MODULE DESCRIPTOR
MECHGM03 – Materials and Fatigue / Fracture Analysis
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MECHGM03
MECHM004
Materials and Fatigue/Fracture
M
15/6 ECTS
September
May
Dr Adam Wojcik (50%) Module Coordinator
Dr Jie Huang (50%)
Prerequisites
This is a level 4 course and students are therefore expected to have a sound basis in materials science
as applicable to engineering contexts. This entails an understanding of the structure-property
relationship in materials and the way in which manufacturing methods affect the latter. A grasp of phase
equilibria and basic metallography is expected, as is an understanding of the way in which mechanical
properties are determined and how engineers utilize materials data to design with, and select,
materials. Additionally, an understanding and knowledge of polymer types and processing, how
materials can be strengthened, and how products and components are manufactured from materials, is
of great utility to this course. An understanding of the influence upon strength of defects within material,
such as cracks, and porosity is helpful.
Course Aims
To build upon a basic theory of materials as would be given in the first years of an undergraduate
programme and to examine specific areas of materials science which are not normally taught as part of a
basic materials curriculum. The course also aims to cover the fundamentals of fracture mechanics, and
the theory of fatigue failure in engineering materials, principally from an analytical perspective.
The course is common to 4th year Mechanical Engineering students and MSc students taken from several
postgraduate programmes including those with an emphasis on Marine engineering. Accordingly,
several of the topics covered will also refer to materials used in marine environments and attempts will be
made to link into this area of engineering. Given the wide range of backgrounds of the students who
attend this course, the first few lectures given cover the basics of materials science and may well be
revision for some students but totally new for others.
Method of Instruction
The course is delivered using lectures, tutorials and one piece of coursework.
Assessment
The course is assessed via a conventional unseen written exam of 2 hours duration. This covers both major
threads of the course – materials theory and failure through fatigue and fracture. 65% of the credit for the
course is predicated on this exam. The paper is split into two equal sections, with three questions to be
answered in time available, and no more than two from either section. The course work (remaining 35%)
consists of a materials orientated report/case study, covering current aspects relevant to advanced
materials science in an engineering context.
Resources
General books on all materials (given below) are useful for providing basic background information that
allows students with insufficient materials backgrounds to bolster their knowledge. An additional
bibliography covering detailed aspects such as corrosion, fatigue and fracture is supplied to all students.
Materials Science & Engineering. (8th ed, 2010 or 7th ed). W. D. Callister, D. G. Rethwisch. Wiley
(hardback with good coverage of most topics, has either CD or web access).*
The Science and Engineering of Materials. (4th ed.) D. R. Askeland & P. P. Phule. Thompson/Brooks.
(hardback, covers more than Callister in places + CD).*
Introduction to Materials Science for Engineers. (7th, 2009 or 6th ed). J. F. Shackelford. Pearson
Education. (general text with emphasis on engineering applications, web access).
Additional Information
This structure of the course is designed to divide into two distinct sections, which nevertheless cross
over at certain points. Students should treat each half as independent and note that in the end of year
exam, the paper is divided into two sections – each one mirroring the two way split of the course
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Content
The lectures are supported by pictorial hand-outs. The syllabus for the materials half of the course is
as follows:
Introduction:
The importance of studying materials, categories, important properties, basic
definitions of yield stress, modulus, toughness etc. Concept of fracture
vs. deformation.
Structure:
The structure of materials, from the atom to the grain based microstructure.
Bonding between atoms, lattice types, alloys as solutions, the
phase diagram.
Steels:
An introduction to steel. Allotropy of iron, carbon solubility. The phase
diagram , the phases and the resultant microstructures. A survey of heat
treatment of steels including annealing, normalising, quenching and
tempering. Martensite and Bainite. TTT and CCT diagrams. The effect of
alloying steel. The ductile to brittle transition temperature and the concept of
strengthening via the restriction of dislocation movement. Structural steels
in the marine and offshore industry - an overview. The problems associated
with high strength steel. Stainless steel, categories, types, properties and
problems with weld decay & sensitization.
Titanium:
Titanium and its alloys - an overview of types and properties. Use in the
offshore industry. Problems of fabrication.
Corrosion:
Corrosion principles and basic definitions. Electrochemical corrosion. The
EMF and saltwater galvanic series. The effect of polarisation on corrosion
rate. Types of corrosion including microbiological and erosion corrosion in
marine environments. Corrosion protection and control via design, coatings
and galvanic methods. Sacrificial; and impressed current methods for the
protection of ships and offshore structures. Biofouling.
