Module Title:   Materials Failure Analysis

Module Credit:   20

Module Code:   ENG3303D

Academic Year:   2015/6

Teaching Period:   Semester 1

Module Occurrence:   A

Module Level:   FHEQ Level 6

Module Type:   Standard module

Provider:   Engineering

Related Department/Subject Area:   School of Engineering

Principal Co-ordinator:   Dr C S Wright

Additional Tutor(s):   -

Prerequisite(s):   None

Corequisite(s):   None

Failure of components & structures can have catastrophic consequences so knowledge of the various means by which engineering structures can fail is crucial in the design, manufacture & operation of engineering systems. This module builds on core knowledge of materials science & structural mechanics acquired in level 4 & 5 modules & aims to provide the integrated knowledge & skills to;
- recognise the important failure mechanisms which lead to catastrophic structural failure under static & cyclic loading
-select appropriate analytical methods in the design & operation of engineering systems

Learning Teaching & Assessment Strategy:
Key lectures will deliver core content; providing students with the opportunity to acquire the information to enhance their knowledge of the subject LOs1.1 and 2.1. The tutorial sessions will allow students to apply this learning to specific engineering problems. The course work will be an individual project requiring the development of a spreadsheet- based life assessment analysis of a specific component.

The examination will assess LOs 1.1, 1.2 .The coursework will assess LOs 1.2, 2.1 and LO3.1

Supplementary assessment will involve repairing deficiencies in the original assessment

Lectures:   36.00          Directed Study:   0.00           
Seminars/Tutorials:   12.00          Other:   150.50           
Laboratory/Practical:   0.00          Formal Exams:   1.50          Total:   200.00

On successful completion of this module you will be able to...

1.1 Differentiate between the important failure mechanisms of engineering structures

1.2 Explain how a particular failure mechanism is influenced by design, loading profile, material and environmental factors.

On successful completion of this module you will be able to...

2.1 Apply analytical techniques to predict or prevent failure of engineering structures or components subjected to static and cyclic loading.

On successful completion of this module you will be able to...

3.1 Apply data analysis and computer modelling techniques to obtain solutions to engineering problems.

  Examination - closed book 1.50 40%
  Examination - closed book
  Coursework   60%
  2500 word equivalent Individual project

Supplementary Assessment:
As Original

Outline Syllabus:
Description of the micro-mechanisms of failure in metallic materials; abrasive, adhesive and fretting wear, ductile failure, brittle fracture, creep, and fatigue mechanisms. Overview of corrosion, corrosion mechanisms - Stress corrosion cracking. The origins of failure initiating defects in manufactured products. Explanation of the `failure triangle` and the role that the interaction between design, material properties and service conditions plays in failure of engineering structures.
Illustrative real world case studies of failures in Engineering Structures and components (e.g. Bridges, shafts, bearings, gears, internal combustion engine components, medical implants) caused by degradation failure (wear, corrosion) or catastrophic failure (fracture, creep, fatigue, stress corrosion cracking).
The Principles of linear elastic fracture mechanics and their application in design to avoid failure under static loading - Examples of the application of fracture mechanics in structural design, `Leak-before-Break`.
Metal Fatigue, Material behaviour under cyclic loading - the Bauschinger effect , cyclic softening /hardening, Factors that influence fatigue life, Fatigue as a damage accumulation process - Miner`s Law. - Strain-life and Stress-life approaches to fatigue life prediction under constant amplitude loading and variable amplitude loading, Notch analysis - Neuber`s Rule. Prediction of the effects of mean stress / mean strain on fatigue life- Goodman Equation; Morrow equation; Smith ,Watson Topper (SWT) equation.

Version No:  1