Coursework Structural Integrity 2023-24

ENGP5202 - Structural Integrity
Faculty of Computing, Engineering and Media
Mechanical and Aeronautical Engineering MSc Programme
Module name: Advanced Materials, Structures and Design

Module code: ENGP5202
Title of the Assignment: Structural Integrity
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:
 Utilize stress analysis and consider the mechanical properties of materials,
as well as operational and environmental factors, to diagnose failure modes
through both theoretical and experimental analysis. Subsequently, formulate
strategies to prevent these failures and ensure the attainment of sustainable
structural integrity: M2, M5, M7, M9 and M12
 Diagnose the type of failure based on the service history, manufacturing
processes, fractography and experimental analysis: SM9M, EA6M, EL12M,
EL13M, P12, G3, G4
Assignment: Coursework and Exam
This coursework is: (delete as Individual Group

appropriate)
If other or a mixed ... explain here:
This coursework constitutes 35% of the Assignment Part of the module mark.
Date Set: 20 November 2023
Date & Time Due: 24 January 2024
The ‘normal’ coursework return date for this work Up to 14 working days after
is: submission
When completed you are required to submit your coursework to:
ENGP5202, via Turnitin link within the Module LearningZone
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 authorisation and have the work capped at 50% if passed
is 14 calendar days. Work submitted unauthorised 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
authorisation which constitutes reassessment of a previously failed piece of
coursework will always receive a mark of 0%.”
Page 1 of 7
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:
https://www.dmu.ac.uk/current-students/student-support/academic-support/
academic-integrity.aspx
Tasks to be undertaken: See coursework descriptions below

Deliverables to be submitted for assessment: See coursework descriptions
below
How the work will be marked:
DMU Mark Descriptors
https://www.dmu.ac.uk/documents/about-dmu-documents/quality-management-
and-policy/academicquality/learning-teaching-assessment/ug-mark-
descriptors.pdf
The Lecturer:
Dr Fuad Khoshnaw,
Contact details:
Office QB 1.15g
E: [email protected]
This assessment Weightings 35% of the Assignment Part of the Module

Type of assessment Component Date Set Date Due Date
Marks Return
Complete all the 100% Week 9 Week 17 Week 19
questions and exercises Friday, 26
with the required graphs, January 2024
tables, calculations, and
appendices.
Part One:
Design Approaches and
Case Studies
Q1: Design 10 M
Q2: Case Studies
Case Study One 20 M
Case Study Two 20 M
Part Two: Theoretical

Calculations
Q4: 25 M
Q5: 25 M
Total 100%
Page 2 of 7
Remarks: All works are individuals, summative and not anonymously

marked.
Lecture sessions and seminars
The Structural Integrity assignment will be supported by 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 prioritize safety, reliability,
economy, and sustainability demands efficient material utilization and the assurance
of structural integrity. Hence, this module is well-suited for postgraduate students
seeking to delve into the mechanical behavior of materials, particularly in areas such
as fracture, fatigue, creep, and corrosion, all while emphasizing sustainability
principles. The Structural Integrity assignment represents one of three tasks within
the "Advanced Materials, Structures, and Design" module, encompassing topics
such as material types and their properties, various failure modes in materials,
stress-based fatigue analysis, innovative fracture mechanics approaches,
considerations for creep, and corrosion resistance, all within the context of
sustainable engineering.
Structural Integrity
Coursework
Note:
The coursework needs to be submitted in one Word file through Turnitin link on the
LearningZone.
Part One: Design Approaches and Case Studies

