Materials 2

Module summary

Module code: MECH1069
Level: 5
Credits: 15
School: Engineering and Science
Department: Engineering
Module Coordinator(s): Mark Bingley

Specification

Aims

The module aims to impart an appreciation of the central place that materials occupy in engineering; after all, engineers make things, and they make them out of materials. An engineer needs to make good choices in his/her selection of materials. To emphasise this, the module will take an applications driven and design approach through the examination of a range of materials selection case studies and challenges, such as selecting materials for the hot end of a gas-turbine engine and preventing failure of aerospace structures. However, it is intended that students also gain an understanding of the complexity of materials, the origin of their properties, to know which material properties are intrinsic and which can be manipulated through manufacturing, processing and heat treatment.

Learning outcomes

On successful completion of this module a student will be able to:
1 Relate experimental procedures and analysis to the wider engineering context
2 Use information gathering, research, practical and communication skills to write a professional report
3 Deduce from the function of the component, the required properties of a material,
and the reason for selection of that material
4 Analyse the performance of materials in various engineering contexts

Indicative content

Enabling Theory and Background Material
• Crystal structures, phases, introduction to phase diagrams, phase changes, solidification, glass transition, precipitation, grain growth, recrystallization.
• Recap of Ashby Materials Selection and Process Selection procedures
• Eco- informed materials choice: resources; life cycle analysis; eco-attributes of materials; eco-informed materials selection

The Importance of Processing – How to Manipulate Materials Properties

Materials Selection Case Studies and Challenges (Examples are given)
• Selection of Materials for Automotive Applications
o Car Bodies – low carbon steels, HSLA and other modern car body steels, aluminium alloys, GFRP
o Engine parts – Q and T steels, alloy steels, cast irons, aluminium alloys, magnesium alloys
o Tyres - elastomers
• Selection of Materials for Oil Rigs (Failure Issues)
o Brittle Fracture
o Marine and Sour Gas Corrosion
• Selection of Strong/Stiff/Light Materials for Aerospace Structures and Components
o Aluminium alloys (precipitation hardening), composites, magnesium alloys, smart materials, future materials developments
• Preventing Failure in Aerospace Structures – Designing for Fatigue Resistance
• Materials for the Gas Turbine Engine
o Stainless steels, titanium alloys, nickel base super alloys, inter-metallics, ceramics
• Preventing Failure and Degradation within the Gas Turbine Engine
o High temperature oxidation, hot corrosion, creep of metals (compare with creep of polymers) thermal fatigue, erosion

• Selection of Materials for Buildings and Bridges
o Structural steel, high tensile wire
o Cement and concrete: properties of concrete, concrete mix design, standard test methods, quality control, strength and failure, deformation of concrete,
o Reinforced concrete, fibre toughened concrete, high performance ductile concrete,
o self-healing concrete
o Brickwork and blockwork: masonry construction and forms, structural behaviour, durability
o Wood and timber: properties, stress grading by visual and mechanical means
o Plastics: mixing, properties and modes of failure
o Glass: applications in construction and properties
o Composites: fibre-reinforcement, particle reinforcement, properties, testing
• Materials for Biomedical Applications
o Stainless steels, titanium alloys, CoCrMo alloys, polymers, glasses and ceramics, shape memory alloys,
• Materials for Domestic Applications – focus on polymers
• Materials for Packaging – focus on polymers, smart materials (e.g. thermochromic materials)