylon etc depending on what is available in
the Mechanical Engineering Workshop. Standard tensile and Charpy
specimens will be manufactured by the ME Workshop and provided to students
for testing. No need to manufacture hardness specimens as any of these two
specimens is suitable for the hardness tests.
The Experiment:
The following tests should be performed:-
(a) Standard tensile tests to evaluate tensile modulus, yield strength,
ultimate tensile strength, and elongation-to-break using the Insron 1195 universal testing machine. (45 minutes)
(b) Measure the Brinell (for metals) and Vicker (polymers) hardness numbers with the universal
hardness tester. (30 minutes)
(c) Study the ductile-brittle transition behaviour
(if any) using the Charpy impact testing machines
for metals and polymers, respectively, in the laboratory. (45 minutes)
Laboratory Report:
Each student has to submit his/her own report and no group report
will be accepted.
The report should contain the mechanical
properties of the chosen materials and comparisons should be made. Comment on
the relationships between hardness and tensile yield or ultimate strength for
metals; as well as hardness and elastic modulus for polymers from these
experimental results. Also the ductile-brittle transition phenomenon should
be explained in relation to the microstructures. (eg hcp aluminium will not show this ductile-brittle transition).
Discuss the fracture surfaces in relation to brittle cleavage and fibrous
shear failures if possible. (In this case, you will need to examine the
failure surfaces with an optical microscope in our laboratory or you may wish
to go the EMU to use the SEM. In the latter case you will need the assistance
of your demonstrator. This additional work will depend on your own
initiative.)
Materials Laboratory
M2:- Weibull Strength of Brittle Materials
Venue: Materials Laboratory, Mechanical
Engineering Building,
Room 163
Purposes of Experiment:
The main aims are:
(a) to familiarise the students about the
non-uniqueness of strength properties of brittle materials; and
(b) to bring to their attention the importance of Weibull
strength theory and probability of failure.
Materials and Testing:
Microscopic glass slides about 1 mm thick will
be used for three point-bending tests. From the load-deflection record
calculate the Young's modulus and the bending strength. You need to test
about 20 glass slides to get a reasonable sample size for Weibull
analysis. Use the Instron 1195 testing machine with
a displacement rate of about 10 mm/min. Make sure that no splints and broken
pieces are left in the machine or fly apart everywhere. (60 minutes)
Take another 20 glass slides and treat them
with hydrofluric acid (HF). Then repeat the bending
tests. Calculate the Young's modulus and bending strength again. (60 minutes)
Laboratory Report:
Each student has to submit his/her laboratory report and there
will be no group report.
In your laboratory report you should plot the
bending strength versus frequency and Young's modulus versus frequency
distribution curves. Use these results to determine the Weibull
moduli for as-received glasses. Comment on the
values of the Weibull moduli
obtained from the Young's modulus and the bending strength results. Do you
expect the Weibull moduli
to be very different and why? Give the Weibull
strength equation for the as-received glass slides tested.
Report the same as above for the glass slides
that were treated with HF. Comment on the Young's modulus and bending
strength distribution curves and their Weibull moduli. What do you think are the effects of the HF
treatment? How does the bending strength distribution curve change?
MECH2300: Materials 1
Unit of Study
Description (from the Engineering Handbook)
4
credit points.
Semester: 2.
Classes: 2 lec
and 1 tut/week plus 2 laboratory sessions per student.
Prerequisite: None
Prohibition: CIVL2101 (students can enrol in either
MECH2300 or CIVL2101, but not both)
Assessment: One 2 hr exam, assignments and
laboratory work.
Second
year core unit of study for the degrees in Mechanical and Aeronautical
Engineering.
Syllabus Summary
Materials
classification; understanding materials properties and their relation to
structure as a function of forming methods and heat treatment processes;
materials behaviour in service; selection criteria and case studies for
engineering applications. Objectives
To
understand the classification of engineering materials, and their properties
in relation to microstructure.
