Teaching, Learning and Pedagogy Division

Reg. No. 200604393R

COURSE OUTLINE FOR STUDENTS AT NTU

Academic Year 2022-2023 Semester 1&2

Course Coordinator TBD (1st semester), TBD (2nd Semester)
Course Code MA2004
Course Title Engineering Materials and Manufacturing Processes
Pre-requisites None
No of AUs 3
Contact Hours Total hours: 39 (26 hours lecture + 13 hours tutorials)
Proposal Date 22 June 2021

Course Aims

This core Engineering course will introduce the fundamental knowledges of engineering
materials—with emphasis on metals and alloys—and their manufacturing processes. The first
half of the course will lay the foundations for the understanding of the relationships between
structure at the atomic level to the properties of materials, the role of defects in determining
properties, and the basics as to how alloys are designed. The second part of the course
provides the student with a basic understanding of the manufacturing processes used in
industry. These include their fundamental principles, theory, quality issues and applications.
This course provides mechanical engineering students the foundations for designing and
selecting materials for virtually any engineering application, as well as understanding the
common manufacturing processes used in industry.

Intended Learning Outcomes (ILO)

By the end of the course, you should be able to:

1) Sketch crystal configurations and compute crystallographic quantities

2) Solve simple problems on mechanical deformation.
3) Evaluate the mechanical properties of solids as a function of their structure.
4) Distinguish between different types of alloys and how microstructures evolve in them.
5) Develop a basic understanding on various types of steels and some basic knowledge
about the microstructural aspects of them.
6) Identify various ways to strengthen metals.
7) Describe the applications of common dimensional and surface measuring equipment.
8) Select basic manufacturing processes for manufacturing a component, for example by
casting or polymer shaping or machining or sheet metalworking.
9) Apply metal casting fundamentals (e.g., solidification, riser design).
10) Calculate forces for sheet metalworking processes (cutting, bending, and drawing).

Teaching, Learning and Pedagogy Division

LT19A-B4-01, 50 Nanyang Avenue, Singapore 639798
65923739
[email protected] http://www.ntu.edu.sg/tlpd
11) Use metal-cutting theory to calculate forces, power, and energy, select suitable tool
materials and determine suitable machining conditions.
12) Explain the fundamentals of metal joining processes.
13) Apply welding fundamentals (e.g., effect of heat and pressure) to select suitable welding
processes.
14) Describe the common engineering polymers, their mechanical properties, and describe
major forming processes (e.g., injection moulding, extrusion, thermoforming, blow
moulding) used in industry.

Course Content
PART I: Engineering Materials
• Materials science and engineering: Introduction (1 h)
Materials as the cornerstone of society. Classification of materials and their basic
characteristics: crystalline and non-crystalline solids; metals, ceramics, polymers, and
composites. Importance of processing-structure-property relationships.
• Crystals and defects (3 h)
Crystal systems and structures. Miller indices. Crystallographic directions and planes,
packing efficiency. Polycrystalline and single crystalline materials. Types of Defects:
Point, line, planar, and bulk. Properties affected by defects. Dislocations. Slip systems.
• Phase diagrams (PDs) and microstructure formation (5 h)
Interpretation of (binary) PDs. Isomorphous PD. Eutectic PD. PD with Intermediate
phases or compounds. Microstructure analysis. The iron-carbon PD; Cast Irons; Heat
Treatment of Ferrous Alloys; Carbon and alloy steels; stainless steels.
• Mechanical behaviour of materials (4 h)
Stress and strain. Elastic and plastic deformation. Ductility. Toughness. Strengthening
mechanisms. Heat treatment of nonferrous alloys; precipitation hardening, Aluminium
Alloys; Superalloys. Recovery, Recrystallisation, and grain growth.

