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MH2101 Metal Powder: Production, Handling and Characterisation 6.0 credits

Course memo Autumn 2020-50036

Version 1 – 10/22/2020, 11:47:31 PM

Course offering

Autumn 2020-1 (Start date 26/10/2020, English)

Language Of Instruction

English

Offered By

ITM/Materials Science and Engineering

Course memo Autumn 2020

Course presentation

Metal powders are vital for many processes, including additive manufacturing, sintering, isostatic pressing and metal injection moulding.  This course gives covers the science of metal powder production in depth, focusing on key technologies and properties.

The way in which powders are characterised is also a major focus of this course: what properties are important?  How can they be measured?  What problems can there be in measurements?

Even the most advanced and successful powder production processes is useless unless the powders are stored and handled correctly.  This and potential hazards of metal powder will be considered.

This course builds on knowledge gained in MH2100. If you did not take MH2100, introductory material will be available during the course.

This course has been designed so that you are in control.  Information will be made available using videos, texts and formative quizzes in Canvas.  Lectures will focus on advanced areas, industrial challenges and issues of metal powders and sustainability.

The course is examined in three parts: a lab exercise, a written exam that includes multiple choice questions and an assignment that is based on a feasible industrial scenario.

This course has been created by project "Utbildning i produktion av metallpulver – Framtidens arbetskraft i Sverige (UPP-FAS)" (reference number 2018-00794), within the strategic innovation program Metallic Materials, a joint initiative by Vinnova, Formas and the Swedish Energy Agency.

Headings denoted with an asterisk ( * ) is retrieved from the course syllabus version Autumn 2020

Content and learning outcomes

Course contents

1.       Explanation for the use of metal powder

2.       Methods for metal powder production

3.       Powder properties and characterisation methods

4.       Handling of metal powder

5.       Process paths for production of components from metal powder

Intended learning outcomes

After passing the course, the student should be able to:

  • Give example of and evaluate different process paths for production of metal powder
  • Compare relevant methods to measure properties of powder and evaluate these for a given powder material and intended application
  • Justify for possible changes in powder properties due to storing and handling and explain how this can be prevented or is mitigated
  • Give example of and justify different process paths for production of PM components (components of metal powder)
  • Explain which different generic properties a powder may depending on production process and justify for the suitability for a specific component manufacturing method
  • Give example of components produced with powder metallurgy and justify why the PM process has been used in these cases

Learning activities

The course consists of sixteen (16) non-mandatory lectures and one mandatory laboratory session for each student (reduced from two laboratory sessions due to limitations on the number of students that can be in the laboratory at any one time due to Covid-19).  Students are expected to perform a project lasting approximately 20 hours during the course.  Information will also be distributed through the online learning platform for students to study in their own time.  There will be an exam after the end of the course.

The non-mandatory lectures provide information and discussion, which is complemented by the information uploaded to the online Learning Management System.  It is highly recommended that students attend all sessions.

The laboratory session provides practical experience and more information about powder characterisation.  Successful participation in the session is required to pass the course.

The project allows students to apply the knowledge they have gained from the course (and any prior training in powder metallurgy) to an industrial scenario and to assess the impact of technical choices on sustainable development.

Assessment of the project is by written project report, laboratory report and examination.  This is intended to allow students the opportunity to demonstrate their knowledge, practice three forms of communication

Detailed plan

Day

Date

Start

End

Location

Activity

Teacher

Description

Tuesday

2020-10-27

1300

1500

Digital

Lecture

Chris Hulme-Smith

Course introduction, Introduction to powders

Thursday

2020-10-29

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder production techniques

Tuesday

2020-11-03

1300

1500

Digital

Lecture

Chris Hulme-Smith

Atomisation

Thursday

2020-11-05

1300

1500

Digital

Lecture

Chris Hulme-Smith

Gas atomisation

Tuesday

2020-11-10

1000

1200

Digital

Lecture

Chris Hulme-Smith

Water atomisation and milling

Thursday

2020-11-12

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder handling and safety issues

Tuesday

2020-11-16

0800

1600

L145, Bergs

Lab

Lorenzo Marchetti

Powder rheometry

Thursday

2020-11-17

1300

1500

Digital

Lecture

Chris Hulme-Smith

Sustainable development I

Tuesday

2020-11-24

1300

1500

Digital

Lecture

Chris Hulme-Smith

Sustainable development II

Thursday

2020-11-26

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder characterisation techniques I

Tuesday

2020-12-01

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder characterisation techniques II

Thursday

2020-12-03

0800

1600

L145, Bergs

Lab

Lorenzo Marchetti

Powder rheometry

Tuesday

2020-12-08

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder consolidation techniques

Thursday

2020-12-10

1300

1500

Digital

Lecture

Chris Hulme-Smith

Additive manufacturing


Schema HT-2020-121

Preparations before course start

Literature

Course literature

There is no compulsory course literature for this course.

