Course syllabus
Course-PM
MMK232 Metals engineering lp1 HT19 (7.5 hp)
Course is offered by the department of Industrial and Materials Science
Contact details
Examiner: Prof. Lars Nyborg, phone 7721257, e-mail: lars.nyborg@chalmers.se
Course leader:Ass. Prof. Yu Cao, phone: 7721252, e-mail: yu.cao@chalmers.se
Guest lecturers:
Dr. Seshendra Karamchedu, Uddeholms AB
Ass. Prof. Joel Andersson, University West
Others involved:
Andrianna Lozinko (AL)
e-mail:adrianna@chalmers.se
Swati Kiranmayee Manchili (SKM)
e-mail:manchili@chalmers.se
Sukhdeep Singh (SS)
e-mail:sukhdeep.singh@chalmers.se
Elanghovan Natesan (EN)
e-mail: elanghovan.natesan@chalmers.se
Ahmad Raza (AR)
e-mail: ahmadra@chalmers.se
Course purpose
The aim of the course is to make sure that you have acquired relevant in-depth knowledge regarding engineering metals for advanced reasoning about and assessment of the most common alloys used in society.
Schedule
Note though that the schedule provided by the course information document is always telling which time slots shown by Time Edit that will be used! See course information /courses/7262/files/135551?verifier=LBMbj5gjXlx80qQtVp7cWmXAfJmbxNn5fMGrRHD3
Course literature
The course will be based on e-literature that is available from Chalmers library (see below). The whole course and its main contents from this e-literature is summarized by the course pack, the lecture handouts as well as final course summary available via the course home page on Canvas. The documents via Canvas will constitute the main course material.
Reference text books for basics in the course are “Mechanical Behaviour of Materials” by M.A. Meyers and K.K. Chawla published by Cambridge University Press (2ndedition, 2008-11, ISBN10: 0521866758, ISBN13: 9780521866750) and Physical Metallurgy and Advanced Materials, R.E. Smallman, A.H.W. Ngan, published by Elsevier Ltd. (7thed. 2007, ISBN: 978-0-7506-6906-1). NOTE: these books are reference books only and will not be used as direct basis for the lectures!
The lecture hand-outs (pdf-format) will be provided only for course participants.
The e-sources used in the course are:
MAIN SOURCE
- Handbook of Mechanical Alloy Design, G.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, L. Xie, K. Funatani, G.E. Totten (Print ISBN: 978-0-8247-4106-8), Source: CRC Press.
- Steel Heat Treatment – Metallurgy and Technologies, G.E. Totten (Print ISBN: 978-0-8493-8455-4), Source: CRC Press.
- Mechanical Properties of Engineering Materials, W. Soboyejo, (Print ISBN: 978-8247-8900-8), Source: CRC Press.
- Physical Metallurgy and Advanced Materials, R.E. Smallman, A.H.W. Ngan, Elsevier Ltd.(Print ISBN: 978-0-7506-6906-1), source: Science Direct
- Engineering Materials Science, M. Ohring, Elsevier Ltd (Print ISBN: 978-0-12-524995-9), source: Science Direct
Course design
Structure
The course includes a lecture series , four compulsory practical classes and an assignment.
Lecture Content and Scope
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.
An important part in the course is hence to acquire understanding how material properties are affected by different manufacturing process, heat treatment protocols and conditions for use in applications. This includes, for example, 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 process modelling including software tools for thermodynamics 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 practical classes are NOTdesigned 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 processing may 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 softwares JMatPro and Thermo-Calcand finally iv) to show how FE-modelling is a real tool used in process modelling, here applied on heat treatment.
Practical classes
The practical classes are compulsory and they will include:
1. Heat treatment of hypereutectoid steel: Class exercise with all participants on three fixed occasions (three events: 4+2+2 hours). Approval requires that all questions in the lab guide are answered and the document is approved by the lab tutors. The occasions for this event are included in the enclosed schedule (see next page). NOTE: in order to finish the work in time, it may be necessary to work with the questions outside the scheduled events.
