Part A: Course Specification - CHED - The Official Website ...



COURSE PACKAGEPart A: Course SpecificationCourse Code:EMATCourse Descriptive Title:Engineering MaterialsPrerequisite:NoneCorequisite:NoneYear Level:First YearSemester Offered :First SemesterCourse Credits:3 UnitsLecture Contact Hours Per Week:3 hoursLaboratory Contact Hours Per Week:NoneCourse Description:The Course provides underpinning knowledge and understanding, which involves identifying the different characteristics and limitations of construction, fabrication, and repair onboard ships. The Course also tackles the structures of matter, metallurgy, mechanical properties, fracture mechanics, ship's iron and steel, metal fabrication techniques, heat treatment of steel, non-ferrous metals and alloys, plastics materials and rubbers, ceramics and glass, adhesives, destructive and non-destructive testing STCW Reference:STCW TableFunctionCompetenceKnowledge, Understanding, and ProficiencyA-III/1Marine Engineering at the Operational levelOperate main and auxiliary machinery and associated control systemsBasic construction and operation principles of machinery systems, including:.1 Marine Diesel Engine.2 Marine Steam Turbine.3 Marine Gas Turbine.4 Marine Boiler.5 Shafting installation including Propeller.6 other Auxiliaries including pumps, air compressor, purifier, freshwater generator, heat exchanger, refrigeration, air-conditioning, and ventilation systems.7 steering gear.10 deck machineryMaintenance and repair at the Operational levelAppropriate use of hand tools, machine tools, and measuring instruments for fabrication and repair on boardCharacteristics and limitations of materials used In construction and repair of ships and equipmentCharacteristics and limitation of processes used for fabrication and repairProperties and parameters considered in the fabrication and repair of system and components Specific underpinning knowledge and understanding under Table III/2 of the STCW Code are incorporated into the Course. A-III/2Marine engineering at the management levelPlan and schedule operationsTheoretical knowledgeTechnology of materialsNaval architecture and ship construction, including damage controlCourse Outcome:Differentiate various metal characteristics, properties, and limitationsSelect appropriate materials conforming to important parameters for fabrication of typical ship-related componentsCourse Intake Limitations:The number of students that can be accommodated shall not exceed 40. Faculty Requirement:InstructorThe faculty that will be assigned to handle the Course must possess the following qualifications:graduate of Bachelor of Science in Marine Engineering;with at least 12 months of seagoing experience as Officer-in-charge of an Engineering Watch on seagoing ships powered by propulsion machinery of 750 kW propulsion power or more;completed Training Course for Instructors (IMO Model Course 6.09);completed Training Course on Assessment, Examination and Certification of Seafarers (IMO Model Course 3.12); andpreferably with teaching experience.ORregistered professional holding a bachelor's degree in Naval Architecture.AssessorThe assigned assessor to conduct the assessment for this Course shall have the same qualification as the instructor outlined above.Teaching Facilities and Equipment:CLASSROOMThe standard classroom size shall be a minimum of 48 square meters, no side shall be less than 6 meters for a class of 40 students. The classroom must be well-lighted and well-ventilated. It should contain the following:Tables and chairs or armed chairsWhiteboards or chalkboardsMultimedia equipmentFacilities and Equipment Quantity Required Material used onboard composed of the following: Bronze AluminumMagnesiumNickelZinc TitaniumSample Plastics or Polymers1 sample for each element Non-metallic materials such as glass fibers and micaAt Least 1 Sample Sample bearings Sample Plastics or Polymers1 sampleCeramics 1 sampleDye Penetrant1 sampleTeaching Aids:Learning Materials with Formative AssessmentsLearning materials such as slide