materials and manufacturingwork based learning

metal

www.project-metal.co.uk | info@project-metal.co.uk | 01792 606540

EligibilityMaterials and Manufacturing Education Training and Learning (metal) is an industry demand led project aiming to up skill over 360 people in the field of Advanced Materials and Manufacturing through the provision of short, 10 credit courses at level 4 and above.

Based within the College of Engineering at Swansea University, a department that ranks inthe top 10 for Engineering in the UK and has gained an international reputation of excellence, metal o�ers a series of Credit Qualifications that can be used towards professional development and also further education if desired.

What are the benefits? • Personal development • Enhanced performance • Improve your promotion potential • Apply knowledge to make process e�ciencies • Knowledge gained can yield improved productivity and adhere to quality standards • Employees gain fundamental understanding of processes and gain confidence boosting morale • Reduction in ine�cient use of time and materials • Positive experience gained via metal training can result in improved team cohesion

What can I do with my qualification?Your Credit Qualification will be at a European recognised academic level. You can use it; • As evidence of Continuous Professional Development and put towards professional qualifications such as Chartered Engineer (CEng) status • To gain a Professional Learner Award by completing six courses • Towards further learning and gain higher education qualifications. • Progress onto part-time degrees and even up to a full doctorate

01792 606541 | tellmemore@project-metal.co.uk | www.project-metal.co.uk

ABOUT

EligibilityThere are two distinct pricing categories for our courses, 'part-funded' which cost from £200per person for those who live or work within West Wales and Valleys area of Wales. Our 'standard' category is for those who live or work outside that area and prices start from £400 per person. This is all to do with the way metal is funded by the EU’s European Social Fund, through the Welsh Government.

The areas shaded in dark pink on the map are those eligible for 'part-funded' courses.

01792 606541 | tellmemore@project-metal.co.uk | www.project-metal.co.uk

PRICING

”The lecturer was enthusiasticand very helpful, who got

everyone involved and madea di�cult subject easier

to comprehend”

Introduction to Materials EngineeringThis course provides an insightinto the world of materials engineering and gives anoverview of both physical andmechanical properties ofdi�erent metallic and non-metallic products.

WHO SHOULD ATTEND?The course is aimed at people who wish to gain/improve their foundation knowledge in materialsand metallurgy. Typical candidates include technical personnel and engineers.AIMSTo provide a core understanding of materials engineering and materials properties. The delegatewill come away with an understanding of materials structure and properties and relate basicscientific principles to engineering applications.

LEARNING OUTCOMESFrom a fundamental understanding of the properties and interaction of materials including thebehaviour of atoms, the formation of crystals and grain structure, gain an appreciation of themechanical properties of di�erent metals and alloys, ceramics and polymeric products. Develop agood knowledge of a broad number of material families, associated physical, chemical andmechanical properties. Gain an understanding of material behaviour with respect to their structureand composition, to facilitate material selection for engineering applications.

COURSE PROGRAMME• Material selection• Atomic structure and bonding• Crystal and grain structure of solids• Solidification and di�usion• Microstructure of metals and alloys• Metals and alloys• Ceramics• Polymers• Composites• Mechanical testing methods and failure mechanisms › Including tensile, hardness, impact, fatigue and creep

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4

Environmental IssuesThis course provides an education on current legislation, the influence industry is having on the environment, andmitigation strategies.

WHO SHOULD ATTEND?The course will suit technical personnel, engineers and production managers whose roles include dealing with environmental issues, or for whom a knowledge of environmental issues is beneficial.

AIMSThis course provides an overview of environmental legislation, an insight into the environmental challenges facing modern industry, practical guidance on environmental permitting, and the actions necessary to achieve ISO14001 status.

LEARNING OUTCOMESAn understanding of environmental legislation and the impact it has on industry, together with a description of the steps required to set up an environmental management system, to ensure compliance with ISO14001, and an awareness of the role technology can play in reducing environmental impact.

COURSE PROGRAMME• A review of key environmental issues relating to the pollution to air, water and land• A description of environmental legislation relevant to industry• The impact of environmental taxation• Defines the process for obtaining environmental permits• Maps out the framework required to set up an e�ective environmental management system• Identifies the role of various organisations involved in policing compliance with environmental legislation• A review of industrial case studies which have addressed specific environmental issues• Describes the role that technology has to play in reducing both current and future environmental damage

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4

Design for Reliability This three day course providesan overview of practical aspects of reliability engineering methodology and unfolds ways to achieve highly reliable and cost-e�ective systems demanded by today’s market.

WHO SHOULD ATTEND?The course is aimed at people who wish to gain and improve their foundation knowledge in bothquality and reliability engineering. Typical candidates include both technical personnel and engineers.AIMSTo provide a basic introduction to both quality and reliability engineering. The delegates will acquirea knowledge on system engineering aspects of monitoring, control, reliability, survivability, integrityand maintenance, and relate design for reliability principles to on-site engineering.

LEARNING OUTCOMESDemonstrate a wide knowledge and comprehensive understanding of reliability engineering principles. Course delegates will be able to critically evaluate design problems, and understand how to apply design for reliability principles.

