The course provides a basic understanding of the relationship between the microstructure and the mechanical properties of metals. It will build on certain aspects of mechanical performance introduced in EG-180 (Introduction to Materials Engineering) and provide a reference point for supplementary modules in Years 2 and 3.
The course provides a basic understanding of the relationship between the microstructure and the mechanical properties of metals. It will build on certain aspects of mechanical performance introduced in EG-180 (Introduction to Materials Engineering) and provide a reference point for supplementary modules in later years of the study. Module Aims: to introduce the underlying principles of the mechanical properties of engineering materials.
Following on from the first year module "Mechanical Properties" this module provides further detail about the deformation characteristics of a wide range of engineering materials. The course aims to develop the understanding of topics taught in the first year module by application to high performance materials such as titanium and nickel. Further understanding of deformation and damage mechanisms is gained through targeted units on elasticity, plasticity, alloy strengthening, mechanics of materials, fatigue and creep. The knowledge provided then allows for topics such as methods of mechanical testing and additive layer manufacturing. The module then seeks to draw these topics together by considering application to three main material classes, metals, ceramics and composites.
The course aims to provide a basic understanding of propulsion systems in order to contribute to graduating students obtaining a holistic understanding of the aerospace sector. The course includes: ¿ Propulsion unit requirements for subsonic and supersonic flight ¿ Piston engine components and operation ¿ Propeller theory ¿ Gas turbine engines: operation, components and cycle analysis ¿ Thermodynamics of high speed gas flow ¿ Efficiency of components ¿ Rocket motors: operation, components and design ¿ Dynamics of rocket flight ¿ Environmental issues
The fatigue process can be simplified into two main stages; the initiation of a crack through cyclic "damage" followed by the growth of that crack to some critical size to instigate an overload failure. This module will focus on the strain based failure criteria and the use of mathematical methods for correlating total fatigue data. Theoretical approaches to strain based lifing will be complemented by industrial case studies.
Each candidate will prepare a detailed project plan covering background to the research, the scheduling of practical and other work, and milestone deliverables. This plan will be produced following: (i) attendance at specialist lectures covering issues of good practice in the conduct of research eg safety, procedures for laboratory work and data reporting/analysis; (ii) discussion with academic and industrial supervisors regarding technical/commercial issues associated with the specific topic; (iii) a review of the formal course units covering technical issues, personal and professional development and research skills. The overall report must demonstrate that each student relates relevant aspects of the training courses to their industry oriented research project. Not available to visiting or exchange students.
Damage tolerant design is the prevention of failure in engineering structures containing cracks or defects. The module applies these design techniques, based on Linear Elastic Fracture Mechanics (LEFM), to structures and components in gas turbine engines. It covers the stress conditions in the components, the derivation of LEFM principles and their application to both static and cyclic loading states. Under cyclic fatigue conditions, subsequent to crack initiation, a crack will grow in a structural metal on a cycle by cycle basis until it reaches a critical size that leads to an overload failure in the final cycle. Linear elastic fracture mechanics (LEFM) based techniques are now a popular tool used by the lifing engineer to predict the behaviour of fatigue cracks and ultimately a safe life for an engineering component. These "damage tolerant" techniques will be reviewed in this module. The module is reinforced by a detailed, computer based case study.
The module defines low and high temperature creep in metallic and ceramic based materials. Deformation mechanisms and bulk measurements are described as a basis for predictions of mechanical component behaviour.
This module, a combination of interactive seminars and computer based exercises, will provide engineering students with a detailed appreciation of financial investment for the technical environment. It will highlight the role of the individual and management during financial decision making procedures and associated risk assessment. Case studies of large scale investments in the aerospace industry will be employed throughout the course.
The module aims to give a complete understanding of the main aspects of gas turbine design. It is ¿holistic¿ in its emphasis on the links between performance aerodynamics, mechanics and the associated materials selection. These design criteria will be applied to the case study of a simple turbofan or intercooled/recuperated marine/industrial engine, using only hand calculations on paper (i.e. without the aid of a computer) and working in small teams.
Titanium alloys are viewed as the archetypical aerospace materials. Developed extensively during the 1950s, they offered significant weight saving opportunities to aero-engine designers who had previously relied on relatively dense steels for the critical static and rotating components within the fan and compressor stages of the gas turbine. This module will review their historical development, current processing techniques (spanning ore extraction, sponge production, melting, casting and forming) and service applications. Failure investigations relating to open literature case studies will be discussed.
This module introduces the concepts and practice of probability and statistics. Topics include: descriptive statistics, exploratory data analysis, the concept of uncertainty, probability theory, discrete and continuous probability models, inferential statistics, point and interval estimation, tests of statistical hypotheses, confidence intervals, correlation and regression.
A series of masterclasses run over five days of 2-3 hours each followed by interactive sessions or examples classes in the afternoon.
