Advanced Materials and Materials Selection Coursework Assessment Brief

School of Engineering UCLan Coursework Assessment Brief Academic Year 202 2-202 3 Module Title: Advanced Materials and Materials Selection Module Code: MP4702 Level 7 MP4702 – COURSEWORK BRIEF This assessment is worth 30 % of the overall module mark THE BRIEF/INSTRUCTIONS • Depending on the last digit of your Student ID you will have to make a different version of the assignment. If your ID last digit is 0, 1, 2, or 3, you need to do version A, if your ID last digit is 4, 5, 6, you need to do version B, if your ID last digit is 7, 8 or 9, you will need to do version C of the assignment, the version is stated at the beginning of the questions. • The coursework should be your own work and should be properly type -written in your own words. Marks will be reduced for the typo -errors and missing units. The assignment will be checked for plagiarism using TURN -IT-IN software. Any plagiarism or copying from others will be dealt through the university’s plagiarism procedures. Similarity (plagiarism) level higher than 10% in the answers are highly suspicious . Cover sheet and assessment questions would have great similarity as expected. • The whole report should be 1500 words plus any relevant material. Any references to materials should be given in standard Harvard or Vancouver form. • Answer al l the questions. • Each question has the marks indicated. Total marks are 100. • Students with special needs will be addressed on individual basis. (Candidates that may require any special requirement will be dealt with on a one -on -one basis which must be disc ussed with the module tutor/lead before the due date). • This assessment is testing all the learning outcomes listed in the module descriptor. Learning outcome (LO) 1 Able to communicate effectively on material selection with material scientists. LO 2 Able to understand the implications of different modes of material failure. LO 3 To understand the effects of composition and heat treatment on the properties of different types of material. LO 4 To select materials to minimise the likelihood of component failure. • To pass this module you must achieve a mark of 50% or above, aggregated across all the assessments. Students registered for an IET -accredited award must also achieve a mark of 40% or above on each of the assessments. PREPARATION FOR THE ASSESSMENT • In order to prepare for this assessment you need to make the tutorial questions and follow the lectures within the module. • Take advantage of the tutorial sessions to ask question you may have in relation to this assessment or request support. • Reading list available at the library for MP4702 https://uclan.alma.exlibrisgroup.com/leganto/public/44UOCL_INST/lists/4484530150003821?auth=SAML RELEASE DATE AND HAND IN DEADLINE Assessment Release date: 4 Oct 2021 Assessment Deadline Date and time: 12 th Dec 2021 at 18:00 Please note that this is the final time you can submit – not the time to submit! Your feedback/feed forward and mark for this assessment will be provided on 13 th January 2023 SUBMISSION DETAILS • Your assignment must be submitted electronically via blackboard by the submission time or before. The report should be contained in a Word do cument or pdf document. No other means of submission will be accepted. • The submission link would be related to the version of the assignment that you needed to do. If your ID last digit is 0, 1, 2, or 3 you need to submit in the link provided for version A, If your ID last digit is 4, 5, or 6 you need to submit in the link provided for version B, if your ID last digit is 7, 8, or 9 the you need to submit in the link provided for version C. • Drawings can be done by hand or electronically. They can either be scanned / copied into your Word or pdf document. • Any assignment submitted late, but within 5 working days of the deadline, will be given a maximum mark of 50%. Assignments submitted more than 5 working days after the deadline will not be marked, and a mark of 0% will be recorded. HELP AND SUPPORT • In case you need any help or support you need to reach out as soon as possible. You can do so during lectures, tutorials or directly with Dr Gonzalo Garcia -Atance ( ggarcia [email protected] ), Dr Nathalie Renevier (NRenev [email protected] ) or Dr Arun Natarajan ([email protected] ) • You will find information links to all our Library resources in the Library area of the Student Hub. For support with using these resources, please contact your subject librarian at SubjectLibrarians@ucl an.ac.uk . • You can get support with your academic skills (academic writing, critical thinking and referencing) through WISER. For details of the WISER support services go to the Study Skills section of the Student Hub. • If you have not yet made the