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Unit Name Design and Failure Analysis of Materials
Unit Code MME501A
Unit Duration 1 Term (online) or 1 Semester (on-campus)
Award

Graduate Diploma of Engineering (Mechanical)
Duration: 1 year


Master of Engineering (Mechanical)
Duration: 2 years  
Year Level One

Unit Coordinator

MME Course Coordinator

Dr Rumana Sultana 

Dr Milind Siddhpura
Common/Stream/Elective: Stream
Pre/Co-requisites Nil
Credit Points

3

Grad Dip total course credit points = 24
(3 credits x 8 (units))

Masters total course credit points = 48
(12 credits (Thesis) + 3 credits x 12 (units))
Mode of Delivery Online or on-campus. 
Unit Workload

10 hours per week:

Lecture – 1 hour

Tutorial – 1 hour

Practical / Lab – 1 hour (if applicable)

Personal Study recommended – 7 hours

Unit Description and General Aims

This unit covers failure analysis of engineering materials and design applications. The common strength criterion, the fracture toughness criterion and its design applications are emphasized. Metals, ceramics, composites, and their failure characteristics will be discussed and compared.

Students will gain an understanding of the fundamentals of fracture and fatigue of materials and structures for design and damage tolerance analysis and learn to apply this knowledge to control and prevent fracture and fatigue damage.

Students are expected to communicate effectively in writing, think and reason logically and creatively, and show competence in the topic by solving practical fracture/fatigue problems. The solutions to the problems must be presented in a logical and clear fashion. Students learn about environmental responsibilities and the need for sustainable development when searching for the solutions to industrial fracture/fatigue problems.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

  1. Judge common modes of fracture of engineering components
    • Bloom’s Level 5
  2. Evaluate the mechanisms governing various types of fracture of materials due to fatigue and cracking
    • Bloom’s Level 5
  3. Formulate plausible explanations to the underlying cause(s) of an identified problem of fracture due to fatigue and cracking problems
    • Bloom’s Level 6
  4. Determine various design equations against fatigue and cracking
    • Bloom’s Level 5
  5. Recommend a solution to rectify/prevent the identified damage of materials
    • Bloom’s Level 5
  6. Evaluate relevant material testing methods for design applications
    • Bloom’s Level 5

Student Assessment

Assessment Type 

When assessed 

Weighting (% of total unit marks)

Learning Outcomes Assessed

Assessment 1

Type: Weekly Quizzes

Description: Students will need to complete multiple-choice quiz questions to demonstrate a good understanding of the fundamental concepts.

Topics covered: 2-11

Weekly  

10%

1,2,3,4,5

Assessment 2 

Type: Test (Invigilated) 

Description: Short/Long answers and Problems to solve.

Topic: Up to topic 4

During Topic/Week 5 or 6

30%

1,2,3

Assessment 3

Type: Practical (Report) & Demonstration

Description: Simulations using software in Remote labs Or Case Study.

Topics covered: 1-7

After Topic 7

25%

1,2,3,4

Assessment 4

Type: Research (Report) & Presentation

Description: A complete report with sections on methodology, implementation / evaluation, verification / validation, conclusion / challenges, and recommendations / future work.

Word length: 3000, excluding diagrams and 

references.

Topics covered: All

Final Week

35%

1,2,3,4,5,6

 

Prescribed and Recommended readings

Required Textbook

  1.  T.L. Andeson., Fracture Mechanics Fundamentals and Application, 4th edition, 2017

Reference Materials

  1. Broek, D., The Practical Use of Fracture Mechanics, Kluwer Academic Publishers, 1989
  2. Dowling, N.E., Mechanical Behaviour of Materials: Engineering Methods for Deformation, Fracture, and Fatigue, 2nd Ed, Prentice Hall, 1999

Unit Content

One topic is delivered per contact week:

Topic 1 

Introduction

  1. Why structure fail
  2. History of Fracture Mechanics
  3. The fracture mechanics approach to design by energy criterion
  4. Design consideration by stress intensity approach 
  5. Design consideration by time dependent crack growth and damage tolerance

Topic 2 

Fundamental concepts

  1. Linear elastic fracture mechanics 
  2. Stress concentration effects of flaws
  3. The Griffith Energy balance
  4. Energy release rate
  5. Instability and the R curve

Topic 3 

Linear Elastic Fracture Mechanics I

  1. Stress at a crack tip
  2. General form of Stress intensity factor
  3. Fracture toughness
  4. Thickness dependence of toughness
  5. Measurement of fracture toughness
  6. ASTM standard
  7. K superposition principle
  8. Relation between k and G

Topic 4 

Linear Elastic Fracture Mechanics II

  1. Crack tip plasticity
  2. K controlled fracture
  3.  Plane strain fracture
  4. Critical Strain energy release rate
  5.  Elastic compliance of cracked structure

Topic 5

Elastic Plastic Fracture Mechanics

  1. Crack tip opening displacement
  2. J contour integral
  3. Crack growth resistance curve
  4. J controlled fracture

Topic 6

Fatigue Failure

  1. Stages of fatigue 
  2. Total life approaches 
  3. Fatigue crack propagation
  4. Factors influencing fatigue crack growth
  5. Plasticity effects on fatigue

Topic 7

Dynamic Fracture

  1. Stability and the R-curve
  2. Rapid crack propagation
  3. High strain rate initiation
  4. Creep and Viscoelastic crack growth

Topic 8

Fracture Mechanism in metals 

  1. Ductile fracture 
  2. Cleavage
  3. The Ductile-Brittle transition
  4. Intergranular fracture

Topic 9

Fracture mechanism in non-metals

  1. Yielding and fracture in polymers
  2. Ceramic and ceramic composites

Topic 10 

Environmentally Assisted cracking in metal

  1. Corrosion Principle
  2. Stress Corrosion Cracking (SCC)
  3. Hydrogen embrittlement
  4. Corrosion fatigue

Topic 11  

Experimental methods in fracture and fatigue

  1. Standard fracture specimens
  2. Test methods and testing standards
  3. Dynamic fracture testing
  4. Experimental methods to determine K

Topic 12  

Recent Trends and Unit Review

  1. Recent trends and future scopes
  2. Unit review

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

Stage 1 Competencies and Elements Competency
1. Knowledge and Skill Base
1.1 Comprehensive, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline.
1.2 Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline.
1.3 In-depth understanding of specialist bodies of knowledge within the engineering discipline.
1.4 Discernment of knowledge development and research directions within the engineering discipline.
1.5 Knowledge of engineering design practice and contextual factors impacting the engineering discipline.
1.6 Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline.
2. Engineering Application Ability
2.1 Application of established engineering methods to complex engineering problem solving.
2.2 Fluent application of engineering techniques, tools and resources.
2.3 Application of systematic engineering synthesis and design processes.
2.4 Application of systematic approaches to the conduct and management of engineering projects.
3. Professional and Personal Attributes
3.1 Ethical conduct and professional accountability.
3.2 Effective oral and written communication in professional and lay domains.
3.3 Creative, innovative and pro-active demeanor.
3.4 Professional use and management of information.
3.5 Orderly management of self and professional conduct.
3.6 Effective team membership and team leadership.

Software/Hardware Used

Software: ANSYS Mechanical

Software Information: ANSYS Mechanical is a powerful FEA software used for structural, thermal, and acoustic simulations, helping engineers solve complex problems and make better design decisions. It reduces the need for physical prototypes, saving time and money, and provides precise simulations for reliable results. Essential for optimizing designs and ensuring safety, it supports a wide range of analyses, from structural to thermal and vibration studies. 

Hardware: N/A

Unit Changes Based on Student Feedback: N/A

Unit Changes Based on Student Feedback