Study Plan for STRC201A/B

Lecture 17.00-18.00 Tuesday

Lecturer David Short
Tutorial 16.00-17.00 Monday
Practical 11.00-13.00 Tuesday
Indicative Syllabus Content see Module Record Code STRC 201 A and B
FABRICATION
26-09-00 Stress Concentration and Joining and Fastening.
Stress Concentration Factor (Kt= max/ ); for an elliptical hole 2a by 2b, with the ,2a, axis
normal to a uniaxial
Stress field:in an infinite plate, Kt =1+2a/b. For a long thin crack an approximate expression is
Kt =2a/ where is the crack tip radius and a is the length of an edge crack
ref 1 -188/9
Factors affecting Kt 1) the shape of the change in geometry (the sharper the change in
geometry, the higher the Value of Kt)
-2) the orientation of the change of shape in the stress field )

Fastening and Joining; In our modern world there is a need to fasten and join things
together, make a list of the ways this is achieved (eg button, welding, dovetail, riveting, zip, glue,
magnetic, rivet, etc). Think of a characteristic that will allow you to group them into like
features, there are of course many ways in which this can be done, (e.g. temporary and
permanent: or the types of mechanism that gives fastening-mechanical force, geometry,
continuity of material, etc: degrees of freedom.)
03-10-00 Welding, (textbooks on welding can be found in section 671.52 in the library) like
most technologies welding has a language of its own. You will need to be familiar with them if
you need to talk to the specialist (ref. BS 499 Welding terms and symbols, or the ISO ASTM
equivalent)
List all the welding processes that you know and add to them those that you have found as a
result of this study. Indicate whether it is a Fusion Welding Process or a Solid Phase Welding
Process (a good introduction is given in three articles about Solid~phase welding starting in
CME March 1976)
By what mechanisms is it possible to obtain a weld without going into the liquid phase?
As nearly all welding processes create a rise in temperature then in order to understand what
might be going on in and around the weld we need to know something about the temperature
history of the material involved in both weld metal and parent metal. The temperatures reached
by any point in the material are likely to cause changes in properties so will the rate at which that
point in the material is cooling. Sketch a graph of the maximum temperatures reached at various
points in the weld and surrounding area, and show the fusion zone for the weld, and the heat
affected zone (HAZ). How will the properties vary through and along the material? To answer
this question we need further information about the welding set-up, e.g. what material was being
welded (steel, stainless steel, aluminium alloy, copper etc) and what was its condition (e.g. cold
rolled, previous heat treatment), as well as the likely temperature history caused by the process.
In regions where the temperature goes above the recrystalisation temperature in the parent plate
then modification to the grain structure will occur (recrystalization and grain growth) with the
accompanying change of properties associated with these effects. In the weld material also there
will be an associated grain structure it will be in the form of a miniature cast structure, (this will
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be modified if successive weld runs heat treat the previous ones) ref 2- 207 gives the structure of
a single pass weld. What will the grain structure in a multipass weld look like? The particular
type of material will also need to be considered for example, with steel as well as the
recrystallization effect at high enough temperatures there will be the transformation into
austenite (a single phase) with the subsequent transformation back to the low temperature form,
this of course depends on the cooling rate, so the range of phases, could be coarse pearlite on
slow cooling, to hard martensite on rapid cooling. ref 2- 377.
The heating and cooling of the metal locally might destabilise the structure, indicated by weld
decay found adjacent to the weld see ref 2- 767/770
10-10-00 Defects; this is a very general term referring to any. feature that would decrease the
integrity of the component or structure. It maybe something that occurs at the macro level, and
all sizes up to the component size; it may be a continuity defect (e.g. volume defect which has
significant bulk as well as surface e.g. porosity, or planar defect like a crack or laminar defect in
a plate etc.).
Local change of properties (reduction in fracture toughness. Fracture toughness is a property of
the material. There are three values of fracture toughness for a material depending on the nature
of the stress causing the crack to propagate; K1c Tensile ; K11c Forward Shear, K111c Parallel
Shear. The stress intensity factor K =operatinga is used to define how serious a defect (length
"a) is, when the K approaches the value of the Fracture Toughness for that stress field type then
there is a danger of brittle fracture.)
Incorrect geometry (a lack of alignment, excessive root bead etc) residual stresses. (Caused by
processing thermally created stress)
There are many causes of defects but remember prevention is better than cure. The weld pool is
at high temperature and so is chemically very active, the energy for the process welding e.g.
electric arc or plasm arc, might also cause other process to take place e.g. production of
hydrogen, oxygen etc, these can diffuse into the weld pool and parent metal. The weld pool
needs to be protected by cleaning the surrounding area (it is a common fallacy that because of
the high temperatures involved welding is self cleaning) by floating a liquid flux (ceramic slag
etc) or covering the pool with an inert gas (argon or CO2 etc).
Some of the features that we identify, as defects may not affect the performance of the
component and under certain conditions could even enhance performance.
Weldability of steel; The Carbon Equivalent is a useful guide to the possibility of cracking in
alloy steels by comparison with an equivalent plain carbon steel.
These have been produced by the International Institute of Welding (IIW)
The plain carbon steel equilant for an alloy steel is given by:
Carbon Equivalent= C+Mn/6 +(Cr+ Mo +V)/5 +(Cu+Ni)/15
Modern Steels with low carbon content (Ito & Bessyo)
Carbon Equivalent =C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+(Bx5)
How are these carbon equivalents determined and describe how they are used as a guide in
planning a welding procedure?. Ref 5 p118; BS 4360
General references to Welding
ref 4- 301/307 ;ref 2- 206,327,377,767/770 ;ref 8- 202/209 ;The Science and practice of
WELDING Volumes 1& 2 A.C.Davies ISBN 0-521-27839.
ASSIGNMENT 1
Hand in date week of 05-12-00 HAND IN DATE 6-12-00
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THE FOLLOWING IS THE FRONT PAGE OF YOUR REPORT.