Superalloys:
Introduction to Ni-Cr and Ni-Fe based superalloys, their properties and
usage. The application of these in jet engines and turbines.
Directionally solidified and single crystal turbine blades. Ceramic
coatings and active cooling.
Weldability:
The weldability of steels. Detailed analysis of the microstructural changes
within a weld. Problems of the heat affected zone, hydrogen cracking and
Martensite formation. Relationship of hardenability to weldability and the
TTT diagram to cooling rates obtained in practical welds. Carbon
equivalent and Schaeffler diagrams.
Advances:
The use of new materials in the offshore environment, including aluminium
alloys, composites, ceramics and high strength polymers.
Options:
Advanced materials and systems including fuel cell materials, biomimetics
and MEMS devices and fabrication. Cement and concrete as smart
composites. Wood as an engineering material. A different area will
be focussed on each academic session.
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Learning Outcomes1 MECHGM03, MECHGR03, MECHM004
General Learning Outcomes
Ability to develop, monitor & update a plan, to reflect a changing operating environment
N/A
Ability to monitor and adjust a personal program of work on an on-going basis, and to learn
independently
As with all taught modules on the programme a significant amount of self learning is expected.
The ability to exercise initiative and personal responsibility, which may be as a team member or
leader
N/A
The ability to learn new theories, concepts and methods etc and apply these in unfamiliar
situations
The module is designed to present new subject matter at M level understanding of which is then
tested by an exam and materials orientated report/case study.
Specific Learning Outcomes
Underpinning science & Mathematics
A comprehensive understanding of the relevant scientific principles of the specialisation
Although many students will have studied materials science and engineering at undergraduate level
the course is designed to provide a common level to their knowledge and then to introduce new
subject matter such as advanced fracture mechanics and fatigue failure in engineering materials
and to provide a detailed look at some areas of materials application which are not normally covered
at undergraduate level. Some of the taught matter is placed in a context that makes it relevant to
materials in marine environments, to ensure relevance to students specialising in this field.
A critical awareness of current problems and/or new insights much of which are at, or informed by,
the forefront of the specialisation.
Both tutors on this course are active in materials science research and there are opportunities for
input of this research experience into the later parts of the course, where advanced topics are
covered. The course is fluid and often uses case studies from the work undertaken by the course
tutors concerned.
An understanding of concepts relevant to the discipline, some from outside engineering, and the
ability to critically evaluate and apply them effectively.
The module is designed to present new subject matter at M level understanding of which is then
tested by an exam and materials orientated report/case study.
1 EAB website http://www.engab.org.uk/documentation document Accreditation Of Masters Degrees Other Than MEng last
accessed 10 Aril 2012
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Engineering Analysis
Ability to use fundamental knowledge to investigate new and emerging technologies The course
begins by providing a levelling to the material science knowledge of the course participants
(who come from a wide range of academic backgrounds). This is then used as a springboard
for dealing with more esoteric and advanced materials based issues which are introduced
as discrete case studies in materials science, particularly drawn from relevant and modern
contexts (e.g. materials for MEMS structures, concrete based composites and materials for
fuel cell applications).
Ability to apply appropriate models for solving problems in engineering and the ability to assess
the limitations of particular cases;
This is addressed by the materials orientated report/case study which forms the
course work component of the module
The ability to collect and analyse research data and use appropriate engineering tools to tackle
unfamiliar problems, such as those with uncertain or incomplete data or specifications, by the
appropriate innovation, use or adaptation of engineering analytical methods.
The coursework (as described above) normally requires substantial collection and critical
analysis of relevant literature and sometimes manufacturer’s data.
Design
The ability to apply original thought to the development of practical solutions for products,
systems, components or processes
N/A
Economic, Social and Environmental Context
Knowledge and understanding of management and business practices, and their limitations,
and how these may be applied appropriately, in the context of the particular specialisation
N/A
The ability to make general evaluations of risks through some understanding of the basis of such
risks
N/A
Engineering Practice
A thorough understanding of current practice and its limitations, and some appreciation of likely
new developments
The case studies are drawn from relevant and modern contexts (e.g. materials for MEMS
structures, concrete based composites and materials for fuel cell applications).
Advanced level knowledge and understanding of a wide range of engineering materials and
components
The module investigates a range of engineering materials and their uses and failure mechanisms.
The ability to apply engineering techniques taking account of a range of commercial and industrial
constraints
N/A
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