COURSE PROGRAMME• Fundamentals of quality and reliability including classification of failures• System Engineering Approach › Block diagram analysis (series, parallel, standby and backup systems) • Cost of Reliability › Initial cost & post-implementation cost › Total lifetime operating cost › Quality (specification, normal distribution and probability) › Root cause analysis › Failure modes & e�ects analysis › Stress-strength analysis › Material selection › Reliability centred maintenance › Breakdown & preventative maintenance › Installation & commissionaing• Principles of Design for Reliability › Element/component selection › Stress-strength relationship › Environment › Minimum complexity › Redundancy › Diversity › System reliability

DURATION

3Days

ASSESSMENT

Course work+

2 hour written exam

LEVEL

4

Materials ResourcesThis course provides anintroduction into the di�erentextraction methods andutilisation of many commonmaterials as well as covering the environmental aspects associated with the various extraction processes.WHO SHOULD ATTEND?Anyone involved in material extraction or utilisation of materials that wishes to expand their understanding of raw material filtering, common uses of a variety of metallic and non-metallicmaterials and environmental impacts.

AIMSTo develop an understanding of material resources from a geological perspective. Gain anappreciation of extraction processes for various metals from rock deposits. Attendees will alsoacquire knowledge of chemical exploitation from crude oil resources

LEARNING OUTCOMESAttendees will be able to describe the origins of materials resources and mechanisms of mineral formation. Gain an appreciation of the methodologies for resource recovery, use and recycling atend of life. Gain an appreciation of the environmental impact of resource exploitation.

COURSE PROGRAMME• Resource geology• Detailed description of processing of a range of materials to include: • A range of metals • Cement and concrete • Ceramics and clays • A range of metals• Corrosion• Polymers• Environmental implications• Recycle, reuse, repurpose

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4”A well delivered course

by a knowledgeable lecturer on key aspects

relating to job role”

Corrosion and Coatings TechnologyThis course provides an in-depth understanding of the world of corrosion, the electrochemical mechanisms and methods for preventing corrosion. A knowledge of corrosion protective coatings and the technology used to apply them will also be gained.

WHO SHOULD ATTEND?The course will suit technical personnel, engineers and production managers whose roles involve or have an interest in corrosion and coatings technology.

AIMSTo provide the attendee with the key understanding of corrosion and the role coatings technology plays in preventing it. This will include an appreciation of metallic and organic coatings, their application and also their defects as well as the corrosion mechanisms they are designed to stop.

LEARNING OUTCOMESAchieve a knowledge of common corrosion mechanisms, Good understanding of di�erent types of coating applications and an ability to select the correct corrosion resistant coatings for the correct applications.

COURSE PROGRAMME• Introduction to corrosion• Corrosion mechanisms• Galvanic corrosion protection• Applied current protection• Metallic barrier coatings• Organic barrier coatings• Painting technology DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4“The course provided excellentpractical examples helping my

personal and technical development. Extremely relevant

course for numerous job roles”

Joining of Sheet Steel ProductsThis course provides a detailed review of the welding, mechanical fastening, adhesive bonding and brazing of sheet steel products.

WHO SHOULD ATTEND?The course will suit technical personnel, engineers and production managers whose roles eitherinvolve or have an interest in joining technology.

AIMSTo provide a fundamental understanding of the principles and mechanisms of joining techniques and an overview of the many di�erent joining methods in common use in manufacturing.

LEARNING OUTCOMESAchieve an understanding of the principles of joining method selection and associated equipment. In addition, to develop an appreciation of the influence of joining techniques on the staic and dynamic performance of both simple joints and complex structures.

COURSE PROGRAMME• Principles of joining• Joining processes › Including welding resistance spot welding, fusion welding (MIG, TIG, Plasma), laser, hybrid laser and weldbonding• Adhesive bonding – both structural and non-structural adhesives.• Soldering• Brazing• Mechanical fastening techniques• Testing techniques › Microstructure, peel, lap shear, cross tension, fatigue and impact

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4”A well presented and informative course with good working examples”

Manufacturing TechnologyThis course provides an overview of common manufacturing processes for material selection to their application in a wide range of industries.

WHO SHOULD ATTEND?The course is aimed at people who wish to gain/improve their knowledge of manufacturing, manufacturing processes and their link to materials. Typical attendees include technical personnel, production managers, production operators, engineers and trainees. The delegates do not need tohave any formal qualifications but as the course is first year degree level they should be able toengage on a technical course.

AIMSTo provide a core understanding of manufacturing processes, material considerations during these processes and general manufacturing mentality. The course will provide an insight into the technical aspects of manufacturing and highlight processing considerations and common defects.

LEARNING OUTCOMESDevelop an understanding of the importance of material selection and preferred manufacturing route associated with respect to final product design, performance and cost.

COURSE PROGRAMME• Overview of manufacturing technologies• Material structure and properties• Casting• Powder metallurgy• Forming• Forging• Machining• Surface Treatments › Including coating, plating, hardfacing, shot peening• Joining• Microstructure control• Heat treatments and annealing• NDT• Introduction to Lean Engineering• Quality Systems• Material and Process Selection• The latest trends in manufacturing technology including additive layer manufacturing

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4

Mechanical Properties of MaterialsThis course provides training and understanding of deformation mechanisms, the influence of microstructure and alloying on mechanical properties and failure modes.

