AER2010 : Materials and Manufacturing for Aerospace
- Inactive for Year: 2026/27
- Module Leader(s): Dr Chuan Cheng
- Lecturer: Dr Priscila Melo, Professor Ana Ferreira-Duarte, Dr Dehong Huo
- Owning School: Engineering
- Teaching Location: Newcastle City Campus
Semesters
Your programme is made up of credits, the total differs on programme to programme.
| Semester 1 Credit Value: | 20 |
| ECTS Credits: | 10.0 |
| European Credit Transfer System | |
Aims
This module introduces students to the materials, failure mechanisms and manufacturing processes that underpin the design and production of aerospace and high-performance engineering components.
Students will explore how materials behave under demanding service conditions, how components fail, and how engineers use calculations, inspection methods and design approaches to improve reliability and performance. The module also develops understanding of modern manufacturing processes, including machining and additive manufacturing, and how these processes are selected and optimised for specific engineering applications.
Through lectures, tutorials, case studies and practical software-based laboratory activities, students will develop the ability to connect material choice, manufacturing method and final component performance.
Outline Of Syllabus
The module will typically cover:
1. Material properties and their relevance to aerospace and mechanical component performance.
2. Yield criteria, strengthening mechanisms and approaches to improving material performance.
3. Failure mechanisms including fracture, fatigue and creep.
4. Case studies of component failure and examples of material inspection techniques.
5. Engineering materials including metals, polymers and composites.
6. Design and assessment calculations, including limit-state and statistically based design concepts.
7. Conventional manufacturing processes including casting, forming and subtractive manufacturing.
8. Machining processes, cutting mechanics, CNC systems, CAM, tooling and machining parameter selection.
9. Non-conventional and advanced manufacturing processes, including EDM, ECM, laser machining and additive manufacturing technologies.
10. Additive manufacturing preparation and optimisation using software tools such as NetFabb and slicer software, including lattice design, build preparation and process parameter selection.
Teaching Methods
Teaching Activities
| Category | Activity | Number | Length | Student Hours | Comment |
|---|---|---|---|---|---|
| Guided Independent Study | Assessment preparation and completion | 1 | 2:00 | 2:00 | Exam Completion |
| Guided Independent Study | Assessment preparation and completion | 6 | 1:00 | 6:00 | Canvas Quizzes for self-assessment |
| Guided Independent Study | Assessment preparation and completion | 1 | 107:00 | 107:00 | Revision of lecture material, attempting tutorial questions and background reading. |
| Structured Guided Learning | Lecture materials | 3 | 1:00 | 3:00 | Online lecture videos |
| Scheduled Learning And Teaching Activities | Lecture | 19 | 1:00 | 19:00 | Lectures |
| Scheduled Learning And Teaching Activities | Practical | 1 | 3:00 | 3:00 | CAM computer labs |
| Scheduled Learning And Teaching Activities | Practical | 3 | 2:00 | 6:00 | NetFabb and Cura lab practical |
| Scheduled Learning And Teaching Activities | Small group teaching | 5 | 1:00 | 5:00 | Tutorial |
| Scheduled Learning And Teaching Activities | Workshops | 1 | 0:30 | 0:30 | Lab tour of processing workshop |
| Guided Independent Study | Independent study | 1 | 48:30 | 48:30 | Revision for Exam |
| Total | 200:00 |
Jointly Taught With
| Code | Title |
|---|---|
| MEC2010 | Materials and Manufacturing Process Selection |
Teaching Rationale And Relationship
The module uses lectures as an efficient way to introduce the students to new subjects and is the primary means of meeting the intended knowledge outcomes. The understanding is further developed and applied in practical and tutorial sessions highlighting some of the lectured topics to meet the intended skills outcomes.
Assessment Methods
The format of resits will be determined by the Board of Examiners
Exams
| Description | Length | Semester | When Set | Percentage | Comment |
|---|---|---|---|---|---|
| Digital Examination | 120 | 1 | A | 100 | Inspera invigilated open-book exam. Paper resources are allowed, no digital resources except for provided Inspera resources. |
Formative Assessments
Formative Assessment is an assessment which develops your skills in being assessed, allows for you to receive feedback, and prepares you for being assessed. However, it does not count to your final mark.
| Description | Semester | When Set | Comment |
|---|---|---|---|
| Computer assessment | 1 | M | One 30 minute Canvas quiz after each of the 6 study units |
Assessment Rationale And Relationship
N/A
Reading Lists
Timetable
- Timetable Website: www.ncl.ac.uk/timetable/
- AER2010's Timetable