guidebook introengmat 2012

Preface Engineering Materials is one of the basic knowledge in the stream of Metallurgy and Materials and Industrial Engineering. In this subject, students will develop the basic understanding of the characteristics of various engineering materials and how to process them for engineering application and fundamental concept of material testing. It lays foundation for further subjects related to manufacturing and processing of materials. For Metallurgy and Materials Engineering, it will lead to the understanding on the relationship between structure, processing, properties and performance of materials, while for Industrial Engineering, it will lead to manufacturing plant and its layout, as well as one of the factor to be considered in logistics and supply chain. This guidebook is intended to provide guidelines for students taking this subject. By reading this guide book, it is expected that students understand the learning objectives and should be able to prepare themselves prior to each topic. It is also to guide students in working in group so that they may make the most of the group exercises. Any comments, critics, correction to this guide book are thankfully accepted. Depok, September 2012 Teaching Team: Prof. Dr. Ir. Bondan T. Sofyan, M.Si. Prof. Dr. Ir. Johny W. Soedarsono, DEA Dr. Ir. Myrna Ariati, MS Dr. Ir. Sotya Astutiningsih, M.Eng.

Table of Content

Preface

Table of Content

Chapter 1. General Information 1

Chapter 2. Learning Objectives 4

Chapter 3. Outlines of Subject 5

Chapter 4: Teaching Methods and Learning Activities 7

Chapter 5: Exercises and Assignments 11

Chapter 6. Assessment 17

References 22

Student Guide Book Introduction to Engineering Materials 1

General Information 1. Subject : Introduction to Engineering Materials

2. Subject Code : ENMT600001 / ENMT610001

3. Semester : 1

4. Credit : 2 SKS

5. Year : 2012/2013

6. Type of Subject : Basic Competence Subject (Mata Kuliah Dasar Keahlian)

7. Prerequisite : None

8. Relationship between this subject and other subjects

See Figure 1 and 2.

9. Teaching Team : Prof. Dr. Ir. Bondan T. Sofyan, M.Si., [email protected] Prof. Dr. Ir. Johny W. Soedarsono, DEA, [email protected] Dr. Ir. Myrna Ariati, MS, [email protected] Dr. Ir. Sotya Astutiningsih, M.Eng., [email protected]

10. Description of the subject The scope of Introduction to Materials Engineering includes the structures of materials, the fundamental concept of material testing, and the processing routes of materials from ores / raw material into final engineering products. The types of materials cover in this subject are metals (iron, steel and aluminium), polymers, ceramic and composites. Learning activities will be conducted through various method, which consists of: interactive lecture, question-based learning, discussion, demonstration and unguided structured assignments. Assessment will be made continuously through a set of exercises, group discussion, mid semester exam and final exam. This guide book will help students prepare for learning activities for whole semester for this subject. Preparation may include reading, preparation of worksheet and practice. Achievement of students will entirely be due to their activities and preparation. Construction of knowledge will be made through exercises, and questions available in this book. Students are expected to do the exercises, and they may move to further stage as they ready for that. Overall, students are expected to be active learners by acquiring knowledge through thinking and exercising. Students may also use this guidebook to self-assess their achievement.

Chapter

1


Figure 1. Relationship of this subject with other subjects in Metallurgy and Materials Engineering


Figure 2. Relationship of this subject with other subjects in Industrial Engineering


Learning Objectives 2.1. Terminal Learning Objectives Upon completion of this subject students are expected to understand the processing, characteristics and application of engineering materials. structure and bonding in materials, material processing for all types of engineering materials as well as basic concept in materials testing. 2.2. Supportive Learning Objectives 1. Students are expected to understand about types of major engineering materials include properties for

each materials (metals, polymer, ceramic, composite, and semiconductor) and their area of application.

2. Students understand the atomic structure and atomic bonding of engineering materials that determine the properties of materials.

3. Students are expected to understand the mechanical properties and mechanical testing of materials to know material’s response and understand physical and chemical properties of materials

4. If a material is loaded for a certain magnitude, they students know the response of material and can predict the mechanical properties

5. Students are expected to understand various manufacturing methods for metallic materials. 6. Students are expected to understand the production of iron and steel, their mechanical properties and

application. 7. Students are expected to understand the production of non ferrous alloys, their mechanical properties

and application. 8. If students are given a particular engineering product made of metallic materials, they are able to

suggest the manufacturing routes. 9. Students are expected to understand different types of polymeric materials, how to produce them and

how to process for final engineering application. 10. Students are expected to understand different types of ceramic materials, how to produce them and

how to process for final engineering application. 11. Students are expected to understand different types of composite materials, how to manufacture them

for final engineering application. 12. If students are given a particular engineering product made of polymer/ceramic/composite materials,

they are able to suggest the manufacturing routes.

