An Innovative Two-Tiered Approach for Teaching Engineering Materials to Manufacturing Engineering Students

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An Innovative Two-Tiered Approach for Teaching
Engineering Materials to Manufacturing
Engineering Students

• P. A. Manohar
• Assistant Prof. of Engineering
• Robert Morris University, Pittsburgh, PA

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Contents

• The three big questions
• Teaching Engineering generic issues
• Engineering Materials inherent issues
• Tuning it for manufacturing
• Proposed solution
• Tier 1 Essential Teaching Elements
• Tier 2 Course Enrichment Elements
• Effectiveness
• ABET outcomes assessment
• Student performance
• Student feed back
• Summary

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The three Big Questions

• What are the generic issues in teaching
  engineering courses in the contemporary
  environment?
• What are Materials-specific issues in teaching an
  introductory course?
• Which aspects of materials knowledge are relevant
  for manufacturing engineering?

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Generic Issues
hands-on, use of multi-media, friendly learning
environment
 
Domain knowledge, student and instructor
satisfaction
awareness of social, ethical responsibilities,
and contemporary issues communication skills
Applicable Outcomes
safe, supportive, motivating environment, value
for money
Skills technical, communication, problem solving
course aligned with program outcomes, ABET
outcomes assessment, FCARs
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Employer Expectations
An ability to learn, adapt, apply, communicate,
solve problems
Airplanes
Easy Open Cans
TruckWheels
Aluminum Beginnings
Automotive Structures
Cookware
Household Foil
2000
1840
1860
1900
1920
1940
1960
1980
1880
Truck Bodies
Heat Exchangers
Roofing
Electrical Conductor
Napoleons Rattle
Model TCastings
Dr. Greg Hildeman
Marine
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What Makes a Good Materials / Manufacturing
Engineer in the Aluminum Industry?

• Key Attributes of a Good Materials /
  Manufacturing Engineer
• Exceptional Communication Skills
• Thinks in terms of Value Creation
• Has Hands-on, Practical experience
• Pays Attention to Detail
• Has a high level of Energy, Passion and Drive
• Takes Initiative and assumes Leadership roles
• Thinks Globally
• Has a strong Technical Education and Analytical
  Skills
• Applies Critical Fundamental Thinking to Solve
  Problems
• Is a Team Player in a Diverse, Multi-cultural
  workplace
• Establishes a Strong Network
• Pursues Continuous Learning
• Promotes Safety, Health and Environmentally
  Sustainable Development

Dr. Greg Hildeman
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Inherent Issues in Teaching Materials Engineering

• 3D visualization and analysis of internal
  structure of materials
• Interdisciplinary nature physics, chemistry,
  mathematics and engineering
• Comprehend correlation between structural details
  that exist at various length-scales nano
  (atoms), meso (crystals), micro (phases), macro
  (bulk)
• Complex and non-linear relationships between
  composition structure processing properties
  and performance
• Read, interpret and apply complex diagrams
• Ever-broadening horizon of engineering and
  engineered materials

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Tuning it for Manufacturing

• Products
• Designs
• Processes
• Variability
• Quality assurance and control
• Economics
• Energy economy, sustainability, environmental
  protection

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Proposed Teaching PlanTier 1 Essential Elements

• Set teaching method
• Generate student assessment tasks
• Plan laboratory work
• Create ideas for continuous learning
• Develop a system for course administration
• Prepare for Faculty Course Assessment Report
  (FCAR)

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Essential Teaching Elements

• Set teaching methods appropriate for the topic
  e.g. material properties laboratory
  crystallography physical models diffusion -
  simulation and mathematical analysis,
  strengthening mechanisms analysis of graphs,
  problem solving
• Student assessment tasks designing questions
  that address specific applicable ABET criteria
  e.g. Given that the atomic radius is 0.143 nm and
  crystal structure FCC, calculate the theoretical
  density of pure Al. How does it compare with the
  experimentally determined density? Explain your
  answer. (ABET 1 an ability to apply knowledge
  of mathematics, science and engineering)

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Essential Teaching Elements (contd.)

