Metals Engineering IMS120/Module B Materials Engineering - fall 2023

Overall Objective

This course comprises both the module B named Metalllic Materials of 5 credit units within the course master programme course Materials Engineering as well as the self-standing course Metallic Materials of 7.5 credit units. The theory and contents is the same, but the latter includes extended project assignment of 2.5 credit units.

The aim is to make sure that the participants have acquired relevant in-depth knowledge regardingengineering metals for advanced reasoning about and assessment of the most common alloys used in society.

The focus is placed on the correlation between microstructure, processing/manufacture and the resulting properties of engineering metals when used in different automotive and mechanical engineering applications. Issues covered are microstructure control and strengthening of metals (ferrous and non-ferrous) including basics behind strengthening of metals and strengthening mechanisms; processing and heat treatment including use of phase diagrams and TTT/CCT diagrams, etc.; hardening, residual stresses, etc.; certain fundamentals of brittleness, toughness and ductility; deformation behaviour; certain fundamentals of environmental impact on materials with respect to oxidation/corrosion. Materials covered are low-alloy and high strength steel, tool steel, stainless steel, superalloys, titanium alloys, cast iron, copper alloys, aluminium alloys and magnesium alloys.

Learning Goals

After completing this module or course, you should be able to:

• Describe and understand the basic principles for microstructure design of engineering metals on advanced level
• Apply this knowledge in various situations of potential importance in practical engineering
• Apply principles for different processes in order to create specific microstructure and properties
• Apply basic corrosion and oxidation mechanisms for assessing the behaviour of engineering metals in various applications
• Describe typical properties for different classes of engineering metals with particular emphasis on role of microstructure and how this can be achieved

Important Issues

An important part in the course is to acquire understanding how material properties are affected by differentmanufacturing process, heat treatment protocols and conditions for use in applications. This includes, forexample, the impact of high and low temperatures, stress levels and strain rates. The course connects in particular to subject areas adjacent to materials technology such as solid mechanics, machine design and manufacturing technology.

In the course we also cover application of optical microscopy and introduction to materials and processmodelling including software tools for thermodynamic and kinetics based tools as Thermo-Calc and JMatPro as well as FE-based tools as Deform 2D/3D. With JMatPro, for example, advanced prediction and modelling of phase constitution and properties of steel, cast iron, aluminium alloys and nickel-base alloys can be done.

Note that the labs are NOT designed to give you training in the laboratory. They should be viewed more as means of introducing specific tools of importance in modern materials technology work. This is why we have selected i) a specific lab on optical microscopy to show how assessment involving image processingmay work out, ii) to have a tutored class on heat treatment of steel to develop your skills in assessing microstructure-property- processing relationships from micrographs and facts, iii) a specific demonstration on prediction of properties and phases of materials using the software tools as JMatPro and Thermo- Calcand finally iv) an event intended to show how FE-modelling is a real tool used in process modelling, here applied on heat treatment.

 

Changes compared to last year:

Course packs covering all parts are further updated and the e-literature and a reference text book aresources for further reading. For master students following the compulsory materials engineering course of 15 credit units, this metallic materials  module of 5 credit units includes no project assignment. For students following the self-standing course of 7.5 credits units, there extended practical in the form of project assignment. The project assignment is compulsory with final oral group presentation and hand in of power point presentation according to instructions announced during the course.

Organisation

The module or course includes a lecture series (see below) and two compulsory  practicals an for participants following the elective self-standing course a project assignment. The tutors involved iare as follows.

Examiner: Prof. Lars Nyborg, phone 7721257, e-mail: lars.nyborg@chalmers.se

Course leader: Prof. Emmy Cao, phone: 7721252, e-mail: yu.cao@chalmers.se

Others involved:

Xiaolong Li                                                        e-mail: xiaolongl@chalmers.se

Fardan Jabir Hussain                                      e-mail: fardan@chalmers.se

The lecture schedule may be changed. Changes will then normally be announced latest the week before.

Student administration

For questions regarding reporting of results for the course , etc, please contact: Hanije Safakar, hanije@chalmers.se.

Student representatives

To be announced

The practical classes

The practical classes are compulsory and they will include:

1. Phase constitution/simulation, heat treatment and properties of alloys for engineering applications:Small group (max 5 participants) tutored practical class where a number of specific problems areaddressed by using the software JMatPro and Thermo-Calc (3 hours per group). There can be maximum 5 students per group. This event is booked by each group by contacting Fardan Jabir Hussain via e-mail: fardan@chalmers.se. The event is organised on Campus. Schedule announced after course start.

 

2. Optical microscopy of cast Al-alloy - the aim of the lab is to demonstrate how modern analytical optical microscopy can be applied to study and assess the microstructure of a metallic material with relevance to industrial application. Small group of (max 5 participants) will be tutored. The lab is run by each group  Xiaolong Li via e-mail: xiaolongl@chalmers.se. The event is organised on Campus. Schedule announced after course start.

