The course enfolds the relationships between metallic materials, their properties, processing technologies as well as fields of application. Because of the ever-increasing loads and demands for resource efficiency, the optimization of material properties through the tailored processing as well as the targeted sequence of processing steps for the manufacturing of the final part are becoming more important than ever. In terms of selecting of an appropriate material for a targeted application, the necessary and appropriate manufacturing technologies have to be taking into consideration. In order to reflect the effects of manufacturing methods, students are imparted knowledge about metallic materials combined with processing technologies. Particular attention is also paid to loading cases as well as damage mechanisms of the materials used in industrial applications. Furthermore, the possible methods for life extension are analysed and discussed. The aim of the course is to make students aware to perform a correct selection of appropriate materials with technological processes for potential applications taking into consideration the different kinds of stress (fatigue, creep, corrosion etc.).
Lecture 1: Introduction. Requirements to structural metallic materials depending on their application. Typical examples for material usage in automotive, airplane and wind energy structures, power plants structures as well as in automotive components including transmissions, bearings, engines etc. Classification of the used materials into groups depending on their application requirements.
Lecture 2: Fundamental aspects of Fe-C-alloys. Mechanical properties, material classes (austenitic and ferritic steels, cast iron etc.), Fe-C phase diagram. Fundamental aspects of heat treatment for Fe-base materials. Discussion of specific alloys and their typical applications.
Lecture 3: Fundamentals of Fe-base materials processing for fabrication of components. From raw material to the component. Typical fabrication routes: casting, forging, machining. Fundamentals of common manufacturing technologies. Cold forming and forging of steels. Fundamentals of formability and materials strengthening mechanisms, typical alloys and applications (e.g. TRIP steels).
Lecture 4: Fundamental aspects of Al-alloys and their base processing technologies for fabrication of components. Fundamental aspects of Mg-alloys and their base processing technologies for fabrication of components.
Lecture 5: Fundamental aspects of Ti-alloys and their base processing technologies for fabrication of components. Intermetallic alloys and metallic glasses: properties, applications and fundamental aspects of production and processing.
Lecture 6: Cu-base alloys: classes of alloys, their typical applications and fundamental aspects of processing; examples for components. Ni- und Co-base alloys: classes of alloys, their properties and typical applications. Fundamental aspects of processing and manufacturing of components.
Lecture 7: Fatigue and fracture of metallic materials. Fundamental aspects of fatigue loading (stress amplitudes, mean stress, high- and low cycle fatigue). Notch effects, crack initiation and propagation. Damage tolerance assessment.
Lecture 8: Degradation and failure of materials and components in service. Stress corrosion cracking and corrosion fatigue of metallic materials.
Lecture 9: Surface engineering: coatings. Functional coatings for wear and corrosion protection, as well as decorative purposes. Electrochemical and physical coating deposition, deposit welding and thermal spraying.
Lecture 10: Surface engineering: modifications. Metallurgical surface modifications (nitriding, surface hardening ect.) and (thermo-)mechanical methods (shot peening, laser shock peening, rolling, friction stir processing ect.).
1. George Krauss, Steels: Processing, Structure, and Performance, 978-0-87170-817-5, 2006.
2. Hans Berns, Werner Theisen, Ferrous Materials: Steel and Cast Iron, 2008. http://dx.doi.org/10.1007/978-3-540-71848-2
3. Bruno C., De Cooman / John G. Speer: Fundamentals of Steel Product Physical Metallurgy, 2011, 642 S.
4. Harry Chandler, Steel Metallurgy for the Non-Metallurgist 0-87170-652-0, 2006, 84 S.
5. Catrin Kammer, Aluminium Taschenbuch 1, Grundlagen und Werkstoffe, Beuth,16. Auflage 2009. 784 S., ISBN 978-3-410-22028-2
6. Günter Drossel, Susanne Friedrich, Catrin Kammer und Wolfgang Lehnert, Aluminium Taschenbuch 2, Umformung von Aluminium-Werkstoffen, Gießen von Aluminiumteilen, Oberflächenbehandlung von Aluminium, Recycling und Ökologie, Beuth, 16. Auflage 2009. 768 S., ISBN 978-3-410-22029-9
7. Catrin Kammer, Aluminium Taschenbuch 3, Weiterverarbeitung und Anwendung, Beuith,17. Auflage 2014. 892 S., ISBN 978-3-410-22311-5
8. Lütjering, J.C. Williams: Titanium, 2nd ed., Springer, Berlin, Heidelberg, 2007, ISBN 978-3-540-71397
9. Magnesium - Alloys and Technologies, K. U. Kainer (Hrsg.), Wiley-VCH, Weinheim 2003, ISBN 3-527-30570-x
10. Mihriban O. Pekguleryuz, Karl U. Kainer and Ali Kaya “Fundamentals of Magnesium Alloy Metallurgy”, Woodhead Publishing Ltd, 2013,ISBN 10: 0857090887