• Laboratory work tension testing of mild steel,
  medium carbon steel, stainless steel and Al 6061
  alloy, Charpy V Notch impact testing at 32, 70,
  212 oF, visual observations and analysis of
  fracture surfaces, hardness testing (HRC, HRB,
  HRA, BHN), heat treatment of precipitation
  hardenable Al-Cu alloys
• Continuous learning Materials are deep seated in
  human culture. Do you agree with this statement?
  Why or why not? Give examples. Research homework
  on modern and emerging materials e.g. smart
  materials (SMA, piezoelectric ceramics, MEMS),
  nanoengineered materials (carbon nanotubes), bio
  and bio-mimetic materials (valves, stents,
  implants, muscles, tissues, membranes)
• Course administration syllabus, policies,
  lecture and lab schedule, attendance sheets
• FCARs review past FCARs before designing the
  course, not as a post script

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Proposed Teaching PlanTier 2 Course Enrichment
Elements

• Multi-media resources
• Virtual Materials Science
• Polymer laboratory
• Physical model building
• Industry visits
• Guest lecturers
• Conferences and Trade Shows

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Polymer Laboratory

• 2 hours hands-on experiments conducted by the
  Colloids, Polymers and Surfaces program of CMU
• Starch, polysacchride, sodium polyacrylate
  water soluble packing beans
• Polystyrene shrink wraps, zoom balls
• Sodium alginate, PVOH polymer gel ingredient
  of the nappies
• Vinyl alcohol sodium tertraborate SLIME
• Polypropelyne cleaning of oil spills

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Physical Models

• Magnets metallic and polymeric structures
• Paper clips straight chain and cross-linked
  polymers
• Minerals Garnet (cubic), Zircon (tetragonal),
  Beryl, Ice (hexagonal), Quartz (rhombohedral),
  Plagioclase feldspars (triclinic), Gypsum
  (monoclinic, raw material to make plaster of
  Paris), Topaz (orthorhombic)

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Conferences and Trade Shows, e.g. MST
Stents Polymer-coated SS wire
Heart Valves Dracon, Ti, Pyrolitic C
Hip Implants Ti, Ultra-high MW PE
Shape Memory Alloy Ni Ti alloy engine valve
springs
ASM Materials Camp half hour each at eight
displays manufacturing processes,
bioengineering, cryogenic phenomena, mechanical
testing, corrosion, plastics, non-destructive
testing and shape memory alloys Trade shows
Pittsburgh Artists Blacksmiths Association
Knee Implants Ti, Co/Cr, HDPE
Permanent Mold Casting 90 Sn Sb, Bi, Cu, MP
425 oF
NDT Dye Penetrant Testing
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Multi-Media Resources and Virtual Materials
Science

• Struers CD tracing the evolution of materials
  through the ages
• Simulations on dislocation motion, diffusion, on
  Instructors Resources CD (Callisters text book)
• MATTER project (www.matter.org.uk) has on-line
  experiments on rolling, recrystallization,
  quantitative metallography along with information
  on application notes, property data, case studies
  in Al and Fe alloys
• Interactive activities on crystallography,
  strengthening mechanisms, phase diagrams,
  diffusion kinetics included on the student
  companion website for Callisters text book.

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Tuning it for Manufacturing CES EduPack
Prof. Ashby
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THE MATERIALS TREE
Prof. Ashby
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THE PROCESS TREE
Prof. Ashby
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Mechanical properties
EduPack Data Analysis
Why the differences? Atom size and weight
Bonds as (linear) springs Spring constant for
various bond types. Manipulating properties
Making composites Making foams
Prof. Ashby
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EduPack Product Design
Design Criteria for Valve Body Low Cost,
Hardness 50 HRC min., Fracture Toughness 18
ksi(in.)0.5 min., Low Coeff. of Thermal
Exapnasion, Youngs Modulus 15 x 106 psi min.,
Service Temp. -30 300 oF, Corrosion Resistance
to Fresh and Salt Water
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Effectiveness of the Proposed Approach ABET
Outcomes Assessment
ABET 1 apply knowledge of mathematics, science,
and engineering 2 design and conduct
experiments and analyze and interpret data 5
identify, formulate and solve engineering
problems 7 communicate effectively 11 use
techniques, skills and modern tools necessary for
engineering practice (not assessed 4 function
on multi-disciplinary team)
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Effectiveness of the Proposed Approach Student
Performance
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Effectiveness of the Proposed Approach Student
Feedback (SIR II Data)
Assessment Item Fall 04 Fall 05
Course Organization and Planning 3.37 4.23
Faculty / Student Interaction 3.33 4.10
Effectiveness of Assignments / Exams / Grading Tasks 3.28 3.94
Course Outcomes (interest, learning, knowledge) 2.93 3.63
Overall Evaluation 2.67 3.97
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Summary

• A two-tiered approach is presented here to deal
  effectively with the complexities of attempting
  to meet the needs of the many stake holders in
  the contemporary teaching learning environment.
• The approach is demonstrated with a case study of
  its implementation in teaching an introductory
  engineering materials course to manufacturing
  engineering students
• The effectiveness of proposed approach shown in
  terms of ABET outcomes assessment, student
  performance in the course and student
  satisfaction survey results