This course aims to give an understanding of the role of crystal defects (dislocations, stacking faults and cracks) on in determining the plasticity and toughness of ultra-high temperature materials and alloys over a wide range of temperature. The approach is to understand the underlying principles involved and to demonstrate these with exercises and specific examples.
This course aims to give a broad knowledge of the physical metallurgy of Nickel-based superalloys, their uses virtues and limitations. Emphasis will be put on understanding the general principles of the alloying strategies used in the various families of alloys and rationalising the physics and chemistry of the resulting compositions to the properties obtained. Teaching will be by interactive lectures and supervised exercises in the afternoons including the use of Thermocalc to investigate phase equilibria. This will include an exercise to design a superalloy.
A wide range of nanostructures is available for ferrous alloys. When the surface to volume ratio of the nanostructure increases, interesting interactions between defects in the crystal structure such as dislocations, vacancies and interstitial atoms occur. These allow for the combination of extraordinary properties, such as tensile strength and ductility exceeding 2.5 GPa and 10%. However, phase stability and low cost heat treatments become a challenge, especially for high temperature applications. Strong emphasis is placed on developing computational skills aiding in conceiving the new emerging families of nanostructured steels.
|Start Date||End Date||Position Held||Location|
|2012||Present||Senior Lecturer||Materials Research Centre, Swansea University|
|2007||Present||RCUK Fellow||Materials Research Centre, Swansea University|
|2003||2007||Research Officer||Materials Research Centre, Swansea University|
|2004||“Texture, microstructure and mechanical properties in Ti6-4”, Ti 2003 Science & Technology 3, pp 1759-1766|
|2006||“Prediction of LCF initiation lives in DEN specimens based on strain control testing of plain Ti6246 specimens”|
|2006||“Prediction of notched specimen behaviour in textured Ti-6Al-4V”, 9th International Fatigue Congress, Atlanta|
|2007||“Torsion fatigue in near alpha and alpha titanium alloys”, 11th International titanium conference, Kyoto|
|2007||“Effect of prestrain on ambient and high temperature creep in Ti834”, 11th International titanium conference, Kyoto|
|2008||“Characterisation of stress concentration features in the + titanium alloys” 11th Portuguese conference on fracture|
|2009||“Time Dependent Fracture of Titanium Alloys” 12th International Conference on Fracture, Ottawa, Ontario, Canada|
|2009||“Fracture mechanisms due to Fatigue, Creep and Environmental damage in titanium alloys” 12th International Conf. on Fracture|
|2009||“Creep fracture of centrifugally-cast HK40 tube steel”, ECCC creep conference, Zurich|
|2011||“Fatigue life variation due to microstructure in Ti6-4” 12th World conference on Titanium, Beijing|
|2012||“The Wilshire Equations for Long-Term Creep Life Prediction”, Creep 2012|
|2012||“High Temperature Creep Behaviour of Gamma Titanium Aluminides (-TiAl)” Creep 2012|
2011 - Present
2012 - Present
|2007||Awarded Chartered Physicist Status|
|2007||Awarded RCUK Research Fellowship|
Within the gas turbine engine, the high transient thermal stresses resulting from throttle movement from idle to high settings give rise to the phenomenon of thermo-mechanical fatigue (TMF). These effects have been widely explored for turbine blade materials, typically single crystal nickel alloys. More recently however, a combination of thinner disc rims and further increases in turbine entry temperature has lead to a situation where TMF in disc materials cannot be ignored. Turbine discs will usually be manufactured from polycrystalline nickel alloys, and as such it is now considered critical that TMF effects in this system of alloys is fully characterised. Research within the Institute of Structural Materials in collaboration with Roll-Royce plc leads the way in the development of modelling approaches to TMF through a range of cutting edge experimental techniques.
Modern creep lifing approaches
Traditional creep lifing techniques based on power law equations have shown themselves to be extremely limited, particularly in the prediction of long term data based only on short term experimental data. More recently, alternative approaches such as the Wilshire equations and hyperbolic tangent methods have been proposed which offer a new insight into the field. Ongoing research within the Institute of Structural Materials focuses on the development of the Wilshire equations in particular, their relationship with microscopic behaviour of engineering alloys and their application to a range of materials that currently includes copper, aluminium alloys, steels, titanium alloys, nickel superalloys and titanium aluminides.
Premature failure of titanium based engineering components in the 1970s brought to attention the phenomenon of dwell effects at low temperatures in these alloys, loosely termed ‘cold creep’, which are currently still a major concern for designers. Ongoing research at the Institute of Structural Materials seeks to address the issue through targeted mechanical testing and microscopic evaluation. The presence, extent and effect on mechanical properties of cold dwell related features such as ‘quasi-cleavage’ facets are investigated with the resultant effect on both creep and fatigue life also studied.
Measures of Esteem