presentations or learning modules shall be readily available, and corresponding formative assessment are prepared for knowledge and understanding check: Structures of Matter and Introduction to Metallurgy Mechanical Properties and Fracture Mechanics Ship's Iron and Steel Metal Fabrication Techniques Heat Treatment of SteelNon – Ferrous Metals and Alloys Plastic Materials and RubberCeramics and Glass Adhesives Destructive Testing Non-Destructive Testing Summative Theoretical Assessments Midterm Summative AssessmentsFinals Summative Assessment References / Bibliographies:References:International Convention on Standards of Training, Certification and Watchkeeping (STCW) for Seafarers 1978, as amended.International Convention for the Safety of Life at Sea (SOLAS), as amendedTextbooks:Young, J.F. and Shane, 1985 R.S Materials and Processes 3rd EditionHiggins, R.A. 1994, Properties of Engineering Materials 2nd Edition Callister, W.D and Rethwisch D.G (2011) Material Science and Engineering 8th EditionRussel, Paul A. (2018) General Engineering Knowledge 6th Edition Tupkary, R.H, V.R Tupkary (2018) Modern Iron Making Handbook Hudd, R.C. & Llewellyn D.T. (1998), Steels: Metallurgy and Application 3rd Edition IACS Requirements concerning Materials and WeldingDNV – G.L. Statutory Interpretations on SOLAS (2018)A Study of the Open Hearth: A Treatise on the Open Hearth Furnace and the Manufacture of Open Hearth Steel. Harbison-Walker Refractories Company. (2015), 102 pages 102 Websites: Hudd, R.C. & Llewellyn D.T. (1998), Steels: Metallurgy and Application 3rd Edition IACS Requirements concerning Materials and WeldingDNV – G.L. Statutory Interpretations on SOLAS (2018)Videos:What is an Atom Steel Crystal Structure : From Start to Finish Manufacturing - Including Blast Furnace and BOS ( )Manufacture of Steel by Bessemer Process ( )Hot Rolling, Cold Rolling & Grain Flow in Rolling Process (3D Animation) forging machine at factory it's Made – Metal Casting , Brass and Bronze alloys explained Alloys Explained of Materials on Society (IMOS) - Magnesium Alloy 6 Alloy Families: Lead B: Course OutlineTermWeekTopicTime Allotment (in hours)TheoreticalDemonstration / Practical WorkMidterm1Structure of Matter and Introduction to MetallurgyIntroductionRecalling the Structures of MatterStates of MatterCarbon and its ComponentsCrystal Structures in Metals and Non-Metallic MaterialsConclusion3-2 – 3Mechanical Properties and Fracture Mechanics IntroductionStatic Properties Cyclic Loads Impact Loads Design Applications Conclusion6-4 - 6Ship's Iron and Steel Introduction to Production of Iron and Steel Types of Steel ProductionProduction of Pig IronProduction of Cast Iron Properties of Cast Iron Steel Making Effects of Alloying Element in SteelWrought Steels9-7 - 8Metal Fabrication Techniques Categories of metal fabrication techniques Methods of forming techniques Methods of casting operations Miscellaneous techniques6-Week 9 – MIDTERM EXAMINATIONFinals10 – 11Heat Treatment of SteelStress relief heat treatmentAnnealingNormalizing SpheroidizingQuenchingTemperingMartemperingAuster tempering Surface HardeningHardenabilityHydrogen Embrittlement and Control6-12 - 13Non-Ferrous Metals and Alloys Copper and its alloys Aluminum and its alloysMagnesium based alloys Nickel-based alloysZinc based alloys Bearing metals Titanium alloys 6-14 Plastics Materials and Rubbers Introduction to Plastics Thermoplastics Polymers Mechanical Applications of Plastics onboardRubber and its uses onboard1.5-Ceramics and GlassIntroductionStructure CeramicUse of Ceramics onboard Ships1.5-15Adhesives The nature of adhesivesTypes of adhesivesPreparation of surfaces Application of adhesivesDurability and reliabilityTesting of adhesive properties 3-16Destructive Testing Introduction TensionCompression Torsion Bending HardnessFatigueCreep ImpactFailure and Fracture of Materials3-17Non-Destructive TestingObjectives of Non-Destructive TestingTypes of DefectVisual InspectionLiquid PenetrantsMagnetic MethodsThermal and Electrical Test X-Ray Methods of RadiographyUltrasonic