Net-shape manufacturing of metals & ceramics processes: casting from liquid state & consolidation of components from powders pressed into almost finished complex shapes. Understanding of the principles of solidification & powder processing & principles used in the manufacture of components.
Engineering components, with a variety of shapes and properties, form the basis of machines, vehicles, aircraft and other equipment. How to make these components with the required properties in an efficient way is a major concern for engineers and scientists. This course will introduce four major techniques, including casting, additive manufacturing (3D printing), powder processing, and forging, to engineering students. It will provide students with scientific and technical knowledge of factors in different processes, which govern the quality and properties of the final components. After successful completion of the course, students will have the knowledge and potential ability to design or select an appropriate process to make required components of different shapes and achieve the required properties through controlling the processes on a cost affordable, sustainable and eco-friendly basis.
An understanding of basic concepts in materials, such as phase diagrams, phase transformation and thermodynamics of phase transformations, to the level provided by first year engineering courses is expected.
You'll need to complete the following courses before enrolling in this one:
MECH2305
Email any questions regarding MECH4304 course and 'Casting' to Prof Nogita at the above email address and face-to-face meetings available on request.
The timetable for this course is available on the UQ Public Timetable.
The aims of the course "Net-Shape Manufacturing (NSM)" are to: (1)ﾠdevelop a high level understanding in factors that govern the solidification process and soundness of castings, (2)ﾠprovide an introduction to the powder processing of materials and additive manufacturing, including ceramics and metals, and (3)ﾠdevelop ability to manufacture various engineering components, to improve the properties or to obtain the required properties of these components through controlling the solidification processes or powder metallurgy process.
After successfully completing this course you should be able to:
LO1.
Understand the principles of NSM processes - Understand the relationship between alloy composition, cast microstructures and mechanical properties.
LO2.
Understand the principles of NSM processes - Appraise the use of forging as a major conventional manufacturing process and understand how the mechanical properties change during this process.
LO3.
Understand the principles of NSM processes - Appraise the use of additive manufacturing as a major direction for future manufacturing and the advantages and limitations of additive manufacturing.
LO4.
Understand the principles of NSM processes - Understand the scientific principles behind powder processing of materials, including ceramics and metals, and the advantages and limitations of powder processing.
LO5.
Understand the principles of NSM processes - Understand how the properties of powder processed components can be controlled.
LO6.
Appraise and select NSM processes - Apply knowledge to compare and contrast the relative strengths and weaknesses of net-shape manufacturing processes
LO7.
Appraise and select NSM processes - Evaluate and select appropriate processes for component production based on economic and technical considerations.
LO8.
Design components for manuf. with net-shape proc. - Demonstrate skills in practical design of sand castings and develop an appreciation of the main casting processes.
LO9.
Design components for manuf. with net-shape proc. - Analyze and report on the relationship between casting design, microstructural development and the final quality of castings.
LO10.
Design components for manuf. with net-shape proc. - Develop skills in design for additive manufacturing.
LO11.
Evaluate the outcomes of NSM processes - Evaluate net-shape manufacturing techniques with respect to their ability to produce high quality components and appreciate the nature and type of potential defects that can be associated with these processes.
LO12.
Evaluate the outcomes of NSM processes - Evaluate appropriate net-shape manufacturing techniques and the impact of these techniques with respect to economy and environment.
| Category | Assessment task | Weight | Due date |
|---|---|---|---|
| Paper/ Report/ Annotation | Laboratory Report Practical #1: Solidification Microstructures | 20% |
26/03/2025 - 9/04/2025
Group 1: Week 5 - Wednesday 16:00. Group 2: Week 6 - Wednesday 16:00. Group 3: Week 7 - Wednesday 16:00. |
| Paper/ Report/ Annotation | Laboratory Report Practical #2: Sand Casting | 20% |
30/04/2025 - 14/05/2025
Group 1: Week 9 - Wednesday 16:00. Group 2: Week 10 - Wednesday 16:00. Group 3: Week 11 - Wednesday 16:00. |
| Examination | Final Exam | 60% |
End of Semester Exam Period 7/06/2025 - 21/06/2025 |
26/03/2025 - 9/04/2025
Group 1: Week 5 - Wednesday 16:00.
