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Content:

This module builds upon a basic theory of materials as would be given in the first years of an undergraduate programme and examines specific areas of materials science which are not normally taught as part of a basic materials curriculum. The module aims to cover the fundamentals of process-structure-property relationships in materials processed by a wide range of advanced manufacturing technologies, including steelmaking, rolling, welding and additive manufacturing. Moreover, we will discuss heat transfer in welds, the physical metallurgy in fusion & heat affected zone, solid-state transformation, and Time-Temperature-Transformation (TTT) diagram. MECH0056 is common to 4th year Mechanical Engineering undergraduate students and MSc students from several postgraduate programmes. Given the wide range of backgrounds of the students who attend this module, the first few lectures given cover the basics of materials science and may well be revision for some students but totally new for others.

Teaching Delivery:

We deliver the module content via weekly lectures, group discussion, interactive learning with Mentimeter, and self-directed learning, e.g. e-books and online videos.

Indicative Topics:

Although many students will have studied materials science and engineering at undergraduate level, the module is designed to provide a common level of knowledge and then to introduce new subject matter such as advanced fracture mechanics and fatigue failure in engineering materials, and to provide a detailed look at some areas of materials application which are not normally covered at undergraduate level. The module begins by providing a common foundation to the material science knowledge of the course participants (who come from a wide range of academic backgrounds). This is then used as a springboard for dealing with more esoteric and advanced materials/processes which are introduced as discrete case studies in materials science, particularly drawn from relevant and modern contexts (e.g. materials for additive manufacturing).

Module Objectives:

• Understand a broad overview of materials and fatigue, materials science and engineering, different types of bonding exist in materials, the relationship between bonding energies and melting temperature, the phase diagram of pure and binary metals, constitution of pure metals and alloys, the structure of crystalline solids and polymer composites, mechanical testing, the concepts of stress and strain, basic processing of materials, including casting, steelmaking, additive manufacturing, and welding/joining processes.
• Describe different classes of materials, the four components that are involved in the design, production, and utilization of materials, the 3 main crystal structures exhibited in metallic systems, the Fe-C phase diagram, the microstructural evolution of plain carbon steel, including pearlite / martensite / bainite, 4 types of strengthening mechanisms in metallic systems, 4 types of transformation that occur in phase diagrams, different types of heat-treatment, the advantages and disadvantages of AM, welding and other joining processes, the key factors that influence theÌýmicrostructure during welding and AM.
• Calculate the engineering stress, shear stress, engineering strain, ductility, Young’s modulus, and stiffness, elastic moduliÌýand tensile strength for metals, polymer, and composites, the fraction of solid and liquid using the lever rule; the interaction times and cooling rates on microstructural features of the fusion and heat affected zones during welding using analytic solution.
• Draw the evolution of microstructure along a solidification path, and sketch the crystal structures of austenite, ferrite, and martensite.
• Conduct comparative analysis between laser beam and electron beam welding in terms of cost, heat input, heat transfer, and microstructural features.

Recommended Readings:

• You will be able to access a reading list from the MECH0056 Moodle page and UCL library.