Materials Technology Course

Lesson 1 • Classification of Engineering Materials

Surveys metals, ceramics, polymers, and composites by structure and application. Provides a framework for material selection decisions.

Lesson 2 • Crystal Structures and Defects

Examines unit cells, lattice systems, and common crystal structures. Connects crystallographic order to mechanical and electrical properties.

Lesson 3 • Material Properties Overview

Introduces mechanical, thermal, electrical, and optical property categories. Prepares students to interpret material datasheets accurately.

Lesson 4 • Atomic Structure and Bonding

Covers atomic models, electron configuration, and primary bond types. Establishes the link between bonding and bulk material behaviour.

Lesson 1 • Fatigue and Cyclic Loading

Examines S-N curves, fatigue crack initiation, and endurance limits. Prepares students to assess component life under repeated loading.

Lesson 2 • Stress, Strain, and Elasticity

Defines normal and shear stress, strain tensors, and elastic moduli. Grounds subsequent plasticity and fracture topics in continuum mechanics.

Lesson 3 • Creep and High-Temperature Behaviour

Describes creep stages, diffusion-controlled mechanisms, and stress rupture. Applies to materials used in elevated-temperature service.

Lesson 4 • Plastic Deformation Mechanisms

Analyses dislocation motion, slip systems, and work hardening. Explains why metals strengthen under cold working.

Lesson 1 • Heat Treatment of Steels

Covers annealing, normalising, quenching, and tempering processes. Connects thermal cycles to microstructure and mechanical property outcomes.

Lesson 2 • Copper, Nickel, and Superalloys

Reviews copper alloy families, nickel-based superalloy strengthening, and high-temperature oxidation resistance. Connects to turbine and electrical applications.

Lesson 3 • Iron-Carbon System and Steels

Analyses the Fe-C phase diagram, steel grades, and heat treatment responses. Establishes the basis for all subsequent steel processing topics.

Lesson 4 • Cast Irons and Specialty Steels

Distinguishes gray, white, ductile, and malleable cast irons by microstructure. Introduces stainless, tool, and high-speed steels for specialised use.

Lesson 1 • Polymer Degradation and Stabilisation

Identifies thermal, UV, oxidative, and hydrolytic degradation pathways. Introduces stabiliser systems to extend service life.

Lesson 2 • Thermoplastics and Thermosets

Contrasts melt-processable thermoplastics with cross-linked thermosets by structure and recyclability. Guides material selection for manufacturing processes.

Lesson 3 • Elastomers and Rubber Technology

Covers natural and synthetic rubber, vulcanisation, and viscoelastic behaviour. Applies to seals, tyres, and vibration-damping components.

Lesson 4 • Polymer Processing Methods

Surveys injection moulding, extrusion, blow moulding, and thermoforming. Links process parameters to final part quality and dimensional accuracy.

Lesson 1 • Ceramic Processing and Sintering

Covers powder preparation, compaction, sintering, and densification. Connects processing variables to final microstructure and mechanical strength.

Lesson 2 • Composite Manufacturing and Failure

Surveys hand layup, resin transfer moulding, filament winding, and autoclave curing. Identifies delamination, fibre pull-out, and matrix cracking failure modes.

Lesson 3 • Composite Material Fundamentals

Defines matrix, reinforcement, and interface roles in composite systems. Introduces rule-of-mixtures and laminate theory for property estimation.

Lesson 4 • Glass Formation and Properties

Explains glass network formers, modifiers, and viscosity-temperature behaviour. Applies to optical, structural, and specialty glass applications.

Lesson 1 • Optical and Electron Microscopy

Covers sample preparation, optical metallography, SEM, and TEM imaging modes. Connects microstructural observation to property interpretation.

Lesson 2 • X-Ray Diffraction Analysis

Explains Bragg's law, diffractometer operation, and phase identification. Applies to residual stress measurement and texture analysis.

Lesson 3 • Thermal Analysis Methods

Introduces DSC, TGA, and dilatometry for phase transformation and stability studies. Links thermal data to processing and service temperature limits.

Lesson 4 • Spectroscopic Composition Analysis

Surveys EDS, WDS, XRF, and AES for elemental composition determination. Enables quantitative analysis of alloy and coating compositions.

Lesson 1 • Corrosion Testing and Monitoring

Introduces salt spray, immersion, electrochemical impedance, and field monitoring methods. Enables quantitative corrosion rate assessment in service.

Lesson 2 • Electrochemical Corrosion Fundamentals

Covers oxidation-reduction reactions, galvanic cells, and electrode potentials. Provides the electrochemical basis for all corrosion forms discussed later.

Lesson 3 • High-Temperature Oxidation

Analyses oxide scale growth kinetics, Pilling-Bedworth ratio, and protective scale formation. Applies to furnace components and turbine hardware.

Lesson 4 • Corrosion Protection Methods

Reviews coatings, cathodic protection, inhibitors, and material selection strategies. Equips students to specify cost-effective corrosion control systems.

Lesson 1 • Cost, Availability, and Sustainability

Evaluates material cost drivers, supply chain risk, and environmental impact metrics. Integrates economic and sustainability constraints into selection decisions.

Lesson 2 • Design for Manufacture and Assembly

Aligns material choice with manufacturing process capabilities and assembly constraints. Reduces redesign cycles by integrating process limits early.

Lesson 3 • Performance Index and Ashby Charts

Introduces performance indices, material property charts, and multi-objective optimisation. Provides a quantitative framework for comparing material families.

Lesson 4 • Case Studies in Material Selection

Applies all selection tools to aerospace, biomedical, and energy sector case studies. Consolidates chapter skills through realistic, multi-constraint design problems.