PART II: Manufacturing

• Introduction and overview of manufacturing (1h)
Introduction to manufacturing. Materials and manufacturing processes. Trends in
manufacturing. Dimensions and tolerances. Conventional measuring instruments and
gages. Surfaces finishing and measurement.
• Metal Casting (2 h)
Fundamentals of metal casting. Metal casting processes. Casting quality, common
defects, and design consideration. Expendable and non-expendable casting.
• Metal Forming (3 h)
Hot/Cold rolling, Sheet metal forming, Blanking, Bending, drawing.
• Metal Machining (2 h)
Theory of metal cutting. Machining operations and machine tools. Cutting tool
technology.
• Metal Joining (2h)
Fundamentals of welding. Welding processes and weld quality. Brazing, soldering and
adhesive bonding.
• Engineering Polymers and Polymer Forming (3h)
Engineering polymers: Polymer basics; thermoplastics, thermosets, and elastomers.
Polymer Forming: Properties of polymer melts. Extrusion. Injection, compression,
transfer, and blow mouldings. Thermoforming & casting.

page 2
Assessment (includes both continuous and summative assessment)

Component Course Related Weighting Team/Individual Assessment

LO Programme rubrics
Tested LO or
Graduate
Attributes
1. Continuous 1 to 7 EAB SLO 20% Individual
Assessment a, b, c
1 (CA1):
Quiz
2. Continuous 8 to 14 EAB SLO 20% Individual
Assessment a, b, c
2 (CA2):
Quiz
3. Final 1 to 14 EAB SLO 60% Individual
Examination a, b, c
– Closed
Book; 2.5
hrs
Total 100%

* EAB SLO stands for the Engineering Accreditation Board Student Learning Outcomes. The
list is below:

a) Engineering knowledge: Apply the knowledge of mathematics, natural science,

engineering fundamentals, and an engineering specialisation to the solution of complex
engineering problems.

b) Problem Analysis: Identify, formulate, research literature, and analyse complex

engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.

c) Design/development of Solutions: Design solutions for complex engineering

problems and design system components or processes that meet the specified needs
with appropriate consideration for public health and safety, cultural, societal, and
environmental considerations.

d) Investigation: Conduct investigations of complex problems using research-based

knowledge and research methods including design of experiments, analysis and
interpretation of data, and synthesis of the information to provide valid conclusions

e) Modern Tool Usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modelling to complex
engineering activities with an understanding of the limitations.

f) The engineer and Society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal, and cultural issues, and the consequent
responsibilities relevant to the professional engineering practice.

g) Environment and Sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for the sustainable development.

page 3
 h) Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.

i) Individual and Teamwork: Function effectively as an individual, and as a member or

leader in diverse teams and in multidisciplinary settings.

j) Communication: Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as, being able to comprehend
and write effective reports and design documentation, make effective presentations,
and give and receive clear instructions.

k) Project Management and Finance: Demonstrate knowledge and understanding of

the engineering and management principles and economic decision-making, and
apply these to one’s own work, as a member and leader in a team, to manage projects
and in multidisciplinary environments.

l) Life-long Learning: Recognise the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change

Formative feedback

You will be provided with formative feedback through the following channels:

- Tutorials: Tutors will address the main misconceptions that emerged from the tutorial
questions and lectures.
- Online Feedback: You will be able to submit online feedback forms to ask questions
anonymously on concepts that you find particularly difficult to assimilate.
- Live Feedback: You will be asked multiple choice questions during lectures. The
lecturers will provide live feedback on the submitted questions.
- Consultations: You will be able to request individual or group consultations with lecturers.

Learning and Teaching approach

Approach How does this approach support students in achieving the

learning outcomes?

Lecture Live lectures (or LAMS), which will integrate multiple choice
questions to gauge your understanding of the topic.

Revision Session Live revision sessions will be held once a week to review the
main concepts presented in live lectures (or LAMS), to run
demonstrations (e.g., mechanical testing of materials), and
discuss case-studies (e.g., the causes of engineering failures in
history). You will be challenged to discuss, analyze, and critique
on fundamental concepts covered in the lectures.

Tutorial During tutorials, you will have to solve and discuss different
problem sets.

page 4
Reading and References

Textbook
1. William D. Callister, David G. Rethwisch, “Materials Science and Engineering – An
Introduction” 9th Edition, John Wiley and Sons, 2014.
2. Groover Mikell P, Principles of modern manufacturing. 5th ed. SI version. John Wiley,
2013.
References
3. Sam Allen, Edwin L. Thomas, “The Structure of Materials”, John Wiley and Sons,
1999.
4. William F. Smith, Javad Hashemi, “Foundations of Materials Science and
Engineering”. 5th Edition, McGrawHill, 2010.
5. James F. Shackelford, “Introduction to Materials Science for Engineers” 6th Edition,
Pearson Prentice Hall, 2005.
6. DeGarmo, E. Paul, Black, J. Temple and Ronald A. Kohser, “Materials and Processes
in Manufacturing”, 10th Edition, Hoboken, New Jersey: Wiley, 2008.
7. Kalpakjian S and Schmid S R, Manufacturing engineering and technology, 7th edition,
Pearson, 2013.