Expected outcomes
Students
should be able to appreciate the properties of a range of engineering
materials and how and why these are connected with microstructures and forming
and treatment methods.
Unit of Study
Aims/Goals:
MECH2300 is your introductory
course in engineering materials. It has no prerequisite subjects and is
therefore intended for students with little or no previous background in
engineering materials. A background in mathematics and science commensurate
with a second year engineering undergraduate student is sufficient.
There are three key focus
areas:
- Atomic structure of the solid state: atomic
bonding, crystal structures, and crystal imperfections.
- Properties of materials and the relationship
between properties and microstructure.
- The effects of heat treatment on microstructure
and properties.
In order to attain these key
understandings the aims of this subject are
- To gain understanding of the ways in which atoms
are arranged in the solid state and of the ways in which their
arrangement and the imperfections of their arrangement affect the
macroscopic properties of a material.
- To gain understanding of the various types of
mechanical properties of materials, how to measure and calculate them,
and how to use these skills in engineering design and failure analysis.
- To gain understanding of the means by which the
properties of materials can be manipulated via heat treatment, alloying,
and other means.
In passing this subject you
will then be able to apply these analysis and design
skills in more advanced ways. You will have the ability to design,
manipulate, and analyse materials in greater depth,
and learn to understand and control more complex materials, in MECH3300, the
third year materials subject.
Relationship
between this UoS and University generic attributes
The University
of Sydney has a set of generic
attributes which it believes a graduate should attain upon completion of
their degree which will provide them with the opportunity of being
“more employable, more able to cope with change and more developed as
people”. These attributes can be seen at http://www.usyd.edu.au/su/planning/policy/acad/102_grad.html.
This
UoS will provide the following generic attributes
- Knowledge Skills – all attributes in this
section will be dealt with in this course. In particular, to acquire a
body of knowledge in materials engineering, application of materials
engineering theory in familiar and unfamiliar situations, and the
ability to communicate this knowledge (especially in the written
form).
- Thinking Skills – all attributes in this
section will be dealt with in this course. In particular, in the field
of materials engineering, the ability to adopt a problem solving
approach and to be able to account for decisions.
- Personal Skills – In particular to generate
the capacity for further learning in the area of materials engineering.
- Personal Attributes – In particular the
ability to value your own engineering judgments in the area of design
with materials and gain a sense of the social responsibility involved in
design with materials.
- Practical Skills – all attributes in this
section will be dealt with in this course. Specifically, to be able to:
(a) use information technology
as part of the learning process.
(b) collect, correlate, display, analyse
and report observations in materials evaluation.
(c) apply experimentally-obtained results to new
theoretical situations.
(d) test hypotheses experimentally.
(e) apply technical skills in materials design and
evaluation.
Student Learning
Outcomes:
The outcomes of this subject are:
- To be able to describe, in relatively simple
terms, the crystal structure and associated crystal imperfections of
materials, describing theoretically, schematically, and mathematically.
- To be able to describe, in relatively simple
terms, the process of solid state diffusion in materials, describing
theoretically, schematically, and mathematically.
- To be able to describe the main properties of
materials, how to test for each, and how to analyse
and calculate the results of a test. This encompasses mechanical,
electrical, thermal, and magnetic properties.
- To be able to describe, in relatively simple
terms, the concepts of mechanical properties of metals and how they are
tested, and to relate the significance of this in terms of engineering
design.
- To understand the basics of binary phase diagrams
and to be able to use them in describing and measuring the effects of
heat treatment on microstructure. The significance of metastability will be a key focus, particularly in
relation to metallurgy.