Useful books

Randall M. German, Powder Metallurgy & Particulate Materials Processing, Metal Powder Industries Federation, 2005, ISBN 978-0976205715.

Andrew J. Yule and John J. Dunkley, Atomization of Melts: For Powder Production and Spray Deposition, Clarendon Press, ISBN 978-0198562580, 1994 (reprinted 2018).

Andrej Salak and V. E. Riecansky, Ferrous Powder Metallurgy, Cambridge International Science Publishing, ISBN 978-1898326038, 1997.

Other sources of informaiton

Extensive use shall be made of the Learning Management System.  Additional content will be published there and it is recommended that you read the course page on the Learning Management System regularly throughout the course.

Equipment

None required.

Support for students with disabilities

Students at KTH with a permanent disability can get support during studies from Funka:

Funka - compensatory support for students with disabilities

Please inform the course coordinator if you need compensatory support during the course. Present a certificate from Funka.

Examination and completion

Grading scale

A, B, C, D, E, FX, F

Examination

  • HEM1 - Home assignments, 3.0 credits, Grading scale: A, B, C, D, E, FX, F
  • LAB1 - Laboratory work, 1.0 credits, Grading scale: P, F
  • TEN1 - Written exam, 2.0 credits, Grading scale: A, B, C, D, E, FX, F

Based on recommendation from KTH’s coordinator for disabilities, the examiner will decide how to adapt an examination for students with documented disability.

The examiner may apply another examination format when re-examining individual students.

The section below is not retrieved from the course syllabus:

Home assignment (HEM1)

Each student shall be set a unique industrial scenario and required to provide a suitable response.  This response form the written report of the assignment.  This shall be submitted via the Learning Management System.  All sources of inforamtion may be used during the home assignment.

Laboratory work (LAB1)

Students shall attend one labroatory exercise session and complete written questions.  Answers should be submitted to the exercise leader.  It is the responsibility of the students to arrange the deadline and submissio nmethod with the exercise leader during the exercise.  All sources of inforamtion may be used during the home assignment.

Written exam (TEN1)

The written exam will take place in two parts.  The first part is a series of randomly selected multiple choice questions completed on the Learning Management System.  The second part will consist of questions that require longer written answers.  THese asnwers must be submitted via the Learning Managemetn System.  The answers can be handwritten, but the student is responsible for submitting the answers in a suitable format via the Learning Management System.  Submissions by email will only be accepted in exceptional circumtances.

All course notes and other soures of information are permitted during both parts of the written exam.

Opportunity to raise an approved grade via renewed examination

It is not permitted to raise an approved grade via a renewed examination.

Alternatives to missed activities or tasks

It is possible to arrange a replacement exercise to replace the laboratory exercise if compelling reasons are provided to explain why it is not possible to attend the laboratory exercise on either occasion it is offered.

Reporting of exam results

Results form all parts of the examinations shall be reported vie the Learning Management System.  This will include a breakdown of the individual grading criteria for the home exam and the multiple-choice and written answer parts of the examination.

Ethical approach

  • All members of a group are responsible for the group's work.
  • In any assessment, every student shall honestly disclose any help received and sources used.
  • In an oral assessment, every student shall be able to present and answer questions about the entire assignment and solution.

Further information

Changes of the course before this course offering

This is the first time this course has been offered.

Round Facts

Start date

26 Oct 2020

Course offering

  • Autumn 2020-50036

Language Of Instruction

English

Offered By

ITM/Materials Science and Engineering

Contacts

Communication during course

Chris Hulme-Smith may be contacted by email, phone (office hours only) or in person at office K121, Brinellvägen 23.

Lorenzo Marchetti may be contacted by email.

Course Coordinator

Teachers

Examiner