Testing3-Week 18 – FINAL EXAMINATION Sub-total48Total Teaching Hours48Part C: Course SyllabusTopicsLearning OutcomesReferences/BibliographiesTeaching AidsStructure of Matter and Introduction to MetallurgyRecall the basic structure of matter with emphasis on the following: Nature of fundamental particles Structure of an atomAtomic nucleusMoleculesStates of Matter Exemplify carbon and its components Evaluate the crystal structures of metallic and non-metallic materials Describes that a metal can exist as a solid, liquid, or a vapor.T1 – p. 19 - 56 T2 – p. 1 – 21 A1 A2 A3 A4V1 V2P1Mechanical Properties and Fracture Mechanics Defines stress as the internal resistance per unit area of a material to an externally applied load Defines strain as the deformation produced in a material by an externally applied loadAssess the mechanical properties and the methods of test performed on the following: Strength StiffnessResilience and Toughness Ductile and Brittle FormationHardnessCreepDescribes three types of loading as:TensileCompressiveShearIllustrates with the aid of simple sketches, a material under each of the applied loadings given in the above objectives, using arrows to indicate load and stress and dotted lines to indicate deformationExplains how stress and strain can be calculated in terms of loading and material dimensions for the cases in the above objectivesDefines, for an elastic material subjected to a tensile load:Elastic limitYield pointUltimate strengthBreaking strengthStates that, within the elastic limit, Hooke's law will applyDefines Hooke's law as: Strain/strain=a constant Defines the constant contained in Hooke's law as the Modulus of ElasticityApplies the above objectives with simple numerical calculationsShows, on a sketched graph of load to a base of corresponding extension values, the behavior of elastic materials under tensile loading and indicates the condition points listed aboveDescribe in simple terms what is meant by the following mechanical properties:ElasticityBrittlenessHardnessStrengthToughnessDuctilityMalleabilityPlasticityT2 – p. 58 – 90T2 - p. 110 – 114T2 - p. 115 – 121A1 A2 A3 A4Ship's Iron and Steel Describes in simple terms the production of pig iron from iron oreDescribes the principles of the open-hearth, the Bessemer, and more modem processes used in the production of steel from pig ironEvaluates the production methodologies of the following: Production of Pig IronProduction of Cast Iron Properties of Cast Iron Evaluate the processes involved in steelmaking Assess the categories of wrought steels with emphasis on the following: Plain carbon steelsLow alloy steels High alloy steelsAlloying limits for low alloy steelsGeneral characteristics of various tool steels T2 – p. 311 – 398A1 A2 A3 A4V3 V4P1Metal Fabrication Techniques Assess the categories of metal fabrication techniques. Evaluate the various methods of forming operations with emphasis on the following: Hot and cold workingForgingRollingExtrusionDrawingEvaluate the various methods of casting operations with emphasis on the following: Sand Casting Die CastingInvestment CastingContinuous CastingEvaluate the various techniques with emphasis on the following: Powder metallurgy WeldingT3 – p. 417 – 420A1 A2 A3 A4V6 V7 V8P4Heat Treatment of Steel Explain the purpose of heat treatment Describe the following heat treatment process and the type of steel to which they may be applied: Stress relief heat treatmentAnnealingNormalizing SpheroidizingQuenchingTemperingMartemperingAuster tempering Surface HardeningHardenabilityHydrogen Embrittlement and ControlT2 – p. 331 - 398A1 A2 A3 A4V6 V7 V8P4Non – Ferrous Metals and Alloys states the purpose of the alloying elements nickel, chromium, and molybdenum in steels used in marine engineeringidentifies the metals used in non-ferrous alloys commonly employed in marine engineering with emphasis on the following:Copper and its alloys Aluminum and its alloysMagnesium based alloys Nickel-based alloysZinc based alloys Bearing metals Titanium alloys gives examples of applications of