Failure of Materials and Components

Learning Outcomes

Subject Specific Practical Skills

Having successfully completed this module you will be able to:

• Assess fractographic images in some detail (P2m, P3)
• Predict how a component/structure would behave under given service conditions (P8m)
• Predict the fatigue strength of a component with a complex geometry, a bolted structure and a welded structure. (P2, P8m)

Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

• Relate these failure micromechanisms to optimised materials microstructures (SM1m, EA1m)
• Describe failure micromechanisms occurring for a range of service conditions (SM1m, EA1m)
• Propose appropriate lifing methodologies for service applications (D4, P1)
• Assess likely service failures for a range of service conditions (D4, P1)
• Identify appropriate testing approaches to evaluate materials' service performance (D4, P1)
• Critically analyse the factors affecting component/structure performance (EA2)
• Analyse complex service failure problems and apply the correct fracture mechanics approach (EA2, EA6m)

Transferable and Generic Skills

Having successfully completed this module you will be able to:

• Work as materials specialist within a design context (P2m, G1, G4)
• Analyse key factors influencing materials failure: evaluate complex materials/structural failure situations and propose appropriate engineering solutions (P1)

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

• Issues involved in predicting the fatigue strength of a component, bolted structure and welded Structure (SM1m)
• What can be done to improve the in-service performance of components/structures, and thus promoting sustainable development through extending service lifetimes (SM3m, SM6m, EL4)
• Why components/structures can give unsatisfactory service (SM1m)
• In-service performance of commercial materials and be able to extend this to the performance of composite systems (SM1m)

• Introduction to the course: excessive deformation, introduction to composite classes (3 lectures).
• Micromechanisms of failure in materials (3 lectures).
• Fracture and fracture mechanics, toughening mechanisms in ceramics and composites, probabilistic failure assessment (6 lectures).
• Fatigue: total life and damage tolerant approaches, persistent slip band formation, stage I and II crack growth, closure mechanisms, long and short crack behaviour, fatigue in ceramics, composites and hybrid laminates (5 lectures).
• Performance of components and structures subjected to mechanical stresses.The influence of design and manufacturing processes on service performance will be examined and the importance of defects and residual stresses associated with manufacturing processes emphasised. A detailed case study on the performance of joints will be undertaken to demonstrate how the fatigue performance of welded and mechanically fastened joints is related to the quality and design of the joint (6 lectures).
• Performance of components and structures subjected to environmental effects. Corrosion, stress corrosion cracking and hydrogen induced failures will be analysed and the methods of preventing these failure modes by correct alloy selection, stainless steels, design and the use of surface coatings, e.g. paints, metallic coatings discussed. (4 lectures).
• The performance of materials at elevated temperatures will be considered: high temperature fatigue, creep, oxidation, high temperature corrosion and liquid metal embrittlement will be discussed. (3 lectures).
• Industrial guest lecture (1 lecture).
• Mid-course classroom quiz (‘pub quiz) (1 lecture).
• Revision lectures (2 lectures).

Teaching and learning methods

Teaching methods include:

• Lectures which develop the themes described in this module. Skeleton notes are given out at the start of the course, which means you only have to note down the key points during the lecture, but still have a full set of notes to work from.
• Additional research review papers are provided to give an overview of the themes of the course.
• Case study forms part of the lectures.
• Industrial guest lecture addresses industrial context and applications.

Learning activities include

• Access to past paper exam question bank
• Small group self-marked classroom quiz (‘pub quiz’)
• Individual work on question sheets supported by surgery sessions & revision lectures
• Revision questions set by both lecturers which are intended for small group self-study teams

Formative

This is how we’ll give you feedback as you are learning. It is not a formal test or exam.

Summative

This is how we’ll formally assess what you have learned in this module.

Referral

This is how we’ll assess you if you don’t meet the criteria to pass this module.

Repeat

An internal repeat is where you take all of your modules again, including any you passed. An external repeat is where you only re-take the modules you failed.

Repeat Information

Repeat type: Internal & External