Chapter

2


Outline of Subject Supportive Learning Objective

Topic Sub-topic

Reference

1 1. Types of engineering materials and their applications

1.1. Materials in Everyday Lives 1.2. Introduction of major engineering materials 1.3. Metals and its properties 1.4. Polymers and its properties 1.5. Ceramic and its properties 1.6. Composites and its properties 1.7. Semiconductor and its properties

[1] Chap. 1

2 2. Structures of engineering materials

2.1. Atomic structures of materials 2.2. Primary bonds 2.1.1. Ionic bonding 2.1.2. Covalent bonding 2.1.3. Metallic bonding 2.3. Secondary bonds 2.2.1. Van der waals bonding 2.2.2. Hydrogen bonding 2.2.3. Mixed bonds 2.4. Bond strength and melting point

[1] Chap. 2

3, 4 3. Properties of material

3.1.Mechanical Properties 3.1.1. Concept of load 3.1.2. Tensile testing 3.1.3. Hardness testing 3.1.4. Impact testing 3.2.Physical Properties 3.2.1.Electrical properties 3.2.2.Magnetic properties 3.2.3. Thermal properties 3.3. Chemical properties corrosion resistance

[1] Chap. 3

5 4. Fabrication of Metals

4.1. Forming 4.2. Casting 4.3. Powder metallurgy 4.4. Joining

[1] Chap. 4

5, 6, 8 5. Steel and iron: production and properties

5.1.Classification of metal alloy 5.2. Steel making 5.3. Classification and characteristics of steel 5.4. Classification and characteristics of iron

[1] Chap. 4

5, 7, 8 6. Aluminium: 6.1. Introduction to aluminium [1] Chap. 5

Chapter

3


Supportive Learning Objective

Topic Sub-topic

Reference

production and properties

6.2. Production of aluminium 6.3. Classification of aluminium 6.4. Properties and application of aluminium

9, 12 7. Polymer: processing and properties

7.1. Introduction to polymer 7.2. Classification of polymer 7.3. Polimerization reactions and processing of

polymers 7.4. Properties and application of polymer

[1] Chap. 7

10, 12 8. Ceramic: processing and properties

8.1. Introduction to ceramic 8.2. Classification of ceramic 8.3. Processing of ceramic 8.4. Properties and application ceramic

[1] Chap. 8

11, 12 9. Composite: processing and properties

9.1. Introduction to composite 9.2. Classification of composite 9.3. Processing of composite 9.4. Properties and application composite

[1] Chap. 9

Texbooks Book: 1. Sofyan, Bondan T, Pengantar Material Teknik, Penerbit Salemba Teknika, 2010 Other References: 2. Callister, W.D, Materials Science and Engineering: An Introduction, 8 th ed., Wiley., 2010 3. Smallman, R.E and Bishop, R.L, Metal and Materials, Butterworth Heinemann 4. Vlack, Van, Elements of Materials Science, Addison Wesley 5. Mangonon, P. L, The Principles of Materials Selection for Engineering Design, Prentice-Hall 6. Mitchell, B.S, An Introduction to Materials Engineering and Science, for Chemical and Materials

Engineers, Wiley, 2004


Teaching Methods and Learning Activities 4.1. Learning method/approach: 1. Interactive lecture (IL) 2. Group discussion 3. Group exercise 4. Self-study 4.2. Learning Resources 1. Text books 2. Reference books 3. Handout 4. Internet 4.3. Instructional Media 1. White board (WB) 2. Infocus (I)

Chapter

4


Week

Supportive Learning Objectives Topic and Sub Topic Reference Learning Method

Assessment and Evaluation

1

‐ Introduction Course objectives, Guidebook, Rules, Grading.

Guidebook

‐ ‐

1. Students are expected to understand about types of major engineering materials include properties for each materials (metals, polymer, ceramic, composite, and semiconductor) and their area of application.

1. Types of engineering materials and their applications


[1] Chapter 1

Interactive lecture

Questions in class

2 2. Students understand the atomic structure and atomic bonding of engineering materials that determine the properties of materials.

