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MH2101 Metal Powder: Production, Handling and Characterisation 6.0 credits

Course memo Autumn 2021-50173

Version 1 – 09/05/2021, 10:40:38 PM

Course offering

Autumn 2021-1 (Start date 01/11/2021, English)

Language Of Instruction

English

Offered By

ITM/Materials Science and Engineering

Course memo Autumn 2021

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

2020-11-02

1300

1500

Digital

Lecture

Chris Hulme

Course introduction, Introduction to powders

Thursday

2020-11-04

1300

1500

Digital

Lecture

Chris Hulme

Powder production techniques

Tuesday

2020-11-09

1300

1500

Digital

Lecture

Chris Hulme

Atomisation

Thursday

2020-11-11

1300

1500

Digital

Lecture

Chris Hulme

Gas atomisation

Tuesday

2020-11-16

1000

1200

Digital

Lecture

Chris Hulme

Water atomisation and milling

Thursday

2020-11-18

1300

1500

Digital

Lecture

Chris Hulme

Powder handling and safety issues

Monday

2020-11-22

0800

1600

L145, Bergs

Lab

Chris Hulme

Powder rheometry

Tuesday

2020-11-23

1300

1500

Digital

Lecture

Chris Hulme

Sustainable development I

Thursday

2020-11-25

1300

1500

Digital

Lecture

Chris Hulme

Sustainable development II

Tuesday

2020-11-30

1300

1500

Digital

Lecture

Chris Hulme

Powder consolidation techniques

Tuesday

2020-12-07

1300

1500

Digital

Lecture

Chris Hulme

Additive manufacturing

Thursday

2020-12-09

0800

1600

L145, Bergs

Lab

Lorenzo Marchetti

Powder rheometry

Tuesday

2020-12-14

1300

1500

Digital

Lecture

Chris Hulme

Powder characterisation techniques I

Thursday

2020-12-16

1300

1500

Digital

Lecture

Chris Hulme-Smith

Powder characterisation techniques II


Schema HT-2020-121

Preparations before course start

Specific preparations

Recommended prior knowledge

Students must have understanding of materials science, at a level that allows them to execute their chosen project.  Prior knowledge of powder metallurgy is advantageous but not essential.

Equipment

None required.

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.

Software

No specialist software will be used in this course, except wen you perform experimental work in the lab exercise (where the software is available).

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.

Grading criteria/assessment criteria

Laboratory Exercise

Both grading criteria must be passed to pass the laboratory execise:

Criterion    
Participation: the students attended and actively took part in the lab session.
Pass
 
The student did attend and was active in the lab session.
Fail
 
The student either failed to attend or did attend but took little or no part in the activities.
Report: the overall quality of the report
Pass
 
The student submitted a report and made a serious attempt to complete all parts of the report to an adequate standard. A significant fraction of the information given was reasonable and/or correct.
Fail
 
The students either submitted no report or submitted a report with fundamental errors. Significant plagiarism will also lead to this grade in addition to other appropriate procedures. Late reports may be failed if they are not of a sufficiently high quality to excuse the lateness. Late submissions with justifiable reasons for the late submission will not be penalised.

Home Assignment

Criterion          
Main topic: this will take approximately 5-6 pages and will include one of the following types of powder technology:
  • production
  • characterisation
  • consolidation
30 to >24 Pts
Excellent
 
You construct an efficient and effective argument about why your chosen technology/technologies are the best for the situation you have been asked to consider. You consider all relevant information and connect different arguments together to create an overall argument.
24 to >16 Pts
Good
 
You consider most of the scientific issues surrounding the problem you are asked to solve with a good level of detail, or you consider all of the relevant issues in some detail, but the level of detail could be improved. You have not discussed any issues that are irrelevant.
16 to >8 Pts
Average
 
You consider some scientific principles that are relevant for your problem, but you also miss several important points, or do not discuss the points in enough detail. One or two of the issues you discuss are not relevant to the problem you have been asked to solve.
8 to >2 Pts
Poor
 
You include almost no relevant information to solve the problem you have been set in your assignment. You either present too little information, or discuss irrelevant information.
2 to >0 Pts
Very poor
 
You do not include any relevant information to find an answer for the situation you are asked to consider in your assignment.