Group 2: Week 6 - Wednesday 16:00.
Group 3: Week 7 - Wednesday 16:00.
Practical #1, Solidification Microstructures, guidelines – Semester 1, 2025
IMPORTANT
You must bring safety glasses, long sleeved shirt or lab coat and enclosed shoes.
All safety rules for each relevant laboratory apply to this practical.
Timetable of the Practical Session 1 for MECH4304, Sem 1, 2025
Group 1: Week 3 - Wednesday 14:00-17:50.
Group 2: Week 4 - Wednesday 14:00-17:50.
Group 3: Week 5 - Wednesday 14:00-17:50.
Module
UQ has published a module that applies to all laboratory practical classes at UQ. This module applies to all undergraduate students (the University considers students “in training” and accordingly, has several expectations for staff and students).The module and assessment for students to complete are:
https://learn.uq.edu.au/webapps/blackboard/content/listContent.jsp?course_id=_11416_1&content_id=_1187521_1&mode=reset (UG Lab Students)
These should be read by students prior to participation in the practical laboratory sessions. Students need to complete and pass the assessment prior to attending their first laboratory session.
Students only need to complete and pass the assessment once during their undergraduate courses.
Grouping
Practical #1, Solidification Microstructures
Objectives
Overview
Four different alloys will be analysed in this practical, all of which will come from the same binary alloy system (your casual demonstrator will inform you of which alloys are being used during your practical). Melting will be done in an electrical resistance furnace prior to sampling. This is done by placing alloy pieces into a boron nitride coated crucible, which is placed in the furnace. The furnace will be set to a temperature that provides sufficient superheat to ensure alloys are completely liquid prior to thermal analysis experiments.
Each of the four alloys of will be sampled for thermal analysis of the solidification process. Samples will then be used for microstructural analysis and hardness measurements to explore the relationship between composition, microstructure and mechanical properties of cast alloys.
It is the responsibility of each student to ensure that they have collected all data during the practical itself, including any digital files required. Please bring a USB stick for this purpose.
Permitted use of Generative AI and MT for this assessment
Artificial Intelligence (AI) and Machine Translation (MT) are emerging tools that may support students in completing this assessment task. Students may appropriately use AI and/or MT in completing this assessment task. Students must clearly reference any use of AI or MT in each instance.
A failure to reference generative AI or MT use may constitute student misconduct under the Student Code of Conduct.
Please refer to Blackboard for a detailed marking criteria.
Submit via TurnItIn on Blackboard.
You may be able to apply for an extension.
The maximum extension allowed is 14 days. Extensions are given in multiples of 24 hours.
To facilitate timely feedback to students.
A Student Access Plan (SAP) can only be used for a first extension. Extensions based on an SAP may be granted for up to seven (7) days, or the maximum number of days specified in the Electronic Course Profile (ECP), if it is less than seven (7) days. Any further extensions will require additional supporting documentation, such as a medical certificate.
A penalty of 10% of the maximum possible mark will be deducted per 24 hours from time submission is due for up to 7 days. After 7 days, you will receive a mark of 0.
30/04/2025 - 14/05/2025
Group 1: Week 9 - Wednesday 16:00.
Group 2: Week 10 - Wednesday 16:00.
Group 3: Week 11 - Wednesday 16:00.
Practical #2, Sand Casting, guidelines – Semester 1, 2025
IMPORTANT
You must bring safety glasses, long sleeved shirt or lab coat and enclosed shoes.
All safety rules for each relevant laboratory apply to this practical.
Timetable of the Practical Session 2 for MECH4304, Sem 1, 2025
Group 1: Week 7 - Wednesday 14:00-17:50.
Group 2: Week 8 - Wednesday 14:00-17:50.
Group 3: Week 9 - Wednesday 14:00-17:50.
Module
UQ has published a module that applies to all laboratory practical classes at UQ. This module applies to all undergraduate students (the University considers students “in training” and accordingly, has several expectations for staff and students).