2. Structures of engineering materials

2.1. Atomic structures of materials 2.2. Primary bonds

2.1.1. Ionic bonding 2.1.2. Covalent bonding 2.1.3. Metallic bonding

2.3. Secondary bonds 2.2.1. Van der waals bonding 2.2.2. Hydrogen bonding 2.2.3. Mixed bonds

2.4. Bond strength and melting point

[1] Chapter 1

Interactive lecture

Questions in class

3. Students are expected to understand the mechanical properties and mechanical testing of materials to know material’s response and understand physical and chemical properties of materials

4. If a material is loaded for a certain magnitude, they students know the response of material and can predict the mechanical properties

3. Properties of material

3.1.Mechanical Properties 3.1.1. Concept of load 3.1.2. Tensile testing 3.1.3. Hardness testing 3.1.4. Impact testing

3.2.Physical Properties 3.2.1.Electrical properties 3.2.2.Magnetic properties 3.2.3. Thermal properties

3.3. Chemical properties corrosion resistance

[1] Chapter 3

• Interactive lecture

• Exercise A2

Questions in class

3 5. Students are expected to understand various manufacturing methods for metallic materials.

4. Fabrication of Metals

4.1. Forming 4.2. Casting 4.3. Powder metallurgy 4.4. Joining

[1] Chapter 4


• Exercise A3

Questions in class


Week Supportive Learning Objectives Topic and Sub Topic Reference Learning

Method Assessment and

Evaluation

4

6. Students are expected to understand the production of iron and steel, their mechanical properties and application.

8. If students are given a particular engineering product made of metallic materials, they are able to suggest the manufacturing routes.

5. Steel and iron: production and properties

5.1. Classification of metal alloy 5.2. Steel making 5.3. Classification and characteristics of

steel. 5.4. Classification and characteristics of iron.

[1] Chapter 4

Interactive lecture

Questions in class

5

7. Students are expected to understand the production of non ferrous alloys, their mechanical properties and application.


5. Aluminium: production and properties

5.1. Introduction to aluminium 5.2. Production of aluminium 5.3. Classification of aluminium 5.4. Properties and application of aluminium

[1] Chapter 5

Interactive lecture

Questions in class

6


Metallic materials, its properties, production and availability in Indonesia

[1] Chapter 1‐5

Presentation +

Question/Answer

Presentation

7


Metallic materials, its properties, production and availability in Indonesia

[1] Chapter 1‐5

Presentation +

Question/Answer

Presentation

8 1‐12 MID SEMESTER EXAM MID SEMESTER EXAM

9

9. Students are expected to understand different types of polymeric materials, how to produce them and how to process for final engineering application.

12. If students are given a particular engineering product made of polymer/ceramic/composite materials, they are able to suggest the manufacturing routes.

6. Polymer: processing and properties

6.1. Introduction to polymer 6.2. Polymer molecule and structure 6.3. Thermoplastic, thermoset and

elastomer 6.4. Crystalline polymer

[1] Chapter 7

Interactive lecture

Questions in class

10

9. Students are expected to understand different types of polymeric materials, how to produce them and how to process for final engineering application.

6.5. Polimerization reactions and processing of polymers

[1] Chapter 7

Interactive lecture

Questions in class


Week Supportive Learning Objectives Topic and Sub Topic Reference Learning

Method Assessment and

Evaluation


6.6. Properties and application of polymer

11 Thurs: Islamic New Year holida

y

10. Students are expected to understand different types of ceramic materials, how to produce them and how to process for final engineering application.


7. Ceramic: processing and properties

7.1. Introduction to ceramic 7.2. Classification of ceramic 7.3. Structure of ceramic 7.4. Processing of ceramic 7.5. Properties and application ceramic

[1] Chapter 8


• Exercise B2

Questions in class

12

11. Students are expected to understand different types of composite materials, how to manufacture them for final engineering application.


