Faculty of Computing, Engineering and Media

Mechanical Engineering MSc Programme

Module name: Structural Integrity: Design against Failure

Module code: ENGT5257
Title of the Assignment: Case Study Assignment
This coursework item is: (delete as Summative Formative
appropriate)
This summative coursework will be marked Yes No
anonymously
The learning outcomes that are assessed by this coursework are:
LO 3: Diagnose the type of failure based on the fractography appearance and experimental analysis.
(IET AHEP3: EA3fl, D1fl, D2fl, EP3fl)
LO 4: Avoiding failures through applying appropriate design approaches and materials selection. (IET
AHEP3: D3fl, ET6fl S2fl)
This coursework is: (delete as Individual Group
appropriate)
If other or a mixed ... explain here:
This coursework constitutes 50% to the overall module mark.
Date Set: 25 Nov 2019
Date & Time Due: 10 January 2020
The ‘normal’ coursework return date for this work Up to 20 working days after
is: submission
When completed you are required to submit your coursework to:
ENGT5257 Structural Integrity, via Turntin link within the Module
Blackboard Shells
Late submission of coursework policy:
Late submissions will be processed in accordance with current University regulations which state:
“The time period during which a student may submit a piece of work late without authorization and
have the work capped at 50% if passed is 14 calendar days. Work submitted unauthorized more
than 14 calendar days after the original submission date will receive a mark of 0%. These
regulations apply to a student’s first attempt at coursework. Work submitted late without
authorization which constitutes reassessment of a previously failed piece of coursework will always
receive a mark of 0%.”
Academic Offences and Bad Academic Practices:
These include plagiarism, cheating, collusion, copying work and reuse of your own work, poor
referencing or passing off of somebody else's ideas as your own. If you are in any doubt about what
constitutes an academic offense or bad academic practice you must check with your tutor. Further
information is available at:
http://www.dmu.ac.uk/dmu-students/the-student-gateway/academic-support-office/academic-
offences.aspx
and
http://www.dmu.ac.uk/dmu-students/the-student-gateway/academic-support-office/bad-academic-
practice.aspx
Tasks to be undertaken: See coursework descriptions below
Deliverables to be submitted for assessment: See coursework descriptions
below

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 How the work will be marked:
DMU Mark Descriptors
The pass mark for this module is 50%
Refer marking scheme provided below:
https://www.dmu.ac.uk/documents/about-dmu-documents/quality-management-and-policy/academic-
quality/learning-teaching-assessment/ug-mark-descriptors.pdf
Module leader/tutor name:
Dr. Fuad Khoshnaw – Q 3.14 Ext. No.: 8886
Contact details:
E: fuad.hassankhoshnaw@dmu.ac.uk

This assessment Weightings 50% of the whole module

Type of assessment Component Date Set Date Due Date Return

Marks
Three Case Studies - 500 words maximum for 75 % Wk 9 Friday, 10 January Week 15
each 25 Nov 2020, 23:59
Complete the question with all the required 2019
graphs, tables, calculations, and appendices. 25%

Total 100%
Remarks: All works are individuals, summative and not anonymously marked.

Lecture sessions and seminars

The “Case Study” assignment will be supported by weekly lectures, and seminars, as well as lab
sessions whenever required, to work on various parts of the assignment. Students can also seek
advice on various aspects of their work, e.g. comments on proposed methods/approaches; advice
on sources of information; etc.

Scope
Designing machines, vehicles and structures that are safe, reliable and economical requires both
efficient use materials and assurance that structural failure will not occur. Therefore, this module is
appropriate for postgraduate students to study the mechanical behavior of materials, specifically for
topics such as fracture toughness, fatigue, creep and corrosion. Structural Integrity: Design against
Failure module covers topics such as types of materials and their properties and types of failure in
materials. Also focuses on stress-based fatigue analysis, relatively new methods of fracture
mechanics, creep and corrosion resistance.
Reading list:

1. Jorge Luis González-Velázquez, Mechanical Behaviour and Fracture of Engineering

Materials.

2. J. Rösler, Mechanical Behaviour of Engineering Materials.

3. Richard W. Hertzberg, Deformation and Fracture Mechanics of Engineering Materials.

4. Fontana and Green, Corrosion Engineering.

5. Serope Kalpakjian, Manufacturing Processes for Engineering Materials.

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 Structural Integrity: Design against Failure
Coursework Two - Case Study

Note:
This coursework includes two parts, case studies, and a question. Both parts need to be
submitted as one-word file through Turnitin.

Part 1 – Case Studies

For the following three case studies, you are required to:
o Justify the precautions about the failed pieces before starting investigations
o Discuss the given microstructure and/or fractography of the failed pieces.
o Diagnose the failure, core issues and discuss the causes
o Explore feasible solutions based on theories and research

Case Study One

Austenitic stainless steel plate was used as heat exchanger tubes to produce a steam
generator in a milk processing plant. The heat exchanger tubes located in the central part
were exposed to high heat input during welding of the tubes with the tube wall. The service
conditions of the heat exchanger were dry saturated steam (9 bar, 180 oC) for heating
softened water, around 36oC, 25 ppm Cl-. After few months of the operation, numerous
cracks on the heat exchanger tubes near welded joints to tube wall were started.

25%

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 Case Study Two
A martensitic microstructure of low alloy steel, AISI/SAE 4330V was used as an oil and gas
well tubular drilling tool. The tool operated with severe torque variation, creating multiple
cracks at the external diameter, and led to the fracture. The drilling tool was already close to
the end of its life.

25%

Case Study Three

Two dissimilar metallic alloys, a plate of mild steel with a larger piece of austenitic stainless
steel, were lap joint TIG-welded using 308 AISI filler metal, serviced in an offshore
environment for one year.
25%
Maximum 500 Words for each case study

Part 2
Fracture Toughness
Crack length versus cycle data is given in the table below from a test on a center-cracked
plate of 7075-T6 aluminum. The specimen dimensions: h = 445, b = 152.4, and t = 2.29 mm.
The force was cycled between 10 kN and a maximum value of 48 kN.

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 o Obtain the da/dN and K values.
o Illustrate the Kth and KiC values on a sketched diagram.
o Discuss the methods to increase the life of the component.

Indicate to all the graphs, charts and diagrams that will be used to solve this question.

J a – mm N – cycles
1 5.08 0
2 7.62 18300
3 10.16 28300
4 12.70 35000
5 15.24 40000
6 17.78 43000
7 20.32 47000
8 22.86 50000
9 25.40 52000
10 30.48 57000
11 35.56 59000
12 40.60 61000
13 45.72 62000
25%

Guidelines for writing in general: 5Cs – Clear, Concise, Complete, technically Correct,
Critical analysis.
All references must be appropriately indicated within the text and will be listed at the end
of the coursework.
Use TurnItIn to submit the assignment.

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