Q1:
Imagine yourself as a materials engineer in a small yet well-equipped research
laboratory. You have access to a range of metallic alloys, an electric oven with the
remarkable capacity to reach temperatures of up to 2000°C, various cooling
solutions, and an array of advanced testing machines and equipment for tensile,
hardness, impact, and corrosion testing.
Your mission is to prepare an ideal material using precise heat treatment techniques
to make a sustainable oil well drilling tool. This scenario requires not only outlining
each step of the process but also providing comprehensive reasons for the selection
of each step and the specific heat treatment involved.
Maximum 300 Words 10 M
Page 3 of 7
Q2:
For the following two case studies, you are required to:
 Precautionary Steps: Justify initial precautions before investigating the drilling
tool failure, including the application of laboratory non-destructive tests.
 Microstructure and Fractography: Analyse the tool's microstructures /
fractography and explain their significance.
 Failure Diagnosis: Define the failure type, its root causes, and associated
challenges.
 Solutions: Propose remedies and how laboratory non-destructive tests can be
integrated for future quality control.
Case Study One: Failed Oil and Gas Well Drilling Tool
A martensitic microstructure of low alloy steel, AISI/SAE 4330V, was utilized as an
oil and gas well tubular drilling tool. The tool operated under severe torque
variations, resulting in multiple cracks at the external diameter and eventually
leading to its fracture. The drilling tool was already nearing the end of its operational
life.
Case Study Two: Lap Joint MIG-Welded Alloys in the Oil Industry
Two dissimilar metallic alloys, a mild steel plate, and a larger piece of austenitic
stainless steel, were joined together in a lap joint using 308 AISI filler metal. This
assembly was subjected to service in an oil industry environment for one year,
where it encountered issues related to pitting and cracking.
Page 4 of 7
Part Two: Theoretical Calculations

Q3: Fatigue Life Estimation
A simply supported rotating shaft, loaded by a force 2.5 kN, made by machining from
a low alloys steel with σu = 700 MPa, and σy = 500 MPa. Analyse the shaft and
conclude some useful results. Estimate and comment on the life of the shaft.
2.5kN
All dimensions in mm
25M
Q4: Fracture Toughness
Crack length versus cycle data is given in the table below from a test on a edge-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.
o Obtain the da/dN and K values.

o Illustrate the Kth and KiC values on a sketched diagram.
Page 5 of 7
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 5.04 0
2 7.60 18300
3 10.25 28300
4 12.00 35000
5 15.50 40000
6 17.75 43000
7 20.30 47000
8 22.80 50000
9 25.50 52000
10 30.50 57000
11 35.75 59000
12 40.50 61000
13 45.75 62000
25M
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.
Page 6 of 7
Recommended Reading list:
1. Jorge Luis González-Velázquez, Mechanical Behaviour and Fracture of Engineering

Materials.
2. Kannadi Balan, Metallurgical Failure Analysis.
3. J. Rösler, Mechanical Behaviour of Engineering Materials.
4. Norman Dowling, Mechanical Behavior of Materials.
5. Richard W. Hertzberg, Deformation and Fracture Mechanics of Engineering

Materials.
6. Fontana and Green, Corrosion Engineering.
7. Fuad Khoshnaw, Introduction to Welding Metallic Materials, Elsevier, 2022
8. Fuad Khoshnaw, Corrosion Atlas Case Studies, Elsevier, 2021.
9. Serope Kalpakjian, Manufacturing Processes for Engineering Materials.
10. John C. Lippold, Welding Matellurgy and Weldbility, 2015, Wiley.
Page 7 of 7

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ENGP5202 - Structural Integrity

Faculty of Computing, Engineering and Media

Mechanical and Aeronautical Engineering MSc Programme

Module name: Advanced Materials, Structures and Design

Assignment: Coursework and Exam

This coursework is: (delete as Individual Group

Late submission of coursework policy:

Academic Offences and Bad Academic Practices:

Tasks to be undertaken: See coursework descriptions below

This assessment Weightings 35% of the Assignment Part of the Module

Part Two: Theoretical

Remarks: All works are individuals, summative and not anonymously

Lecture sessions and seminars

The Structural Integrity assignment will be supported by lectures, and seminars, as

Part One: Design Approaches and Case Studies

Part Two: Theoretical Calculations

o Obtain the da/dN and K values.

o Discuss the methods to increase the life of the component.

Guidelines for writing in general: 5Cs – Clear, Concise, Complete, technically

Recommended Reading list:

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

2. Kannadi Balan, Metallurgical Failure Analysis.

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

4. Norman Dowling, Mechanical Behavior of Materials.

5. Richard W. Hertzberg, Deformation and Fracture Mechanics of Engineering

6. Fontana and Green, Corrosion Engineering.

7. Fuad Khoshnaw, Introduction to Welding Metallic Materials, Elsevier, 2022

8. Fuad Khoshnaw, Corrosion Atlas Case Studies, Elsevier, 2021.

9. Serope Kalpakjian, Manufacturing Processes for Engineering Materials.

10. John C. Lippold, Welding Matellurgy and Weldbility, 2015, Wiley.

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