8. Composite: processing and properties


[1] Chapter 9

Interactive lecture

Questions in class

13


Non‐metallic materials, its properties, production and availability in Indonesia

[1] Chapter 7‐9

Presentation +

Question/Answer

Presentation

14


Non‐metallic materials, its properties, production and availability in Indonesia

[1] Chapter 7‐9

Presentation +

Question/Answer

Presentation

15

9‐12 FINAL EXAM FINAL EXAM


Exercises and Assignments

Week Activity Group Assignment 1


Assignment A1, to be submitted by Week 6

2

2.1. Atomic structures of materials 2.2. Primary bonds

2.1.1. Ionic bonding 2.1.2. Covalent bonding 2.1.3. Metallic bonding

2.3. Secondary bonds 2.2.1. Van der waals bonding 2.2.2. Hydrogen bonding 2.2.3. Mixed bonds

2.4. Bond strength and melting point

Assignment A2, to be submitted in class on Week 2

3.1.Mechanical Properties 3.1.1. Concept of load 3.1.2. Tensile testing 3.1.3. Hardness testing 3.1.4. Impact testing

3.2.Physical Properties 3.2.1.Electrical properties 3.2.2.Magnetic properties 3.2.3. Thermal properties

3.3. Chemical properties corrosion resistance 3 4.1. Forming

4.2. Casting 4.3. Powder metallurgy 4.4. Joining

Assignment A3, to be submitted in class on Week 3

4

5.1. Classification of metal alloy 5.2. Steel making 5.3. Classification and characteristics of steel. 5.4. Classification and characteristics of iron.

5

6.1. Introduction to aluminium 6.2. Production of aluminium 6.3. Classification of aluminium 6.4. Properties and application of aluminium

6 Metallic materials, its properties, production and availability in Indonesia Presentation by students 7 Metallic materials, its properties, production and availability in Indonesia Presentation by students 8 MID SEMESTER EXAM 9

7.1. Introduction to polymer 7.2. Polymer molecule and structure 7.3. Thermoplastic, thermoset and elastomer

Assignment B1, to be submitted by Week 13

Chapter

5


Week Activity Group Assignment 7.4. Crystalline polymer

10

7.5. Polimerization reactions and processing of polymers 7.6. Properties and application of polymer

11 Thurs: Islamic

New Year holiday

8.1. Introduction to ceramic 8.2. Classification of ceramic 8.3. Structure of ceramic 8.4. Processing of ceramic 8.5. Properties and application ceramic

Assignment B2, to be submitted in class by Week 11

12


13 Non‐metallic materials, its properties, production and availability in Indonesia Presentation by students 14 Non‐metallic materials, its properties, production and availability in Indonesia Presentation by students 15 FINAL EXAM

Assignment A1 Some engineering products made of metallic materials are shown in Fig.1. Your task is to discuss in your group, and make a report on results of discussion, that covers:

1. The type and major properties of the materials, which compose the products. 2. The manufacturing process of the products (it will be better to find a video on this!) 3. Find out the range of basic price of the products. This is to give you the idea on how the total cost

of a product is determined. 4. The companies in Indonesia that make the products. If it is imported product, explain what

companies in what countries that produce it. Prepare a report in a powerpoint presentation, and be ready to present it! Rule for your report: You have to quote all references that you read properly. Format of references:

• Author (s), Year of publication, Title of book, Publisher, Place of publication, page no. • Author (s), Year of publication, Title of article, Title of magazine / journal, Vol, Issue, page no. • http://.... (complete address), accessed on ………

References worths 5 points. At the last page of your PowerPoint report, you should sign Statement of Authorship:

We the undersigned declare that the following paper is purely our own work. No work of others that we use without mentioning the source. This paper has never been used or presented for other assignment. We understand that this paper may be reproduced and or communicated for the purpose of detecting plagiarism. Name: NPM : Signature: Title of paper: Date: Subject: Engineering Materials (All group members must sign. No signature, no marks)


Rule of presentation: - You can use either English or Bahasa Indonesia for presentation. - Please equally share the time of presentation among your group members. - Duration of presentation is 15 minutes + 3 minutes Q/A session. So please prepare your

PowerPoint slides to match the time slot. - The mark of this Assignment is the mark of your presentation.

a. Nails b. Hollow rivets c. Chisel

d. Shock absorber e. Coca cola can f. Kitchen sink

g. Handsaw h. Bullets i. Body of SS1 rifle

j. Titanium ring k. Car body frame l. Pressing dies


m. Gold pendant n. Amalgam dental filling o. Balls in ball bearing All figures were taken from: http://www.google.co.id/imghp?hl=id&tab=wi Assignment A2 Problem 1. A cylindrical bar of metal having a diameter of 18.8 mm and a length of 198 mm is deformed elastically in tension with a force of 49,400 N. Given that the elastic modulus and Poisson's ratio of the metal are 67.1 GPa and 0.34, respectively, determine the following: (a) The amount by which this specimen will elongate (in mm) in the direction of the applied stress. (b) The change in diameter of the specimen (in mm). Indicate an increase in diameter with a positive number and a decrease with a negative number. Problem 2 Consider a brass alloy the stress-strain behavior of which is shown below.