Learning
Situations
There will be two lectures per week where the theory,
ideas, and engineering implementation to real systems will be discussed. The
lectures will be held in:
l
Farrell Lecture Theatre 1 (Farrell LT) on
Mondays at 12pm
l
Farrell Lecture Theatre 1 (Farrell LT) on
Thursdays at 11am
You are required to attend one tutorial a week. Tutorials
begin in week 2 and you can choose which tutorial to attend, but once you
have registered for a particular room and time, you must not change to a
different one without the permission of your tutor. The following are the
tutorial times:
l
Mechanical Engineering Tutorial Room 3 on
Tuesdays at 11AM
l
Electrical Engineering Tutorial Room 620 on
Tuesdays at 11AM
l
Mechanical Engineering Tutorial Room 2 on
Wednesdays at 11AM
l
Mechanical Engineering Tutorial Room 3 on
Wednesdays at 11AM
l
Mechanical Engineering Tutorial Room 3 on
Thursdays at 9AM
l
Mechanical Engineering Tutorial Room 4 on
Thursdays at 9AM
l
Mechanical Engineering Tutorial Room 3 on
Thursdays at 10AM
l
Mechanical Engineering Tutorial Room 4 on
Thursdays at 10AM
During the tutorial you will work through the allocated
problems, seeking the assistance from your tutor as required. You will be
expected to complete the pre-tutorial work before attending tutorials.
Laboratory
Laboratories will
be held on Wednesday, Thursday, and Friday afternoons from 2PM to 5PM. Each student is required to attend only
twice during the semester, once for the Mechanical Properties Laboratory, and
once for the Weibull Strength Laboratory. Your
specific two days will be allocated to you in the tutorials.
Assessment –
Tasks:
There are four assignments. These are based on problems
from the textbook. (Callister 6th
Edition, see below).
- Assignment
1 is on structure of the solid state and diffusion. Callister
problems 3.9, 3.15, 4.19, 5.11.
- Assignment
2 is on mechanical properties and phase diagrams. Callister
problems 6.40, 7.18, 9.20, 9.24
- Assignment
3 is on electrical properties and semiconductors. Callister
problems 18.2, 18.8, 18.10, 18.12.
- Assignment
4 is on dielectric, magnetic and thermal properties. Callister
problems 18.54w, 19.9, 20.6, 20.23.
Assessment –
Timetable:
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No.
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Component
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Due Date
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Weight
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1
|
Assignment 1,
structure of the solid state and diffusion
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Week 3
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5%
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2
|
Assignment 2,
mechanical properties and phase diagrams
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Week 6
|
5%
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3
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Assignment 3,
electrical properties and semiconductors
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Week 9
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5%
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4
|
Assignment 4,
dielectric, magnetic and thermal properties
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Week 12
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5%
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5
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Laboratory 1, mechanical properties of
engineering materials
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Report due 2
weeks after lab attendance
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10%
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6
|
Laboratory 2: Weibull
strength of engineering materials
|
Report due 2
weeks after lab attendance
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10%
|
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7
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Theory (Individual, written assessment of entire course)
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Exam Period
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60%
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Assessment –
Grade Attributes:
The following grade descriptors describe what is required
from you to achieve the following grade levels.
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Grade Level
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Descriptor
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Pass
|
•
Students who aim for a Pass should be able
to
–
Understand the concepts of atomic
structure and microstructure
–
Identify the various properties of
materials
–
Use simple equations for problem solving and
enumeration
–
Be able to interpret phase diagrams
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|
Credit
|
•
Students who aim for a credit will have to
accomplish the requirements of a Pass and should be able to
–
Understand the complexities and their
significance of atomic and microstructural modification techniques.
–
Clearly describe the relevance of material
properties, and their relative significance, in terms of design with
materials.
–
Manipulate simple equations in order to
test new theories and be able to graph them accordingly in a clear and
concise manner for communication purposes
–
Explain and understand the assumptions
behind phase diagrams: equilibrium, metastability, solution, and
immiscibility, and their relationship with reality.
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Distinction & High Distinction
|
•
Students who aim for a distinction and
higher will have to accomplish the requirements of a Credit and should be
able to
–
Describe in detail the various atomic and
microstructural modification methods, their relative merits, and suggest
other possibilities.