2. Phase constitution, heat treatment and properties of alloys for engineering applications: Small group (max 5 participants) tutored practical class where a number of specific problems are addressed 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 Adriana Lozinko via e-mail: adrianna@chalmers.se.
3. 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 will be done in the laboratory of the Materials Processing Laboratory of the department. and ManufacturingEach participant shall write her/his own short report according to instructions (see lab instruction document) that will be reviewed and finally approved.The lab is booked by each group by contacting Sukhdeep Singh via e-mail: sukhdeep.singh@chalmers.se.
4. Simulation of materials processing - tutored class of demonstration character with small group (max 5 participants) where some basic material model aspects for use of FE-based tools for process modeling will be considered. The topic will be the heat treatment using Deform 2D/3D. The lab will be booked by contacting Elanghovan Natesan via e-mail: elanghovan.natesan@chalmers.se
Group assignment
Participating in group assignment is compulsory. You will form a group of maximum around 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 to be announced). The result of the group assignment should be communicated in a written report of maximum 4 pages as well as a final seminar. The group assignment will be evaluated based on the quality of the report and the quality of the seminar presentation. Depending on these two merits, the group members will benefit from bonus pointsadded to their final exam results as follows:
Outstanding: 5, Excellent: 4, Very good: 3, Good: 2, Weak: 1, Unsatisfactory: 0
NOTE: the group assignment report will thus be evaluated and you will get certain bonus points depending on your result/performance, but you will not be asked to return a corrected report (based on the feedback obtained) provided that the report is NOT completely unsatisfactory. In such case you will have to return a corrected report and will of course also not benefit from any bonus points!
Changes made since the last occasion
Course packs covering all parts of the course are now even furtherupdated and the e-literature and a reference text book are sources for further reading. The problem solving is also further updated and introduction to thermodynamics is revised.
Learning objectives and syllabus
After completing this 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
Link to Syllabus https://student.portal.chalmers.se/en/chalmersstudies/courseinformation/Pages/SearchCourse.aspx?course_id=29350&parsergrp=3
Examination form
There will be a final written exam on 1 Nov. at 8:30.
The total score will be 50 points and the grading will on this sum will be as follows: Grade 5, 80% or better, Grade 4, 60% or better, Grade 3, 40% or better. Passing the exam qualifies for 6 credit units.
Participating in all four practical classes and having final reports approved for practical classes as outlined above qualifies for 1.5 credit units.
Having both final exam and labs approved qualifies then for 7.5 credit units for the whole course. Passing the course requires passed final exam, approved practical classes and approved group assignment.
Schedule
The enclosed schedule (next page) is preliminary and may be revised pending on circumstances. Updated information will be communicated via Canvas.
Acronyms: L = Lecture, E = Problem Solving, P = Practical Class (compulsory), S = Seminar (compulsory). G = Guest lecture.
Thursday 2019-09-05
08:00 - 09:45 SB-H4 L Course introduction (YC/LN)
Introduction – basic elements of the course
Crack course – basics of engineering metals
(BSc level repetition)
10:00 - 11:45 SB-H4 L Basics of strengthening (YC/LN)
Crack course – basics of engineering metals
(BSc level repetition), cont.