Secondary topic: this will take approximately 1-2 pages and is another of the three topics listed in the "main topic":

  • powder production
  • characterisation
  • consolidation
10 to >8 Pts
Excellent
 
You have described many relevant scientific issues, relating to the problem you have been asked to consider and have provided information to cover the topic thoroughly.
8 to >4 Pts
Good
 
You have included at least three relevant scientific issues for the problem you have been asked to consider and none of them are inappropriate or incorrect.
  4 to >0 Pts
Poor
 
You have not included more than two relevant scientific comments for the problem you have been asked to consider, or multiple statements are simply incorrect.
 
Sustainable development: 1-2 pages answering the questions set i your assignment that deal with the area of sustainable development, including health and safety. 10 to >8 Pts
Excellent
 
You include the required number of discussion points for the problem you have been asked to consider and all are correct, relevant and described well.
8 to >4 Pts
Good
 
You include multiple relevant discussion points, but not the number you were asked to provide. Alternatively, one of your discussion points is completely incorrect or irrelevant. Alternatively, you include enough discussion points, but do not include enough explanation or detail to answer the question(s) you have been asked to consider.
  4 to >0 Pts
Poor
 
You fail to consider sustainable development, or include discussion that is irrelevant for the problem you have been asked to consider.
 
Citations: inclusion of appropriate citations for any information you include that is not found in the course material. 4 to >2 Pts
Excellent
 
You have included citations to the information that you have collected form sources other than the course material. The citations are detailed enough that the information could be found by a reader.
  2 to >0 Pts
Average
 
You have either not taken any information form sources outside the course material, or you have provided some good citations, while missing others, or you have cited information but not well enough to let a reader find the information easily.
0 Pts
Poor/missing
 
You have taken information from sources but have not cited them at all.
 
Language and figures: the quality of language in your report, as well as the clarity and usefulness of any images, graphs, tables, etc. you include.

You should present graphs, tables, images, etc. if they improve the quality of your report, but you do not need to do so to achieve the top grade, as long as you present information in the most appropriate way in your report. In other words, if you choose to not use graphs, tables, images, etc. and it would make your report better if you did include them, you may lose points. If your report would not be improved by including images, graphs, tables, etc. then you will not lose points if you do not include them.
6 to >4 Pts
Excellent
 
There are only a few mistakes in your English and the meaning of your writing is clear.
4 to >2 Pts
Good
 
There are only minor mistakes in your English, but the meaning of your writing is fairly easy to understand.
2 to >0 Pts
Average
 
There are many mistakes in your English, but the general meaning can still be understood.
0 Pts
Poor
 
Your use of English is so poor that it is very difficult to understand. You may also lose marks form other assessment criteria as a result, if you fail to demonstrate the required knowledge as a result of the standard of your English.
 

Written exam

The written exam shall take place on Canvas. The exam shallb e unsupervised and you may use any resources you choose. The exam shall be graded out of 40 points. Points shall first be awarded based on multiple choice answers give in the first section of the quiz. Once this section concludes, extended answer questions shall be revealed. The total of the points accumulated in these two parts gives the final score out of 40.

Opportunity to complete the requirements via supplementary examination

Should any student miss any deadline or mandatory exercise, they should discuss the matter with the examiner to agree an alternative examination exercise or task.

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

The question "The assessment on the course was fair and honest" was graded at 4.7/7.0. This was partly due to the changing nature of the assessmetn due to the Covid-19 pandemic. I will include new explanations about the assessments and try to improve the perception of fairness - I can assure students that the assessment is anonymous and fair between students. Opinion was divided regarding the home assignment and whether it was reasonable to expect students to do such an exericse and a written exam. I have decided to retain both this year to collect more opinions about their usefulness and fairness.  Some responses were very positive about the assignments, which is why I have not removed them for 2021.

Following an excellent suggestion in the 2020 course evaluation, one of the debates in the second sustainable development lecture shall consider health and safety issues surrounding metal powder.

Students did not feel particularly strongly that they could collaborate with others, but I hope this shall improve naturally as we return to Campus.  I shall try to increase the ampunt of group work of the debates and laboratory sessions.

One student requested more laboratory teaching.  The original course plan included two labortory sessions per group, but we had to reduce the group sizes due to Covid restrictions, so we were forced to reduce the number of laboratory sessions to one.  This year, with the reduction in restrictions, we shall return to larger groups with two sessions.

Round Facts

Start date

Missing mandatory information

Course offering

  • Autumn 2021-50173

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