Group assignment

Participating in group assignment is compulsory only for students following the self-standing course of 7.5 credit units. You will form a group of maximum 5 participants. Each group will have its own scientific/technical topic related to the contents of the course. The topic will be among some pre-defined topics of industrial/technical relevance (separate list). The result of the group assignment should be communicated by oral presentation and power point presentation. There will be no grading, only pass/fail, but follow-up/feedback for each group.

Examination

For Module B Metallic Materials:

Final written exam on 25 Oct. at 8.30. No aids allowed, only approved calculator.

For the self-standing course Metallic Materials:

Final written on 26 Oct at 14.00. No aids allowed, only approved calculator.

Course literature

The lecture hand-outs (pdf-format) will be provided only for course participants.

Via Canvas you will find downloadable documents for the practical classes mentioned and different sets of problems for the problem-solving events as well as other text documents (old exams, course summarynotes, etc.). Only students being registered for the course will have access to these documents.

The e-sources behind the course are:

MAIN SOURCE

• Handbook of Mechanical Alloy Design, M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), source: CRC Press

OTHER SOURCES

• Handbook of Metallurgical Process Design, Xie, K. Funatani, G.E. Totten (Print ISBN: 978-0-8247-4106-8), Source: CRC Press.
• Steel Heat Treatment – Metallurgy and Technologies, E. Totten (Print ISBN: 978- 0-8493-8455-4), Source: CRC Press.
• Mechanical Properties of Engineering Materials, Soboyejo, (Print ISBN: 978- 8247-8900-8), Source: CRC Press.
• Physical Metallurgy and Advanced Materials, E. Smallman, A.H.W. Ngan, Elsevier Ltd. (Print ISBN: 978-0-7506-6906-1), source: Science Direct
• Engineering Materials Science, Ohring, Elsevier Ltd (Print ISBN:978-0-12-524995-9), source: Science Direct

Schedule

The enclosed schedule is preliminary and may be revised pending on circumstances. Updated information will be communicated via Canvas.

Acronyms: L = Lecture, E = Problem Solving. For lecture rooms, see Time Edit, IMS120.

Topic		Time and	Lecturer	Source materials
Introduction Basics of metallic materials (BSc level repetition)	L	2023-09-04 13.15-15:00	Lars Nyborg/ Emmy Cao	PPT: crack course on metallic materials
Basics of heat treatment	L	2023-09-04 15:15-17:00	Emmy Cao	Microstructural control and development (course pack)
Basics of heat treatment	L	2023-09-07 8.00-11.45	Emmy Cao	Microstructural control and development (course pack)
Heat treatment of hypereutectoid steel	E	20023-09-08 15:15-17:00	Emmy Cao	Practical class: Heat treatment of hypereutectoid steel
Heat treatment of hypereutectoid steel	E	2023-09-11 13:15-15:00	Emmy Cao	Practical class: Heat treatment of hypereutectoid steel
Basics of strengthening	L	2023-09-11 15:15-17	Lars Nyborg	Strength of metals (course pack)
Basics of strengthening	L	2023-09-14 8:00-11:45	Lars Nyborg	Strength of metals (course pack)
Basics of corrosion and oxidation	L	2023-09-15 15:15-17:00	Emmy Cao	Corrosion/oxidation (course pack)
Designing with steel	L	2023-09-18 13:15-17	Lars Nyborg	Designing with steel (course pack)
Designing with aluminium alloys	L	2023-09-21 8:00-9:45	Emmy Cao	Designing with aluminium alloys (course pack)
Problem solving	E	2023-09-21 10:00-11:45	Emmy Cao	Problems pack (course pack)
Designing with stainless steel	L	2023-09-22 15:15-17:00	Lars Nyborg	Designing with stainless steel (course pack)
Heat treatment of hypereutectoid steel	E	2023-09-25 13:15-17:00	Emmy Cao/Lars Nyborg	Practical class: Heat treatment of hypereutectoid steel
Designing with copper alloys	L	2023-09-28 8:00-9:45	Emmy Cao	Designing with copper alloys (course pack)
Problem solving	E	2023-09-28 10:00-11:45	Emmy Cao	Problems pack (course pack)
Designing with tool steel	L	2023-09-29 15:15-17:00	Emmy Cao	Designing with tool steel (course pack)
Cast iron design	L	2023-10-02 13:15-15:00	Lars Nyborg	Handbook of Mechanical AlloyDesign, G.M. Totten et al. (e-literature on Chalmers library)
Designing with titanium alloys	L	2023-10-02 15:15-17:00	Lars Nyborg	Designing with titanium alloys (course pack)
Designing with nickel-base alloys	L	2023-10-05 8:00-9:45	Lars Nyborg	Handbook of mechanical alloy design, G.M. Totten et al. (e-literature on Chalmers library)
Problem solving	E	2023-10-05 10:00-11:45	Lars Nyborg/Emmy Cao	Problems pack (course pack)
Project assignment presentations		2023-10-09 13:15-17:00	Presentation by students following free standing course	Group presentations
Problem solving	E	2023-10-12 8:00-11:45	Lars Nyborg/Emmy Cao	Typical prior exam questions

Laborations

The time and place for the two laborations will be announced at course start and these events will be run using options according to Time Edit for IMS120.