The course enfolds the relationships between metallic materials, their properties, processingtechnologies as well as fields of application. Because of the ever-increasing loadsand demands for resource efficiency, the optimization of material propertiesthrough the tailored processing as well as the targeted sequence of processingsteps for the manufacturing of the final part are becoming more important thanever. In terms of selecting of an appropriate material for a targetedapplication, the necessary and appropriate manufacturing technologies have tobe taking into consideration. In order to reflect the effects of manufacturingmethods, students are imparted knowledge about metallic materials combined withprocessing technologies. Particular attention is also paid to loading cases aswell as damage mechanisms of the materials used in industrial applications.Furthermore, the possible methods for life extension are analysed anddiscussed. The aim of the course is to make students aware to perform a correctselection of appropriate materials with technological processes for potentialapplications 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 energystructures, power plants structures as well as in automotive componentsincluding transmissions, bearings, engines etc. Classification of the usedmaterials into groups depending on their application requirements.
Lecture 2: Fundamentalaspects of Fe-C-alloys. Mechanical properties, material classes (austenitic andferritic steels, cast iron etc.), Fe-C phase diagram. Fundamental aspects ofheat treatment for Fe-base materials. Discussion of specific alloys and theirtypical applications.
Lecture 3: Fundamentalsof Fe-base materials processing for fabrication of components. From rawmaterial to the component. Typical fabrication routes: casting, forging,machining. Fundamentals of common manufacturing technologies. Cold forming andforging of steels. Fundamentals of formability and materials strengtheningmechanisms, typical alloys and applications (e.g. TRIP steels).
Lecture 4:Fundamental aspects of Al-alloys and their base processing technologies forfabrication of components. Fundamental aspects of Mg-alloys and their baseprocessing technologies for fabrication of components.
Lecture 5: Fundamentalaspects of Ti-alloys and their base processing technologies for fabrication ofcomponents. Intermetallic alloys and metallic glasses: properties, applicationsand fundamental aspects of production and processing.
Lecture 6: Cu-basealloys: classes of alloys, their typical applications and fundamental aspectsof processing; examples for components. Ni- und Co-base alloys: classes ofalloys, their properties and typical applications. Fundamental aspects ofprocessing and manufacturing of components.
Lecture 7: Fatigueand 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: Degradationand failure of materials and components in service. Stress corrosion crackingand corrosion fatigue of metallic materials.
Lecture 9: Surfaceengineering: coatings. Functional coatings for wear and corrosion protection,as well as decorative purposes. Electrochemical and physical coatingdeposition, deposit welding and thermal spraying.
Lecture 10:Surface engineering: modifications. Metallurgical surface modifications(nitriding, surface hardening ect.) and (thermo-)mechanical methods (shotpeening, laser shock peening, rolling, friction stir processing ect.).