WHO SHOULD ATTEND?Technical personnel, engineers and production managers with a basic understanding of materials properties (attending the introduction of materials course provides an excellent foundation).

AIMSTo provide an understanding of the di�erent mechanical properties of materials and the fundamentals behind them including microstructure, deformation and failure modes.

LEARNING OUTCOMESAchieve an understanding of the relationship between microstructure and mechanical properties, alloy strengthening mechanisms, basic fracture mechanisms, determine stress fields through manipulation of stress data and relate fracture surface detail to failure behaviour.

COURSE PROGRAMME• Deformation processes in crystals• The concept of microstructure dislocations• The behaviour of dislocations• Work hardening• Hot and cold working – recrystallization and growth• Precipitation and particle strengthening• Ductile and brittle fracture• Fatigue• Creep DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4

Arc WeldingThe course provides a detailedtechnical description of the key arcwelding processes explaining thee�ects of changes in weldingparameters on weld quality.

WHO SHOULD ATTEND?The course is aimed at people who wish to gain an introductory understanding of arc weldingprocesses with a materials focus. This may include practical welders, weld inspectors and technical engineers. No prior knowledge of welding is required.

AIMSThe course aims to provide an understanding of arc welding processes, an understanding of weld metallurgy,typical test regimes and an appreciation of the causes of typical weld defects.

LEARNING OUTCOMESGood understanding of arc welding processes, a basic understanding of the metallurgy of welds, an awareness of joint preparation, joint design and selection, an awareness of weld testing techniques, an awareness of typical weld defects, and an understanding of the e�ects of material composition on both the selection of welding conditions and weld quality.

COURSE PROGRAMME• Overview of welding processes• The basics of metallurgy• TIG welding• MIG/MAG welding• The Welding Conditions › Gases › Joint preparation › Preheat/post heat• Weldability of di�erent steel types › Carbon steels › High strength steels › Alloy steels › Stainless steels• Weldability of aluminium and titanium• Weld testing › Destructive testing › NDT• Weld defects• Advances in welding technology• Cutting/cladding processes

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4

Practical MetallurgyThis course provides theattendee with the practical abilities to carry out sample preparation and mechanical testing as well as the theoretical knowledge to interpret results.

WHO SHOULD ATTEND?Technical personnel, engineers, production managers, and quality control personnel whose roles will benefit from an understanding of practical metallurgy methodology and the relationship of test datato physical properties.AIMSTo provide the attendee with the practical abilities to carry out sample preparation and testing as well as the theoretical knowledge to interpret results

LEARNING OUTCOMESThe ability to prepare metallurgical samples, carry out mechanical testing, interpret test data, relatemicrostructure to mechanical properties, Produce a technical report to communicate findings.

COURSE PROGRAMMEIntroduction to metallurgical testing• Metals, alloys, crystals (grains)• Phases, microstructure, phase diagrams, phase transformations• The influence of mechanical work and temperature (heat treatment) on microstructure• The relationship between microstructure and materials properties• Detailed consideration of two alloy phase diagrams, Cu - Ni and Fe -C.• Principles of metallurgical etching• Principles of testing techniques

DURATION

3Days

ASSESSMENT

Submit report of practical write up and conclusions

LEVEL

4

Practical’s – A number of di�erent alloys will be studied• Sample polishing• Metallographic etching and microscopy• Tensile testing › Includes the extrapolation of yield, UTS and Young’s modulus• Hardness Testing• Impact testing• Surface assessment › Microscopy » Identifying grain structure and phases » Grain size measurement » Coating thickness measurement › SEM » Fracture surface assessment » Surface morphology › EDX » Element analysis

Process Evolution in the Steel IndustryThis course provides a general overview of the standard process routes required to transform raw materials into rolled steel and theirrespective history and evolution.

WHO SHOULD ATTEND?The course is aimed at people working in the steel industry, or the steel industry supply chain, who will benefit from a broad understanding of processes in common use in the steel industry. Typical delegates include technical and engineering personnel.

AIMSTo provide a core understanding of steel processing, the scientific relevance of processes and an appreciation of the historical developments that have led to current best practices.

LEARNING OUTCOMESAchieve an understanding of the steel manufacturing process from raw materials to coil, an appreciation of technological developments that have occurred resulting in the modern day technology used within steel manufacture, an overview of the latest in the steel industry and future trends.

COURSE PROGRAMME• Introduction and history of iron and steel production• Ore preparation › Coke production › Sinter and pellet production• The principles and practice of iron making › Operating practice in relation to iron composition and modern developments in blast furnace operation• Steel making• Steel university blast furnace eLearning simulation• Development of high volume steel production• Secondary steel making• Production of specialist steels• Hot and cold rolling• Refractories• Future trends in the steel industry

DURATION

3Days

ASSESSMENT

2 hour written exam

LEVEL

4