university aware of any disability, specific learning difficulty, long -term health or mental health condition, please complete a Disclosure Form . The Inclusive Support team will then contact to discuss reasonable adjustments and support relating to any disability. For more information, visit the Inclusive Support page of the Student Hub. • To access mental health and wellbeing support, please complete our online referral form . Alternatively, you can email [email protected] , call 01772 893020, attend a drop -in, or visit our UCLan Wellbeing Service pages for more information. • If you have any other query or require further support you can contact Student Support via [email protected] . Speak with us for advice on accessing all the University services as well as the Library services. Whatever your query, our expert staff will be able to help and support you. For more information please visit the Student Hub. • If you have any valid mitigating circumstances that mean you cannot meet an assessment submission deadline and you wish to request an extension, you will need to apply online prior to the deadline. Disclaimer: The information provided in this assessment brief is correct at time of publication. In the unlikely event that any changes are deemed necessary, they will be communicated clearly via e -mail and a new version of this assessment brief will be circulated. Version: 1 QUESTION 1 B Tom Stanton is a youtuber that makes projects that are engineering challenging. He is developing a powered plane to be flown from the energy stored in a flywheel. The plane is already built and therefore the maximum weight of the flywheel is given. The fl ywheel is designed to store as much kinetic energy as possible. The width and the radius are also fixed due to the dimensions of the fuselage. The thickness and the rotating speed are not defined. Figure B.2. Plane powered by a flywheel (Credit Tom Stanton). Flywheel sketch. The flywheel must not burst by excessive stress due to the rotating speed and must not exceed the prescribed mass. The kinetic energy store in the flywheel is given by = ∙ 2∙3 The stress in the rotating flywheel is given by: = 2 2 2 Where is the density and is the angular velocity. The mass of the flywheel is given by: ≈ 2 a) Translate the problem indicatinting the function, the objective, the constraints and the free variables. 6 Marks b) Derive a material performance index for the selection of a material for this application. [Hint] Note that the problem has two free variables and two constraints . 6 Marks c) Select some material candidates using Granta Edupack. Justify your final choice of a specific material. 6 Marks Total: 18 marks QUESTION 2 B A new pipeline for natural gas is being planned between Argelia and Spain. The seabed is at 2000m depth. The pipeline is made out of a material that can be welded together, to avoid leakage of gas. The buoyancy of the pipeline is not a concern since ballast can be added to the pipeline at certain intervals. Figure 2: (a) The layout of a pipeline , (b) pipe lying ship , (c) Sp ain and Algeria map. (Source Wikimedia commons). You are requested to select a material for the walls of the pipeline following the method that we have seen in the lectures. It is surrounded by water at high pressure . It must withstand an external pressure without failure. It must resist some lateral and tension forces, therefore tension stresses might also be considered. It should be as cheap as possible since the main burden is the cost of the infrastructure. You need to follow the selection of materials process seen in the lectures and you will need to define constraints, free variables, objective, function… Note that not everythin g is given in the text above and you will need to make your own documented decisions. You have to document the whole selection process. (a) Using the above information and your own assumption (if applicable), translate the problem (4 marks) (b) From y our translation, derive the performance index. [Hint] Pending on your own assumptions, you may have more than one performance index (10 marks) (c) Use Granta Edupack 202 2 software to create a graph representing the single or multiple stage material index and identify the region of the chart with the candidate materials for the tunnel. [Hint] Pending on your own assumptions, you may have more than one performance index (6 marks) (d) Select one of the suitable material s highlighted in you r material selectio n and compare your material choice with actual materials used in similar tunnels. (4 marks) QUESTION 3B A crack with a depth of 12 mm is found in a cast iron rod of an old steam engine. Every weekend the machine is used for 8 hours for demonstration purposes, during which it is run at 15 rpm and the load in the rod would vary between +5×10 