DEPARTMENT OF MECHANICAL & MARINE ENGINEERING
SEMESTER 3 2000/2001
STRC 201 A & B-ENGINEERING STRUCTURES
ASSIGNMENT 1
NAME
DATE
TASK
To present a report on the fabrication and life care proposals for an engineering structure of your choice. This can be
any structure from an offshore platform to an aircraft or engine component, a micro mechanical component to a
biomechanical system.
You must select a component that is suitable for welding and indicate the interaction of welding on the structure of
the weld and properties of the material. Suggest an appropriate welding system and methods for assessing the
integrity of the welds. For an NDT system suggested for evaluating the integrity of the system outline the features
that effect its sensitivity.
If you do not select your own component then write your report on the manufacture of a welded pressure vessel
include a specification for your vessel, the welding procedure, the nde applied to establish the integrity of the welds
and the life testing recommendations. (View V10 if you decide to choose this assignment)
Indicate throughout the fabrication and life of the component or structure, any measures that must be taken to ensure
that defects are not created or existing defects do not developed to cause the failure of the component.
Your life study should evaluate the risk of corrosion damage, and possible protection methods and procedures.
You may assume that the reader is an Engineer.
Your report should be a maximum of 3500 words, not including, title page, content page and references. You many
also add appendices if you wish to record information for future reference.
ASSESSMENT
Choice of structure and clarity of description of duty manufacture and use in service
10%
Technical content of the report
60%
Application of existing up to date information
10%
References
10%
Presentation
10%
TOTAL
100%

17-10-00 NDT
BS 5289 Visual inspection of welded joints
V7 Seeing is believing: basic ultrasonic /produced by the Ministry of Defence 1987
24-10-00 JOINT DESIGN (postponed until later in the course) START CORROSION
TUTORIAL 1

1) Fastening & joining; there is a need to fasten and join things that we make. What methods do
we use and how do they work. Define the purpose.
2) List the techniques for welding, Can they be grouped together under some classification.
Clearly there are many ways this can be done.
3) Two of the main mechanisms for welding are pressure and fusion. What factors need to be
considered to make the weld and what conditions? Need to be considered
4) Identify defects that might occur in welds, their cause and methods of prevention
5) What is meant by the Carbon Equivalent of Steel, how is it obtained and how is it used?
3