non-ferrous metals in marine engineeringT1 – p. 403 – 468A1 A2 A3 A4V9 V10 V11 V12P6Plastic Materials and rubbers Evaluate the structure of plastics and polymers Assess the mechanical applications of Plastics onboardAssess the rubber characteristics and its uses onboardT2 – p. 275 – 314 A1 A2 A3 A4P7AdhesivesEvaluate the nature of adhesivesCompare the different types of adhesivesConduct a preparation of surfaces where adhesives shall be usedGive examples where adhesives are used onboard shipsAssess the durability and reliabilityEvaluate the testing of adhesive properties T2 – p. 314 - 333 A1 A2 A3 A4P8Destructive Testing Evaluate the different destructive testing methodologies with emphasis on the following: TensionCompression Torsion Bending HardnessFatigueCreep ImpactFailure and Fracture of MaterialsT2 – p. 331 – 398A1 A2 A3 A4P9Non – Destructive TestEvaluate the different non-destructive testing methodologies with emphasis on the following: Objectives of Non-Destructive TestingTypes of DefectVisual InspectionLiquid PenetrantsMagnetic MethodsThermal and Electrical Test X-Ray Methods of RadiographyUltrasonic TestingT2 – p. 324 -410 A1 A2 A3 A4P10Part E: COURSE ASSESSMENT AND EVALUATION To ensure the effectiveness and precision of the course objectives, specific controls of examination and assessment have been set. This ensures that the Intended Learning Objectives are carried out according. The purpose of the Assessment and Evaluation is to: To assist the student learningTo identify the student's strength and weaknessTo assess the effectiveness of a particular instructional strategyTo assess and improve the effectiveness of the curriculum program To assess and improve teaching effectiveness The various methods of assessment and evaluations shall be carried out during the course delivery. Diagnostic AssessmentsFormative AssessmentsSummative AssessmentEvaluation for Quality AssuranceThis takes place before a student commences a course to ensure that they are on the right path. Diagnostics assessment is an evaluation of the student's skill knowledge, strength, and areas for development. Formative assessment shall be an integral part of the learning process and hence is considered a continuous evaluation. It provides information on the students' progress and may also be used to encourage and motivate themSummative assessment is designed to measure the students' achievement against defined objectives and targets. These are administered after the Course is taken, and these may be in the form of examination or practical demonstration. Evaluation for quality assurance shall be carried out after the Course has been delivered. It shall provide feedback to the instructors on the students learning, the modules strength, weakness and improve the teaching methodologies. To ensure presentation of all topics covered in an objective type of test and to measure the desired level of thinking skills, the test items to be conducted shall be based on a Table of Specification (TOS).Both assessment methods used to measure the students' knowledge, skills, and attitudes are reflected in the corresponding Assessment Plan.Part E: AssessmentTable of SpecificationsTermTopicsTime Allotment% of Teaching TimeThinking Skills No. of Test ItemsRememberUnderstandApplyAnalyzeEvaluateCreateMIDTERMStructure of Matter and Introduction to Metallurgy312.57Mechanical Properties and Fracture Mechanics62512Ship's Iron and Steel937.519Metal Fabrication Techniques625 12Total2410050TermTopicsTime Allotment% of Teaching TimeThinking Skills No. of Test ItemsRememberUnderstandApplyAnalyzeEvaluateCreateFINALStructure of Matter and Introduction to Metallurgy36.253Mechanical Properties and Fracture Mechanics612.56Ship's Iron and Steel918.7510Metal Fabrication Techniques612.53Heat Treatment of Steel612.56Non-Ferrous Metals and Alloys 612.56Plastics Materials and Rubbers1.53.122Ceramics and Glass1.53.122Adhesives36.254Destructive Testing36.254Non- Destructive Testing36.254Total8010050 ................
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