The module will introduce the following aspects of the shaping of materials:
Metals - solidification behaviour of metals; zones in ingot casting; segregation, constitutional undercooling and porosity; grain size control (inoculation and vibration); shaped casting - sand, die and investment; casting defects - inclusions, hot tearing. Characteristics of hot and cold forming; directionality and grain size; forging; rolling; extrusion and cold drawing. Fusion welding of metallic components; welding processes - MMA, MIG, TIG, SAW, power beam, resistance and friction; welding defects.
Polymers - calendaring of sheet polymers (differences from sheet metal forming); thermoforming of polymeric sheets; injection moulding of polymers; modifications of injection moulding for ceramics. Extrusion of polymers (differences from metals). Adhesive bonding and fasteners.
Ceramics - modifications for extrusion of ceramics; ceramic powder preparation - colloids and gels; cold and hot uniaxial pressing; isostatic processes; slip casting. Material and process selection examples for polymers, metals and ceramics.