School of Technology

High Temperature Materials 2009 1

Programme Title(s): BEng (Hons) Mechanical Engineering

BEng (Hons) Manufacturing Engineering BSc (Hons) Motorsport Technology

Programme Code: H300, J901, H334 Module Title: High Temperature Materials and Applications Module Code: 6ME012 Module Leader: J Robertson-Begg Lecturer: J Robertson-Begg Assignment Title: Materials Selection Weighting 50% Issue Date: w/c 2nd November 2009 Hand-in Date: 15th March 2010

School of Technology

High Temperature Materials 2009 2

Introduction This assignment is based on a materials selection case study. Learning Outcomes On successful completion of the assignment, the student should be able to:- 1 Apply advanced materials concepts to specific components in case studies. The Brief The component shown below is part of a land-based gas turbine. It is made from Hastelloy X material by a fabrication and welding process. The component measures approximately 0.75 m in diameter, is of complex shape and has wall thicknesses of 10mm. Its depth is 200mm. The component has been in service for 10 years and needs to be replaced. Your boss, the chief engineer is implementing a cost cutting exercise and thinks this component could be made much cheaper by changing both the material and the way it is manufactured. You have been given the task of finding an alternative material and manufacturing process. The company labels itself as green and likes to advertise this fact to share holders. Your boss also needs you to carry out an eco-audit of the new component in comparison with the old component.

The component needs to operate at temperatures up to 800oC, have exceptional thermal shock resistance, be corrosion resistant, and be capable of being manufactured by casting. The demand for the product is likely to be 50 over a 5 year refurbishment project. The material cost must be at least half the price of the current alloy, and preferably cheaper still. There must also be significant savings in manufacturing cost. Your task is to use Cambridge Engineering Selector to select suitable candidate materials for the part. You must then use CES to specify the manufacturing process and produce some realistic component costings. The original part did not require coatings but it may be that in order to achieve the heat and corrosion resistance the redesigned part may require them. Other data is listed below: Minimum Tensile Strength 300MPa Has to operate above 550 oC Maximum thermal expansion 15 μstrain/ oC Minimum Yield Strength 300MPa

School of Technology

High Temperature Materials 2009 3

Corrosion resistance – no lower than acceptable (CES classification) You must also carry out an eco audit on the existing material and your chosen new material using the facility in CES. Reading Materials Module lecture and supporting notes. Internet websites i.e GrantaDesign. Ashby – Materials Selection in Mechanical Design Submission Requirements An A4 document in the form of a technical report which contains your selection methodology using appropriate graphs or tables. A high level of critical analysis and reflection is expected at this level. Your report and should be 2000 words. A CD containing your CES files and your report is required. Turnitin software will be used to check for plagiarism. Submission Date See front sheet. The assignment must be handed in to the Student Information and Support services at Markeaton Street on or before the date of submission. Marks Allocation Report 40% Use of CES 40% Eco Audit 20% Assessment Criteria University of Derby UG Regulatory Assessment criteria will be used. All grades given for assignment work are provisional until confirmed by the examination/assessment board. Performance Criteria For a First (A+ to A-) you will have demonstrated advanced critical and reflective understanding of materials selection and processing requirements, and have made extensive use of CES. For a 2.1 Pass (B+ to B-) you will have demonstrated a competent critical and reflective understanding of materials selection and processing requirements. For a 2.2 Pass (C+ to C-) you will have demonstrated a reasonably competent critical and reflective understanding of materials selection and processing requirements. For a 3 Pass (D+ to D-) you will have demonstrated a limited critical and reflective understanding of materials selection and processing requirements. To FAIL (FM to Z) you will clearly not have understood the brief and may not have engaged with one or more aspects of the work e.g. use of CES.