Mechanical Engineering, MSc

Swansea University

Upon completion of the module the students will: LO1 learn the basic terminology and principles of AM technologies; LO2 learn general capabilities and limitations of AM with respect to other manufacturing technologies; LO3 learn classifications of metal-based AM technologies; LO4 be able to compare AM technologies and select for specific design/manufacturing applications; LO5 develop an in-depth understanding of specific metal-based laser powder-bed system; LO6 learn about design constraints, and the practicalities of setting-up builds and running AM machines; LO7 learn about the underlying physics of lasers, and thermal transfer of laser-powder interaction; LO8 learn how process maps are developed for specific materials and AM machines; LO9 learn how to select optimal machine parameters from process maps; LO10 understand the causes of errors and failures in AM parts, how to identify and avoid them; LO11 learn to identify features of part design and material which will be problematic for AM, and suggest alternatives; LO12 learn how scientific methodologies such as Design of Experiments are used to optimise machine parameters; LO13 learn about important research challenges in AM such CAE of melt pool/residual stress modelling; LO14 learn how to evaluate and select best build orientations and prepare a build report; LO15 plan, produce and evaluate a novel 3D metal printed component specifically designed for AM.

This module covers material that is important to Engineers when working in an advanced design environment where non-linear effects such as large displacement, plasticity, creep, fatigue and bolted joint mechanics are to be considered. A knowledge and understanding of advanced theories associated with non-linear material and component behaviour; plasticity, creep and large displacements and how such behaviours are numerically modelled within a finite element code. An ability to apply these advanced theories to practical problems such as plastic bending and torsion, residual stresses and spring back, plastic buckling and low cycle fatigue. An ability to use finite element analysis for predicting the non-linear behaviour of components and structures and to interpret the predictions in a meaningful way. A knowledge and understanding of design codes of practice applied to such components as pressure vessels and piping structures.

This module advances thermal-fluid flow modelling from that studied at a previous level. Students are assumed to have an understanding of the flow of air and water, but this module advances knowledge into multiphase materials that may be Non-Newtonian and have temperature dependent properties. It also includes study of heat transfer, solidification and melting processes. The aim is to equip the student with the theoretical understanding to solve thermal and fluid flows problems and their application to real life situations. Examples will be drawn from oil and gas applications and processes such as casting of metals, moulding of polymers, printing of inks and melting of powders.

A detailed coverage of current polymer, metal and ceramic matrix composite systems for engineering applications focusing on their performance envelope, advantages and limitations. The units will cover the following: The components and their attributes - an overview (reinforcements, matrices and interfaces), Properties of the matrix materials (Thermosets/thermoplastics, metals, ceramics, structure and mechanical behaviour), Properties of fibres and particles (Glass fibres, organic fibres, carbon fibres, ceramic particles and fibres; processing, structure, mechanical response), Composite manufacture (Piles, weaves, preforms, moulding pultrusion, filament winding, powder metallurgy, casting spraying), Mechanics of reinforcement (Rule of mixtures, anisotropy, laminate structures, stress- strain response), Basic stress analysis and failure mechanisms (Stress transfer and partitioning, multiple failure events, progression of fracture, toughness), Fatigue design considerations (Damage progression, reinforcement effects); Calculations, Environmental effect on / of composites and joining techniques.

This module presents the principles of life cycle analysis and Circular Economy. It covers the assessment of resource conservation by optimal use of resources, including consideration of primary extraction processes, design/manufacturing/fabrication, improving product life and end of life usage. It also reviews the current and planned European legislation that is of relevance to materials and energy and considers its implementation in the UK.

The module aims to develop fundamental research skills. It comprises the development of supervised research work leading to a dissertation in the field of the Master's degree programme. The specific research topic will be chosen by the student following consultation with academic staff.

The module will be presented with real life in-process quality improvement case studies for casting processes and cover the necessary metallurgical knowledge required to review the state-of-the-art in the field. It is expected that the critical literature review will be an exemplar document for foundry process engineers and metallurgists. It should enable them to evaluate risks and opportunities in their in-process quality improvement projects as required by the Clause 6.1 of ISO9001:2015 quality standard.

The module will provide a deeper understanding of the technology of plastics processing. The material covered will cross cut the engineering disciplines of advanced manufacturing technology and polymer science to broaden the technical and industrial context of polymer processing. Within the content of the module simulation software will be applied to industrial case study examples for critical evaluation. In addition, the application of polymer replication technologies within the emerging field of micro manufacturing will be presented, focusing on the advantage and limitations of size effect and length scale integration. The module will include practical demonstration laboratories and also include industrial visits.

This module provides an overview of the role that simulation can play in the design process of a product. A series of lectures introduce computational modelling and the computational tools and techniques employed in the design process. The application of simulation in the design of a number of industry based research projects is presented. Computer workshops lead students in using simulation tools and applying the tools in the optimisation of the design of a product.

Engineering interventions interact with and shape society, the environment and the economy. Research engineers have a responsibility to explore the potential wider impact of their engineering interventions and processes beyond the technical domain. This could take the form of an aerospace engineer confronting the fact that components for an essential control system use elements sourced from conflict zones, or it could be a civil engineer using limited financial resources to decide which of several in-need communities benefit from infrastructure upgrades and which do not. There are often no simple answers or perfect solutions to engineering projects which operate within their own cultural and financial constraints. A holistic and sustainable engineering approach is one that characterises potential impacts as fully as possible, so that engineering judgement is applied using this insight. This module will introduce both quantitative and qualitative research methods, showing how different methodologies are appropriate when targeting various objectives. While quantitative approaches are necessary to determine product safety, not all important factors can be reduced to a numeric quantity and a wider toolbox of techniques is required when engaging with intangible factors. Qualitative approaches can a better way of understanding how end-users appreciate or interact with the end product or process, which in turn may dictate success. Ethical issues concerning negative impacts on environment or society may raise questions of value, duty or morality. This requires the application of moral reasoning rather than scientific reasoning. Through the introduction of research methods and techniques to explore and characterise wider impacts, this module will equip students with the skills and background research needed to embark on their dissertation research project.

This module has been accredited by the professional body - the Association for Project Management (APM). At the end of this course students will be able to recognise and define the key characteristics and components of a project, understand the advantages/disadvantages associated with the management of both small and large projects, and have an appreciation of the strategic tools and techniques available to enable effective project management leading to a 'High Performance Team'. The acquired skills will be reinforced by the completion of a group project to produce an initial feasibility report (e.g. a business case/project plan document) for a major regional project.

The module will provide overview of the system engineering aspects of monitoring, control, reliability, survivability, integrity and maintenance. Areas of interest to be studied will encompass an engineering application from mechanical, marine and aerospace. The important underlying system engineering concepts on plan-do-check-act cycle, reliability in relation to quality engineering, design considerations on system survivability, integrity and maintenance will be highlighted and demonstrated with relevant examples. Of particular example will be looked at, including but not limited to, plant operation (hazard analysis, on-condition monitoring, majority voting system and high integrity protective system), marine and aerospace applications such as pump, propulsion subsystem and commercial satellite solar array subsystem (combination of series and parallel systems). Failure Modes and Effects Analysis and Load (stress)-Strength analysis will be introduced and the important links between type of failure, failure rate and safety margin will be quantified.