The module and assessment for students to complete are found here:
https://learn.uq.edu.au/webapps/blackboard/content/listContent.jsp?course_id=_11416_1&content_id=_1187521_1&mode=reset
These should be read by students prior to participation in the practical laboratory sessions. Students need to complete and pass the assessment prior to attending their first laboratory session.
Students only need to complete and pass the assessment once during their undergraduate courses.
Grouping
Practical #2: Sand Casting
Objectives
The objectives of this practical are to become familiar with the issues surrounding design for sand casting and understand the opportunities and limitations of the sand casting process. This includes an appreciation of common defects that can be associated with sand-casting and how sand-casting compares to other casting processes. An additional objective is to develop an understanding of how additive manufacturing/3D printing can be used for the fabrication of patterns for sand-casting.
Overview
As discussed in the introductory lecture and tutorial (week 1), this practical experiment involves the design of a 3D printed pattern (using plastic material extrusion/FDM) for sand casting, followed by the analysis of the sand-casting made using this pattern.
Assessment will be based on both the communication and intent of your design along with a consideration and discussion of how the casting geometry and process influences the design of both the part and the mould along with a discussion of a selected casting defect (this does not have to be a defect that was observed in your casting).
Permitted use of Generative AI and MT for this assessment
Artificial Intelligence (AI) and Machine Translation (MT) are emerging tools that may support students in completing this assessment task. Students may appropriately use AI and/or MT in completing this assessment task. Students must clearly reference any use of AI or MT in each instance.
A failure to reference generative AI or MT use may constitute student misconduct under the Student Code of Conduct.
Please refer to Blackboard for a detailed marking criteria.
Submit via TurnItIn on Blackboard
You may be able to apply for an extension.
The maximum extension allowed is 14 days. Extensions are given in multiples of 24 hours.
To facilitate timely feedback to students.
A Student Access Plan (SAP) can only be used for a first extension. Extensions based on an SAP may be granted for up to seven (7) days, or the maximum number of days specified in the Electronic Course Profile (ECP), if it is less than seven (7) days. Any further extensions will require additional supporting documentation, such as a medical certificate.
A penalty of 10% of the maximum possible mark will be deducted per 24 hours from time submission is due for up to 7 days. After 7 days, you will receive a mark of 0.
End of Semester Exam Period
7/06/2025 - 21/06/2025
The final exam will cover all course content delivered throughout the semester.
Permitted use of Generative AI and MT for this assessment
This assessment task evaluates students' abilities, skills and knowledge without the aid of generative Artificial Intelligence (AI) or Machine Translation (MT). Students are advised that the use of AI or MT technologies to develop responses is strictly prohibited and may constitute student misconduct under the Student Code of Conduct.
| Planning time | 10 minutes |
|---|---|
| Duration | 120 minutes |
| Calculator options | (In person) Casio FX82 series only or UQ approved and labelled calculator |
| Open/closed book | Closed Book examination - no written materials permitted |
| Exam platform | Paper based |
| Invigilation | Invigilated in person |
You may be able to defer this exam.
You will receive a mark of 0 if this assessment is submitted late.
Full criteria for each grade is available in the Assessment Procedure.