Friday 2019-09-06 L Basics of heat treatment (YC)
15:15-17:00 SB-H4 Fundamental concepts in steel heat treatment
Source: Microstructural control and development
(course pack)
Monday 2019-09-09
13:15 - 15:00 SB-H4 L Basics of strengthening (LN)
Elastic properties and plasticity
Dislocations and plastic deformation
Source: Basics – strength of metals (course pack)
15:15 - 17:00 SB-H4 E Problem solving (LN)
Source: Problems pack
Thursday 2019-09-12
08:00 - 09:45 SB-L208 L Basics of strengthening (LN)
Defect structure and properties
Dislocations mechanisms
Strengthening mechanisms
Source: Basics – strength of metals (course pack)
10:00 - 11:45 SB-L208 L Basics of heat treatment (YC)
Fundamental concepts in steel heat treatment
Source: Microstructural control and development
(course pack)
Friday 2019-09-13
15:15 - 17:00 SB-H4 L Basics of heat treatment (YC)
Classification and mechanisms of steel treatment
Steel heat treatment – metallurgy and technology
Source: Microstructural control and development
(course pack)
Monday 2019-09-16
13:15 - 17:00 SB-H4 P Heat treatment, 1stevent (SKM, EB)
Source: Practical class:
Heat Treatment of Hypereutectoid Steel
Thursday 2019-09-19
8:00-11:45 SB-H4 P Heat treatment, 2ndevent (SKM, EB)
Source: Practical class:
Heat Treatment of Hypereutectoid Steel
Friday 2019-09-20
15:00-17:00 SB-H4 Designing with steel (LN)
Designing with carbon, low alloy and medium alloy
steels
Source: Designing with steel (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6),(e-literature on Chalmers library)
Monday 2019-09-23
13:15 - 15:00 SB-H4 L Designing with aluminium alloys (YC)
Source: Designing with aluminium alloys (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6),(e-literature on Chalmers library)
15:15 - 17:00 SB-H4 E Problem solving (YC)
Source: Problems pack
Thursday 2019-09-26
8:00-11:45 SB-H4 L Designing with copper alloys (YC)
Source: Designing with copper alloys (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), (e-literature on Chalmers library)
Friday 2019-09-27
15.15 – 17.00 SB-H4 L Designing with tool steel (SK)
Guest lecture, S. Karamchedu, Uddeholms AB
Monday 2019-09-30
13:15 - 15:00 SB-H4 L Designing with stainless steels (LN)
Source: Designing with stainless steels (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), (e-literature on Chalmers library)
15:15 – 17:00 SB-H4 L Designing with titanium alloys (LN)
Source:Designing with titanium alloys (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), (e-literature on Chalmers library)
Thursday 2019-10-03
08:00 - 9:45 SB-L208 L Cast iron design (LN)
Source: Cast iron design (course pack)
Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), (e-literature on Chalmers library)
Friday 2019-10-04
15.15 – 17.00 SB-H4 E Problem solving (YC)
Source: Problems pack
Monday 2019-10-07
13:15 – 15:00 SB-H4 L Corrosion and oxidation (YC)
Source: corrosion and oxidation (course pack)
15:15-17:00 SB-H4 E Problem solving (LN)
Source: Problems pack
Thursday 2019-10-10
8:00-9.45SB-H4 L Corrosion and oxidation (YC)
Source: corrosion and oxidation (course pack)
10:00 – 11:45 SB-H4 E Problem solving (YC)
Source: Problems pack
Monday 2019-10-14
13:15 - 15:00 SB-H4 L Designing with nickel alloys
(J. Andersson, Univ. West/GKN)
Designing with nickel alloys, Source: Handbook of Mechanical Alloy Design, G.M. Totten, L. Xie, K. Funatani, CRC Press (Print ISBN: 978-0-8247-4308-6), (e-literature on Chalmers library) + added Info
15:15-17:00 E Problem solving (YC)
Source: Problems pack
Thursday 2019-10-17
08:00 - 11:45 SB-H4 P Heat treatment, 3rdevent (SKM, EB)
Source: Practical class:
Heat Treatment of Hypereutectoid Steel
Friday 2019-10-18
15:15 - 17:00 SB-H4 E Problem solving, old exams (LN)
Source: old exams
Monday 2019-10-21
13:15-15:00 SB-H4 S Seminars, project presentations (YC)
Friday 2019-10-25 E Time for questions/tutoring (YC)
15.15-17.00 SB-H4
Course summary:
| Date | Details | Due |
|---|---|---|