Surface Engineering

Learning Outcomes

Learning Outcomes

Having successfully completed this module you will be able to:

• C1/M1 The students apply engineering principles based on mathematics to solve complex problems related to contact conditions (pressure, deformation) and corrosion. C2 At least 25% of exam is devoted to complex solutions combining knowledge of two or more relatively distant fields, such as coating technology and contact mechanics. Their solutions combines math principles and engineering principles. C15/M15 The assessment require deep knowledge of engineering management principles and commercial context. For example, it checks whether students can distinguish between optimum technical solution and solution supporting sustainable goals being commercially viable (typically asking about coating selection for a specific application).

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

• Pros and cons of different approaches in surface engineering.
• Fundamental coating properties and their relationship.
• Principles of coating deposition methods
• Introduction to corrosion and corrosion protection.
• Fundamentals of tribology and related contact mechanics.

Transferable and Generic Skills

Having successfully completed this module you will be able to:

• Think, observe, communicate, evaluate information and data, analyse and solve problems

Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

• Compare different coating technologies from various perspectives.
• Write an essay on a technical topic.
• Search and critically review technical literature.
• Analyse advantages and limitations of surface engineering methods

Subject Specific Practical Skills

Having successfully completed this module you will be able to:

• Possess the basic skills to work in surface engineering and related industry or the government.

In this module, the emphasis will be on the performance of surface engineered materials and matching these to service conditions. Topics to be covered will include:

• Tribologically induced stress, Hertz, dynamic Hertz, residual stresses, etc.
• Stress field and wear interactions.
• Measurement of surface / coating properties.
• Wear mechanisms, including lubricated wear, wear-corrosion and erosion.

Surface engineering processes.

(1) Erosion resistant coatings deposited by Chemical Vapour Deposition, Physical Vapour Deposition, High Velocity Oxy-Fuel (thermal spray), and weld overlay.

(2) Plating and nano-composite coatings/surfaces.

(3) Corrosion resistant surfaces/high temperature.

(4) Surface modification: induction hardening, ion- implantation, carburising, carbo-nitriding, nitriding and nitro-carburising.

The lectures will draw on examples from applications within the marine, oil and gas, power generation, aerospace and biomedical sectors. Emphasis will be placed on gaining sustainability through correct surface engineering technology. Engineering assessment of each failure problem is described and the associated micromechanical failure modes. The economics of surface selection

will be discussed for various examples, e.g. machine tool coatings, thermal barrier coatings and hard chromium replacement for aerospace.

The teaching methods to be employed in the delivery of this module include:

• 36 lectures (three 45 minute sessions per week) which develop the themes described in this module. Skeleton notes are given out at the start of the course, which means you only have to note down the key points during the lecture, but still have a full set of notes to work from. These will also be made available on Blackboard.
• Additional research review papers are provided to give an overview of the themes of the course.
• Formative online quizzes on Blackboard.
• Solutions to assigned problems
• Demonstrations and video materials where and when appropriate.

The learning activities include:

• Individual reading of background materials and course texts, plus work on examples.
• Example sheets and solutions.

Summative

This is how we’ll formally assess what you have learned in this module.

Referral

This is how we’ll assess you if you don’t meet the criteria to pass this module.

Repeat

An internal repeat is where you take all of your modules again, including any you passed. An external repeat is where you only re-take the modules you failed.