| Grade | Cut off Percent | Description |
|---|---|---|
| 1 (Low Fail) | 0.00 - 29.99 |
Absence of evidence of achievement of course learning outcomes. |
| 2 (Fail) | 30.00 - 44.99 |
Minimal evidence of achievement of course learning outcomes. |
| 3 (Marginal Fail) | 45.00 - 49.99 |
Demonstrated evidence of developing achievement of course learning outcomes Course grade description: Falls short of satisfyingﾠbasic requirements for a Pass. Or less than 40% in the IVA requirement explained below.ﾠ |
| 4 (Pass) | 50.00 - 64.99 |
Demonstrated evidence of functional achievement of course learning outcomes. Course grade description: Satisfies all of the basic learning requirements for the course, such as knowledge of fundamental concepts and performance of basic skills; demonstrates sufficient quality of performance to be considered satisfactory or adequate or competent or capable in the course. And a minimum score of 40% in the IVA requirement explained below. |
| 5 (Credit) | 65.00 - 74.99 |
Demonstrated evidence of proficient achievement of course learning outcomes. Course grade description: Demonstrates ability to use and apply fundamental concepts and skills of the course, going beyond mere replication of content knowledge or skill to show understanding of key ideas, awareness of their relevance, some use of analytical skills, and some originality or insight. And a minimum score of 40% in the IVA requirement explained below. |
| 6 (Distinction) | 75.00 - 84.99 |
Demonstrated evidence of advanced achievement of course learning outcomes. Course grade description: Demonstrates awareness and understanding of deeper and subtler aspects of the course, such as ability to identify and debate critical issues or problems, ability to solve non-routine problems, ability to adapt and apply ideas to new situations, and ability to invent and evaluate new ideas. And a minimum score of 40% in the IVA requirement explained below. |
| 7 (High Distinction) | 85.00 - 100 |
Demonstrated evidence of exceptional achievement of course learning outcomes. Course grade description: Demonstrates imagination, originality or flair, based on proficiency in all the learning objectives for the course; work is interesting or surprising or exciting or challenging or erudite. And a minimum score of 40% in the IVA requirement explained below. |
Grading Criteria
Specific grading criteria will be provided for each assessment item. These are available on Blackboard in the assessment folder.
Individually verified assessment
Individually verified assessment (IVA) will be through:
1. Obtaining at least 40% of the available marks in the final exam.
You need to pass the IVA hurdle to pass the course regardless of your final mark. Students who achieve a total mark of 50 or greater but do not pass the IVA hurdle will receive a grade of 3.
Supplementary assessment is available for this course.
Assessment items submitted using the Turnitin link on the course Blackboard site, will check your work for evidence of plagiarism, collusion, and other forms of academic misconduct.
A failure to reference AI use may constitute student misconduct under the Student Code of Conduct.
You'll need the following resources to successfully complete the course. We've indicated below if you need a personal copy of the reading materials or your own item.
Find the required and recommended resources for this course on the UQ Library website.
Extra reading materialﾠwill be provided through Blackboard.
For the project study, students can use information that is related to theﾠselected topics from anyﾠpublishedﾠliterature, including books and journal papers andﾠthrough internet searching.
Laboratory access
Students must have completed the Student Laboratory Safety Induction, Annual Fire Safety Training and Health Safety and Wellness (HSW) to a specific laboratory induction, all accessed via Blackboard.
If you require access for experimental work, then register for an induction by searching for that laboratory at the following link:
https://student.eait.uq.edu.au/urite/
Additional requirements to be inducted into each laboratory will be listed on that link.
Students can also check their HSW training card here:
https://student.eait.uq.edu.au/safe
Access to laboratories will be granted after all of the specific laboratory requirements have been met.
If you have any enquiries regarding HSW please contact the School’s Technical Services Team on labsupport@mechmining.uq.edu.au.
The learning activities for this course are outlined below. Learn more about the learning outcomes that apply to this course.
