Unit 2107: Materials Processing and Manufacturing

1. Introduction to Materials Processing and Manufacturing

• Importance in industries (automotive, aerospace, construction, electronics)
• Key concepts: raw materials, processing, manufacturing flow
• Overview of manufacturing processes and systems

2. Material Properties and Selection

• Mechanical properties (strength, ductility, hardness, toughness)
• Physical properties (density, thermal conductivity, electrical conductivity)
• Chemical properties (corrosion resistance, reactivity)
• Material categories: metals, polymers, ceramics, composites
• Criteria for material selection in manufacturing

3. Casting Processes

• Fundamentals of casting
• Sand casting: process, advantages, limitations
• Investment casting: process, applications
• Die casting: process, typical uses
• Comparison of casting methods and selection considerations

4. Forming and Shaping Techniques

• Overview of plastic deformation processes
• Forging: open die and closed die forging
• Rolling: hot and cold rolling
• Extrusion: direct and indirect
• Sheet metal forming techniques (bending, deep drawing, shearing)
• Industrial applications and process selection

5. Machining Operations

• Introduction to subtractive manufacturing
• Turning operation: lathe basics and tooling
• Milling: types of milling and applications
• Drilling: process, tool types
• Grinding: surface finishing and precision
• Importance of machining in precision component production

6. Joining and Assembly Methods

• Overview of joining techniques
• Welding: arc welding, MIG, TIG
• Brazing and soldering: principles and differences
• Mechanical fastening: bolts, rivets, adhesives
• Selection criteria based on material and application

7. Additive Manufacturing

• Introduction to additive manufacturing (AM)
• Technologies: 3D printing, selective laser sintering (SLS), fused deposition modeling (FDM)
• Advantages and limitations of AM
• Impact of AM on modern manufacturing workflows

8. Surface Finishing and Coating

• Purpose of surface finishing: protection, aesthetics, functionality
• Plating techniques: electroplating, electroless plating
• Painting: types and industrial applications
• Powder coating process and benefits
• Selection of finishing methods based on product requirements

9. Quality Control in Manufacturing

• Principles of quality control
• Inspection techniques: visual, dimensional, non-destructive testing (NDT)
• Statistical process control (SPC): control charts, process capability
• Quality management systems (QMS): ISO 9001 overview

10. Sustainable Manufacturing Practices

• Importance of sustainability in manufacturing
• Resource efficiency: material and energy conservation
• Waste reduction strategies
• Environmentally-friendly production methods
• Case studies and industry examples