Structural Integrity

MATS31601 Structural Integrity 10 Semester 1 Undergraduate Level 6 Fabio Scenini Unit coordinator Department of Materials 1 FHEQ level (Framework for Higher Education Qualifications) ' Last part of a Bachelors ' European Credit Transfer & Accumulation System Rating : 5.0 This unit introduces key factors that influence the performance and failure of materials in service with particular emphasis on wear/corrosion protection and asset management/ lifetime prediction, in energy and transport applications.The unit will cover fracture, fatigue, wear processes, failure mechanisms and life prediction. Aspects of aqueous corrosion of metals and coating processes to provide protection will also be considered.  Students will develop an understanding of how materials performance may be managed to improve economic benefits and optimise use of scarce resource. This unit introduces key factors that influence the performance and failure of materials in service with particular emphasis on wear/corrosion protection and asset management/ lifetime prediction, in energy and transport applications.The unit will cover fracture, fatigue, wear processes, failure mechanisms and life prediction. Aspects of aqueous corrosion of metals and coating processes to provide protection will also be considered.  Students will develop an understanding of how materials performance may be managed to improve economic benefits and optimise use of scarce resource.The lectures on failure mechanisms will:<ul><li>Introduce the different forms of corrosion, tribology, metallurgical and mechanical degradation and their synergisms (e.g. corrosion fatigue).</li><li>Introduce principles of corrosion and wear protection methods and their typically applications, including  coatings and surface technologies, as well as testing and evaluation methods.</li><li>Discuss the principle of corrosion resistant alloys, including passivity and localised corrosion, and passivity breakdown.</li></ul>The lectures on lifetime prediction and asset management will cover the following aspects:<ul><li>Linear fracture mechanics, KIC, fracture toughness, and J integral will be revisited and applied for structural integrity assessment of infrastructure assets, using failure assessment diagrams.</li><li>Effects of materials, geometry and residual stress will be discussed.</li><li>Energy methods and plastic collapse of structures will be presented alongside examples of their application for the analysis of engineering structure.</li><li>Life-time estimation of materials subjected to fatigue and stress corrosion cracking will be calculated using relevant rate and law mathematics. Statistics of failure, probability models (including a revisit of the Weibull distribution) will also be used for residual life prediction.</li><li>Whole-of-life (including Life Cycle Analysis) costing and analysis, risk analysis and risk register will be introduced. Examples of the performance, economic benefits, and impact on sustainability relevant to transport (aerospace and automotive) processing plants (manufacture and mining), nuclear industry (generation and waste disposal), and oil and gas (production, refining) will also be provided.</li></ul> <ul><li>Provide an overview of failure mechanisms, the different forms of corrosion and tribology, and their effect on properties and applications of industrial alloys.</li><li>Deliver an understanding of the performance of materials in industrial service with a focus on transport, petrochemical, nuclear and process plant.</li><li>Introduce strategies for component testing and life-time prediction and the management of assets.</li></ul> A greater depth of the learning outcomes will be covered in the following sections: <ul> <li> Knowledge and understanding</li> <li> Intellectual skills</li> <li> Practical skills</li> <li> Transferable skills and personal qualities</li> </ul> <ul><li>Describe and discuss corrosion resistant alloys, their application and degradation mechanisms.</li><li>Analyse key material problems and failure mechanisms in typical industrial sectors and create strategies for corrosion protection.</li><li>Apply structural integrity principles in the prediction of materials performance and evaluate the residual life of an asset. </li><li>Relate statistical failure assessments to materials performance.</li><li>Analyse plastic limit of structure and analyse structure with energy method.</li><li>Discuss and analyse tribology behaviour of alloys and ceramics.</li><li>Discuss surface engineering and its application in aero industry. </li></ul> <ul><li>Relate how material degradation mechanisms can affect component life-time behaviour.</li><li>Interpret how physical assets may be managed to optimise lifetime performance.</li><li>Apply structural integrity principles in the prediction of materials performance.</li></ul> <ul><li>Explore and analyse the different forms of corrosion/ wear material degradation.</li><li>Apply failure in service analysis.</li></ul> <ul><li>Presentation and communication skills.</li><li>Demonstrate the ability to understand practical problems.</li></ul> This unit is delivered using a blended learning approach, which integrates technology and digital media with traditional classroom activities. A variety of learning and teaching processes will be used including: lectures, discussions, group activities and independent study. Canvas will be used to present online study materials, including videos, lecture notes, guided reading, articles and other information. Canvas will also be used for the submission of assessments. 1 Written exam 70% 2 Written assignment (inc essay) 30% Written and verbal N The recommended reading for this unit can be found on the <a href="https://www.readinglists.manchester.ac.uk/leganto/public/44MAN_INST/lists/338986348730001631?auth=CAS">online unit reading list</a>. Lectures 20 Practical classes & workshops 6 Tutorials 6 0 68