Course Policies and Student Responsibilities

1. You are responsible to check regularly and follow-up with all courses, continuous
assessment, and course related announcements.

2. You are expected to complete all prescribed reading materials (notes and chapters
in recommended textbooks). The notes provided are not intended to be complete
but serve as a summary of topics and concepts that are covered in the course. The
readings of prescribed textbooks are necessary for complete coverage of course
contents.

3. You are expected to attend and to actively participate during live lectures and
tutorial classes, asking and answering questions and contributing to the discussion.

4. There will be two Continuous Assessments in the form of Quizzes, each

constituting 20% (total 40%) of the Course marks.

5. Your Final Examination constitutes 60% of the Course Marks.

6. If you are unable to attend your tutorials or Continuous Assessments (CAs)

because of illness or participating in a University Approved Event, You MUST
submit your Medical Certificates (MCs) or Leave of Absence (LOA) respectively to
the MAE Undergraduate Office promptly within 7 days. Failure to do so promptly
will result in “ABS” and given “0” mark for that CA and tutorial participation
components. The original MC or LOA form must be endorsed by your tutor and
submitted to the MAE Undergraduate Office. Email a scanned version of the MC or
LOA to the Course Co-ordinator and your tutor for reference.

Academic Integrity

page 5
Good academic work depends on honesty and ethical behaviour. The quality of your work
as a student relies on adhering to the principles of academic integrity and to the NTU Honour
Code, a set of values shared by the whole university community. Truth, Trust and Justice
are at the core of NTU’s shared values.

As a student, it is important that you recognize your responsibilities in understanding and

applying the principles of academic integrity in all the work you do at NTU. Not knowing
what is involved in maintaining academic integrity does not excuse academic dishonesty.
You need to actively equip yourself with strategies to avoid all forms of academic
dishonesty, including plagiarism, academic fraud, collusion, and cheating. If you are
uncertain of the definitions of any of these terms, you should go to the academic integrity
website for more information. Consult your instructor(s) if you need any clarification about
the requirements of academic integrity in the course.

Course Instructors

Instructor Office Location Phone Email

Matteo Seita N3.2-02-73 6790 5520 [email protected]
Upadrasta Ramamurty N3.2-02-05 6790 4040 [email protected]
Zhou Wei N3.2-02-16 6790 4700 [email protected]
Su Pei-Chen N3.2-02-10 6790 5586 [email protected]
Hortense Le Ferrand N3-02b-54 6790 6329 [email protected]

Planned Weekly Schedule

Topic Course
Week Readings / Activities
LO
1-2 PART I: MATERIALS 1, 3 Callister Ch. 1, 3, 4.1 to 4.5, and 6
Materials science and
engineering: Introduction
Crystals and defects
3-4 Phase diagrams and 4, 5 Ch. 11
microstructure formation
5-7 Mechanical behaviour of 2, 6 Ch. 8, 9
materials
Recess week
8 PART II: Manufacturing: 7 Groover Ch. 1, 1.1, 1.2, 1.3 and 1.6
Introduction, Dimensions (1h)
9 Casting 8,9 Groover Ch.6 − 6.1 to 6.5
Groover Ch. 7 − 7.1 to 7.3
Groover Ch. 8 − 8.2.4, 8.3.1, 8.3.3,
8.5, 8.7
10 Sheet Metal Forming 10 Groover Ch. 3 − 3.1.1, 3.1.4
Groover Ch. 16 − 16.1 to 16.3
11 Machining 11 Groover Ch. 17 – 17.1 to 17.5
Groover Ch. 18 – 18.1 to 18.4
Groover Ch. 19 – 19.1 to 19.3
12 Welding & joining 12, 13 Groover Ch. 25 - 25.1 to 25.4
Groover Ch. 26 – 26.1 to 26.8
Groover Ch. 27 – 27.1 to 27.3
13 Engineering Polymer and 14 Calister Ch 14, 15
Polymer Forming Process
page 6
Groover Ch. 10 − 10.1, 10.2.1,
10.2.3, 10.6 to 10.10

page 7