–
Describe, in a wholistic
manner, the overall relationship between the various strands of the course,
within the context of responsible engineering design: atomic structure and
microstructure, properties, heat-treatment and chemical composition.
–
Manipulate equations from first principles
to new systems.
|
Unit of Study
Program:
The following
program is indicative only.
|
Lecture
|
Description (Dr Ruys will give lectures 1-13, Dr Parakala
Lectures 14-26).
|
Tutorials
|
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1
|
Objectives, structure
and assessment of the course
|
No tutorials in
week 1
|
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2
|
Introduction to
materials (Chapter 1)
|
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3
|
Introduction to
materials (Chapter 1)
|
Tutorial 1
Callister Problems
3.4, 3.6, 4.5, 4.30
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4
|
Structure of crystalline
solids (Chapter 3)
|
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5
|
Imperfections in solids
(Chapter 4)
|
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6
|
Diffusion in solids and
engineering applications (Chapter 5)
|
|
|
Assignment #1
due
|
|
|
7
|
Mechanical properties of
metals (Chapter 6)
|
Tutorial 2
Callister Problems
5.8, 5.12, 6.7, 6.29
|
|
8
|
Mechanical properties of
metals (Chapter 6)
|
|
9
|
Dislocation and
strengthening mechanisms (Chapter 7)
|
|
10
|
Dislocation and
strengthening mechanisms (Chapter 7)
|
|
11
|
Phase diagrams (Chapter
9)
|
Tutorial 3
Callister Problems
9.5, 9.7, 9.9
|
|
12
|
Phase diagrams (Cont'd
Chapter 9)
|
|
|
Assignment #2
due
|
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13
|
Annealing, heat
treatment, and precipitation hardening (Chapter 10,11)
|
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14
|
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15
|
Electrical properties of materials (Chapter 18)
|
Tutorial 4
Callister Problems
18.1, 18.11, 18.30
|
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16
|
Semiconductors (Chapter 18)
|
|
17
|
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18
|
|
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Assignment #3
due
|
Tutorial 5
Callister Problems
18.56w, 18.59w
|
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19
|
Dielectrical Behavior (Chapter 18)
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20
|
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21
|
Magnetic Properties (Chapter 20)
|
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22
|
Magnetic Properties (Chapter 20)
|
Tutorial 6
19.12, 20.1
|
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23
|
Thermal Properties (Chapter 19)
|
|
24
|
|
|
|
Assignment #4
due
|
|
25
|
Revision
|
|
26
|
Revision
|
Unit of Study
References:
- The
textbook by WD Callister, Jr:
Materials Science and Engineering, 6th Edition will be used.
- Some
lecture notes are also on the website
http://www.camt.usyd.edu.au/education/MECH2300
- Printed
lecture notes are available at the University Copy Centre
Further, information on the course and on the laboratories
is also on the website http://www.camt.usyd.edu.au/education/MECH2300
Staff Contact
Information
|
Position
|
Name
|
Email
|
Telephone
|
Room Number
|
|
Lecturer
Coordinator
|
Dr Andrew Ruys
|
a.ruys@aerommech.usyd.edu.au
|
9351 8610
|
Rm 521 Mechanical
|
|
Lecturer/Tutor
|
Dr Padmaja Parakala
|
paddy.parakala@aeromech.usyd.edu.au
|
9351 3723
|
Rm 515Mechanical
|
|
Demonstrator
|
Philip Boughton
|
boughton@aeromech.usyd.edu.au
|
|
Rm 342 Mechanical
|
|
Demonstrator
|
Elizabeth Kolos
|
Elizabeth.Kolos@aeromech.usyd.edu.au
|
|
Rm 342 Mechanical
|
|
Tutor
|
Ryan Prasad
|
npra7729@mail.usyd.edu.au
|
|
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|
Tutor
|
Sav Shimada
|
sshi4720@mail.usyd.edu.au
|
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|