Filter activity type by
| Learning period | Activity type | Topic |
|---|---|---|
Week 1 (24 Feb - 02 Mar) |
Lecture |
Lecture - Introduction of net shape manufacturing Learning outcomes: L01, L02, L03, L04, L05 |
Tutorial |
Introductory tutorial Overview of tutorial structures and introduction to sand casting and die casting Learning outcomes: L01, L02, L03, L04, L05, L06, L07 |
|
Week 2 (03 Mar - 09 Mar) |
Lecture |
Lecture - Casting fundamentals - I Learning outcomes: L01, L06, L08 |
Tutorial |
Tutorial for Casting fundamentals - I Learning outcomes: L01, L06, L08 |
|
Week 3 (10 Mar - 16 Mar) |
Lecture |
Lecture - Casting fundamentals - II Learning outcomes: L01, L06, L07, L08 |
Practical |
Practical#1 Casting - G01 Prac #1: Solidification Microstructures Learning outcomes: L01, L06, L09, L11 |
|
Tutorial |
Tutorial for Casting fundamentals - II Learning outcomes: L01, L06, L07, L08 |
|
Week 4 (17 Mar - 23 Mar) |
Lecture |
Lecture - Sand casting Learning outcomes: L01, L06, L07, L12 |
Practical |
Practical#1 Casting - G02 Prac #1: Solidification Microstructures Learning outcomes: L01, L06, L09, L11 |
|
Tutorial |
Tutorial for Sand casting Learning outcomes: L01, L06, L07 |
|
Week 5 (24 Mar - 30 Mar) |
Lecture |
Lecture - Additive manufacturing - I Learning outcomes: L03, L10, L11, L12 |
Practical |
Practical#1 Casting - G03 Prac #1: Solidification Microstructures Learning outcomes: L01, L06, L09, L11 |
|
Tutorial |
Tutorial for Additive manufacturing - I Learning outcomes: L03, L10, L11, L12 |
|
Week 6 (31 Mar - 06 Apr) |
Lecture |
Lecture - High pressure die casting and others Learning outcomes: L01, L06, L07, L11, L12 |
Tutorial |
Tutorial for High pressure die casting and others Learning outcomes: L01, L06, L07, L11, L12 |
|
Week 7 (07 Apr - 13 Apr) |
Lecture |
Lecture - Cast defects and Forging Learning outcomes: L02, L06, L07, L11, L12 |
Practical |
Practical#2 Sand Casting - G01 Prac #2: Sand Casting Learning outcomes: L01, L03, L06, L08, L09, L10, L12 |
|
Tutorial |
Tutorial for Cast defects and Forging Learning outcomes: L02, L06, L07, L11, L12 |
|
Week 8 (14 Apr - 20 Apr) |
Lecture |
Lecture - Additive manufacturing - II Learning outcomes: L01, L03, L06, L07, L11, L12 |
Practical |
Practical#2 Sand Casting - G02 Prac #2: Sand Casting Learning outcomes: L01, L03, L06, L08, L09, L10, L12 |
|
Tutorial |
Tutorial for Additive manufacturing - II Learning outcomes: L01, L03, L06, L07, L11, L12 |
|
Week 9 (28 Apr - 04 May) |
Lecture |
Lecture - Additive manufacturing - III Learning outcomes: L01, L03, L06, L07, L11, L12 |
Practical |
Practical#2 Sand Casting - G03 Prac #2: Sand Casting Learning outcomes: L01, L03, L06, L08, L09, L10, L12 |
|
Tutorial |
Tutorial for Additive manufacturing - III Learning outcomes: L01, L03, L06, L07, L11, L12 |
|
Week 10 (05 May - 11 May) |
Lecture |
Lecture - Powder processing & metallurgy - I Learning outcomes: L01, L04, L05 |
Tutorial |
Tutorial for Powder processing & metallurgy I Learning outcomes: L01, L04, L05 |
|
Week 11 (12 May - 18 May) |
Lecture |
Lecture - Powder processing & metallurgy - II Learning outcomes: L01, L04, L05, L06, L07 |
Tutorial |
Tutorial for Powder processing & metallurgy II Learning outcomes: L01, L04, L05, L06, L07 |
|
Week 12 (19 May - 25 May) |
Lecture |
Lecture - Powder processing & metallurgy - III Learning outcomes: L01, L04, L05, L06, L07, L11, L12 |
Tutorial |
Tutorial for Powder processing & metallurgy III Learning outcomes: L01, L04, L05, L06, L07, L11, L12 |
|
Week 13 (26 May - 01 Jun) |
Lecture |
Revision and Guest lecture from industry Learning outcomes: L01, L02, L03, L04, L05, L06, L07, L11, L12 |
Tutorial |
Revision Revision Tutorial Learning outcomes: L01, L02, L03, L04, L05, L06, L07, L11, L12 |
University policies and procedures apply to all aspects of student life. As a UQ student, you must comply with University-wide and program-specific requirements, including the:
Learn more about UQ policies on my.UQ and the Policy and Procedure Library.