A cylindrical specimen of this alloy 20 mm in diameter and 188 mm long is to be pulled in tension. Calculate the stress (in MPa) necessary to cause a 0.0105 mm reduction in diameter. Assume a value of 0.34 for Poisson's ratio.


Assignment A3

Figure 2 shows a pile of reinforced steel

A. What type of material is usually used for the product? B. Explain the main processing route for making the product. C. Predict the microstructure of the product at the bent areas.

Assignment B1 Some engineering products made of non-metallic materials are shown in Fig.1. Your task is to discuss in your group, and make a report on results of discussion, that covers:

1. The type and major properties of the materials, which compose the products. 2. The manufacturing process of the products (it will be better to find a video on this!) 3. Find out the range of basic price of the products. This is to give you the idea on how the total cost

of a product is determined. 4. The companies in Indonesia that make the products. If it is imported product, explain what

companies in what countries that produce it. Prepare a Powerpoint report, and be ready to present it! Rule for report and presentation is the same with that for Assignment A1!

a. Leak-proof Bakmi GM boxes b. School bag c. Leather shoes

d. Aqua bottle e. Aqua gallon f. Melamine wares g. Snack wrap


h. Pipes i. Tiles j. Body of this aircraft

k. Tile l. Body of water purifier tank m. Ceramic fiber for insulation

n. Body of a printer o. Mug All figures were taken from: http://www.google.co.id/imghp?hl=id&tab=wi Assignment B2

1. Explain why car windshield is not scattered when broken? 2. What are the difference when using clay and metallic roof for a house? Please explain.


Assessment 6.1. Instrument

1. Group assignments 2. Midsemester and final exam (written test, essay, modified essay question)

6.2. Assessment

No Component Weight 1 Group assignments 40% 2 Mid semester exam 30 % 3 Final exam 30 % Total 100 %

6.3. Grading ≥ 85 80-85 75-80 70-75 65-70 60-65 55-60 50-55 40 - 50 < 40

A A- B+ B B- C+ C C- D E

6.4. Code of Conduct o No cheating and plagiarism. Cheating and plagiarism will be sanctioned with “E” mark. o No sandals o No smoking o Attendance is required min 75 %. Why? Knowledge can be transferred through handout, but

“values” can’t be! So, please come and we may share good values in life. All of the following are considered plagiarism:

• turning in someone else's work as your own • copying words or ideas from someone else without giving credit • failing to put a quotation in quotation marks • giving incorrect information about the source of a quotation • changing words but copying the sentence structure of a source without giving credit • copying so many words or ideas from a source that it makes up the majority of your work,

whether you give credit or not Most cases of plagiarism can be avoided, however, by citing sources. Simply acknowledging that certain material has been borrowed, and providing your audience with the information necessary to find that source, is usually enough to prevent plagiarism. However, “borrowing” a whole paragraph is already considered plagiarism! (http://www.plagiarism.org/plag_article_what_is_plagiarism.html)

Chapter

6


6.5. Matrix for Mid semester exam

Cognitive Domain

Instrument Number of question/problem

Weight

K2 (comprehension)

Restricted response essay (Interpret information on a graph and details of phenomenon)

2-3 45 %

K3 (application) Restricted response essay (Apply a concept on real case in manufacturing)

1-2 20%

K4 (analysis) Extended response essay (Analysis of a case)

1-2 35%

Total 4-7 100%

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References Textbooks Sofyan, Bondan T, Pengantar Material Teknik, Penerbit Salemba Teknika, 2010 References

1. Callister, W.D, Materials Science and Engineering: An Introduction, 8 th ed., Wiley., 2010 2. Smallman, R.E and Bishop, R.L, Metal and Materials, Butterworth Heinemann 3. Vlack, Van, Elements of Materials Science, Addison Wesley 4. Mangonon, P. L, The Principles of Materials Selection for Engineering Design, Prentice-Hall 5. Mitchell, B.S, An Introduction to Materials Engineering and Science, for Chemical and

Materials Engineers, Wiley, 2004

guidebook introengmat 2012

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