4 N and -5×10 4 N. It is assumed that the crack is completely closed under compressive load and negligible under tensile load. The Paris relation is sufficiently accurate to describe the problem until failure. To answer the following questions, you have been given the f ollowing: Kc = 12 MPa m 0.5 ∆Kth = 2 MPa m 0.5 cross section rod = 0.007 m 2 factor in the Paris relation: C = 4.3×10 -8 m(MPam 0.5 )-4 KI = 1.12  (a)0.5 a) Using the above information, justify if it is safe to use this machine for demonstrations and if so for how long? (5 marks) b) If the crack found is 7 mm instead, justify if it is safe to use this machine for demonstrations and if so for how long? (5 marks) ----------------------------------------------------------------------------------------------------------------------------- -- QUESTION 4 B a) Using appropriate drawings, examples and references discuss the following statement: “ Creep mechanism “bu lk diffusion” is highly dependent with stress ”. (2 marks) b) Using appropriate drawings, examples and references discuss the following statement: “C reep mechanism “bulk diffusion” is highly dependent on grain size ”. (2 marks) c) Using suitable examples and references explain w hat mechanism of creep can be completely prevented using a single crystal part . (2 marks) d) Using suitable examples and references explain what mechanism of creep can be accentuated with alloying elements . (2 marks) ----------------------------------------------------------------------------------------------------------------------------- -- QUESTION 5 B Blackpool Tower has developed problems of corrosion as seen in Figure 3. The corroded parts must be replaced by new parts made of the same material as the original parts. a) Suggest two strategies that can be used to prevent or reduce the corrosion of Blackpool Tower after the replacement of the corroded components. You need to show that the strategie s can be applied to Blackpool Tower . (4 marks) b) Justify the selection of the two strategies with examples in similar structures. (2 marks) c) Discuss the advantages and disadvantages of the two strategies suggested. (4 marks) Figure 3 : Corroded parts http://www.amteccorrosion.co.uk/ ----------------------------------------------------------------------------------------------------------------------------- -- QUESTION 6A a) Modern bicycle frames are made with aluminium ALU 6061, which tend to crack after years of use. Whereas steel frames may last decades and never fail. Contrast the behaviour of aluminium versus steel subjected to many cycles of stress. (5 marks) b) Using the information seen in class and suitable examples or references, contrast Aluminium grade 6061T0 with Aluminium grade 6061T6 (2 marks) c) Explain the process to transform Aluminium 6061T0 into aluminium 6061T6 (3 marks) d) Bike users, often ask ,if their cracked aluminium frames can be repaired. Commonly, cracks appear on the weldments (Figure 4). Peter suggested that it would be easy to weld again by grinding the crack, expose new base material and weld again on the new material. However, Peter ’s approach is never advised. Discuss one reason why this is advised against from the structural point of view. (5 marks) Figure 4: Cracks located along weld. https://www.mtbr.com/attachments/2016 -04 -25 -jpg.1066277/ e) Aluminium grade 6061 T6 is shown in Figure 5, indicate three features that are clearly seen in the picture. (3 marks) Figure 5: Metallography of aluminium grade 606 1 T6 f) Sketch the microstructure of aluminium of the previous question after being subjected to a heat treatment to reach microstructural phase equilibrium. (2 marks) ----------------------------------------------------------------------------------------------------------------------------- -- QUESTION 7B A tube (Figure 1) has failed. Some researchers investigated the root cause of the failure and presented the outcome of the investigation in a research article. J.M. Pardal, G.C. de Souza, E.C. Leão, M.R. da Silva, S.S.M. Tavares, Case Studies in Engineering Fatigue cracking of high pressure oil t ube Failure Analysis, Volume 1, Issue 3, July 2013, Pages 171 –178, DOI: 10.1016/j.csefa.2013.07.001 https://doi.org/10.1016/j.csefa.2013.07.001 Although the alloy of the tube was not heat treat ed as stated clearly in the article, “since the joint was not heat treated, welding residual stresses may also contribute to the increase of mean stresses ” the authors d id not include the suitable heat tre atment as one of the recommendations given in the “Conclusions and recommended actions”. Discuss why the authors d id not recommend the heat treatment and justify your answer with relevant data from the article . (10 Marks) ------------------------------- ------------------------------------------- END OF ASSESSMENT