6) What structures would you expect to find in the weld and parent metal for steel, at the
maximum temperature during welding, after cooling of a low hardenability steel and a high
hardenablity steel. How would the hardness vary across the weld and parent metal for the
cold specimens
7) Review the welding of polymers
8) Read about NDT (NDE) techniques select one of the processes and list the factors that effects
the sensitivity of the process.
9)The composition of an alloy is;
Carbon,0.22%,Phosphorus,0.05%,Sulphur0.05%,Vanadium0.10%,Chromium0.10%,
Manganese1.50%,Silicon0.50%.
a) Calculate the carbon equivalent.
b) Give two of the precautions that should be taken when welding this type of steel.
10-10-00
ASSIGNMENT 1
Hand in date week of 05-12-00 HAND IN DATE 6-12-00
CORROSION (started 24-10-00)
Corrosion occurs because in general the metal is at a higher energy level than its compounds.As
a consequence of this it will try and reform one of these compounds in order to reduce its energy
level. Obeying the third condition of equilibrium, Which states that the energy of the system
must be a minimum for equilibrium. The corrosion process gives out energy, design a heat cell.
Make up your definition for corrosion. It should imply the following if you are thinking only of
metallic degradation. Chemical or electrochemical reaction between a metal and its environment.
Will lead to-removal of metal-formation of oxide-formation of another compound. Translation of
metal atoms from the metallic state to the ionic state (conversion of bonding).effects of corrosion
very expensive. Electrochemical Corrosion-occurs in the presence of water or presence of
aqueous solutions of ionic compounds (acids, bases or salts). At the ANODE the metal is
changed into its ionic state and electrons are released, these have to be used up if the reaction is
to continue ( M anodicreaction ---M++ +2e-). They will pass through the metal to be neutralised
elsewhere this is the CATHODIC reaction (this is the site at which metal is deposited in the
electroplating bath).this is basic electro chemistry. We need then to be aware of all conditions
that will create a potential difference that will cause electrons to flow from the anode to the
cathode. Make a list of these conditions.
31-10-00
07-11-00 Corrosion film build up. Direct chemical corrosion by dry gas. This is the reaction of a
metal with dry oxygen or any other gas. The reaction will be driven by the decrease in free
energy as the metal reduces to the lower energy metallic compound. In the case of noble metals
like gold and platinum, oxidation involves an increase in free energy, therefore these metals can
appear in nature as pure metals.
As well as the free energy consideration from a practical engineering point of view the rate at
which the reaction proceeds is important. e.g. although aluminium has a large driving energy, a
very thin film of about 10-5m at room temperature will stop further corrosion in air.
Pilling Bedworth Rule, If the volume of the oxide is is greater than the metal from which it is
formed then the oxide will protection, but if the volume is less then the oxide film will crack.
This is true for many cases, however if the film is ductile then plasticity will relieve the stress set
up by the difference in volume. Remember that the properties are temperature dependent, so
check them at the operating conditions. The oxide film formed on Uranium does not crack at
high temperatures and so high temperature protection is better than that at low temperature.
There are three types of growth laws for corrosion.
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1) Parabolic Growth
2) Linear Growth
3) Logarithmic Growth
Anaerobic corrosion
Pourbiax diagram
14-11-00 This week 2 hours used by Jeff Barlow. David Short away
21-11-00. This week 2 hours used by David Short 1st hour Corrosion protection, 2nd hour start
Struts, bring with you to this lecture a flexible ruler and an empty aluminium ring pull soft drinks
can
28-11-00
Tutorial 2 Corrosion
ref 2 p748-774; ref 4 ch 18;
STRUTS (structures in compression)
05-12-00

06-12-00 HAND ASSIGNMENT 1 INTO DMME OFFICE

12-12-00
REFERENCES;

Books
1 William D Callister,Jr., Materials Science and Engineering an introduction, third edition, John
Wiley and Sons,Inc,
ISBN 0-471-30568-5

2 Donald R Askeland, The Science and Engineering of Materials, third edition, Chapman and
Hall
ISBN 0-412-53910-1

3 Thomas H Courtney, Mechanical Behaviour of Materials, McGraw Hill Material Science

Series
ISBN 0-07-100680-X

4 Richard A Flinn & Paul K Trojan, Engineering Materials and their Applications, Forth
Edition,Houghton Miffin Co
ISBN 0-395-62836-9

5 D T Llewellyn Steels Metallurgy and Applications Butterworth Heinemann Second Edition

ISBN 0-7506-2086-2

6 Michael F Ashby & David RH Jones, Engineering Materials 2 (An introduction to

Microstructures, Processing and Design) First Edition, Pergamon press
ISBN 0 08 032532 7

7 DRH Jones, Engineering Materials, Materials Failure Analysis, First Edition, Pergamon Press.
ISBN 0 08041905 4

FAA Crane and JA Charles Selection and use of Engineering Materials, First
Edition.Butterworth & Co

ISBN 0-408-10859-2

John m. West Basic Corrosion and Oxidation Second Edition Ellis Horwood Limited

ISNB 0-7458-0050-5

Videos
V1 Av620.11260PE Open University-Course T351/05 Measuring Fracture Toughness
V2 Av620.11260PE Open University-Course T353/01 Last of the Liberties
V3 Av620.11260PE Open University-Course T351/08 Fatigue
V4 Av620.11260PE Open University-Course T353/04 Foretelling Fatigue Life
V5 AV 620.11OPE Open University-Course T353/03 Living with Cracks
V6 AV 620.11260PE Open University-Course T353/07 Something in the Air
V7 Seeing is believing: basic ultrasonics /produced by the Ministry of Defence 1987
V8 AV 620.1126 OPE Sure Offshore Parts 1 & 2 (NDT, welding, offshore drilling platform.)
V9 AV 620.11OPE Magnus- a suitable case for treatment (Corrosion Protection Offshore )
V10 AV 620 1126OPE Made without Flaws? (Welding and Testing of High Pressure
Vessels)
Papers
P1 KJ Miller Twenty-seventh John Player Lecture Metal fatigue-past, current and future.
Proceedings of the Institution of Mechanical Engineers , March 1991
P3 G.A.Raine The changing face of inspection of oil and gas offshore installations, INSIGHT
Vol 40 No 6 June 1998
P4 NDT Technology in Aerospace, Digest No 1990/010, 620 112.7 COL
P5 New techniques for manual and automated Offshore NDT, Digest No 1994/240, 620 112.7
COL
P6 Non Contacting and remote NDT Digest No 1992/200, 620 112.7 COL