Learning outcomes:
Structure and properties of materials:
After successfully completing this module, students be familiar with the basics of the mechanical properties of metallic materials (elastic behavior, plastic behavior, fracture behavior).: Students will be familiar with the principles behind strength hypotheses and yield conditions, understand the relationships between multiaxial stress states, equivalent stress and dislocation mobility, and be aware of the risks of stress embrittlement and brittle fracture, including in conjunction with notches. They will be able to describe the deformation behavior of metallic materials and will be familiar with the significance of material parameters. They will be able to work with stress-strain diagrams and determine the material parameters from them. Based on the deformation mechanisms at high temperatures and the additional processes that take place at these temperatures, such as recovery, recrystallization and grain coarsening, students will be able to derive relationships between material properties (yield stress, stacking fault energy), manufacturing parameters (temperature, degree of deformation, deformation rate) and product properties (grain size distribution, material characteristics). In addition, they will be able to identify the mechanisms that lead to creep and creep fracture at high temperatures. Furthermore, they will understand strengthening mechanisms (solid solution hardening, precipitation hardening, dispersion hardening, grain refinement, cold working and texture), know their advantages and disadvantages as well as the interactions between them, and know how to use them to produce high-strength materials. Students will be familiar with how cracks form and spread, and the causes of the various types of fracture. They will understand the meaning of fracture work and transition temperature and be familiar with their dependence on metallic lattice structure and temperature, as well as on chemical composition, grain size and strain rate. They will be able to describe the effects of a vibratory load on materials, evaluate fatigue fracture surfaces and work with the Wöhler curve.
Students will understand the basics of heat treatment on age-hardenable Al alloys and the modification of Si-containing Al casting alloys. Furthermore, they will be familiar with the effects of alloying elements in Al alloys and will be able to draw conclusions about processing and usage properties based on chemical composition. In addition, they will understand the alloying concepts of the Al materials commonly used in mechanical engineering and be able to describe and select materials based on their composition, structure and properties.
Students will be able to work with the iron-carbon diagram (metastable) and describe the structure of steels. They will understand the basics of heat treatment (tempering unalloyed and low-alloy steels) and know its effects on structure and properties. Furthermore, they are familiar with the mode of action of alloying elements and can draw conclusions about the processing and usage properties of low- and high-alloy steels based on Fe-Ni, Fe-Cr and Fe-Cr-Ni based on chemical composition. Students will understand the alloying concepts of steels commonly used in mechanical engineering, such as construction, tempering, case-hardening, spring, dual-phase, deep-drawing and AFP steels, as well as steels for screw connections.
Introduction to Manufacturing Engineering:
After successfully completing this module, students will be able to classify manufacturing technologies in the context of production technology, know their interfaces to product development, design technology, materials technology and quality management and will be familiar with the basics of manufacturing accuracy. They will be able to take a holistic view of complex and interconnected manufacturing chains for the production of mechanical engineering products and will be familiar with the manufacturing processes for primary forms (in particular continuous casting, sand casting, gravity and low-pressure die casting, pressure die casting, centrifugal casting), forming (esp. rolling, compressing, extruding, deep drawing) and cutting (esp. turning, drilling, countersinking, reaming, milling, broaching, grinding) in terms of how they work and how they are used. They will be able to select suitable processes and identify and establish their main manufacturing parameters.
“Fertigungs- und Werkstofftechnik” (Manufacturing and Materials Technology) Lab:
Students will be able to apply selected methods of destructive material testing and metallography under supervision and evaluate the results independently. In the “Machining Technology” lab, students will become familiar with the different machinability of metallic materials and determine the most important production parameters for the “turning” and “milling” processes.
The Manufacturing and Materials Technology module will expand and strengthen students’ knowledge and understanding of the subject and their ability to apply it.
[updated 08.04.2025]
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Module content:
Structure and properties of materials:
• Mechanical properties of metallic materials
o Elastic behavior - introduction: force-distance curve between atoms, normal stresses, strains, Poisson´s ratio, shear stresses, slips, law of elasticity, energy-elastic deformations
o Elastic behavior - introduction: Deformation mechanism, ductility as a function of the crystal lattice type, influence of the state of stress on dislocation movement, strength hypotheses/yield conditions, notch effect, dislocation movement and reactions
o Deformation behavior - introduction: Tensile test, stress-strain diagram with continuous flow beginning and with pronounced yield point, material characteristics, Lüders strain, strain aging, Bauschinger effect, true stress-strain diagram, flow stress, degree of deformation, flow curve
o Deformation behavior at high temperatures: deformation mechanisms, recovery, recrystallization, dependence of flow stress on temperature, strain and strain rate, dependence of grain size distribution of the recrystallized microstructure on temperature and strain, influence of stacking fault energy, strain and strain rate on the grain size distribution of the product, change of material characteristics during recovery and recrystallization, creep including the underlying mechanisms
o Solidification mechanisms: solid solution hardening, precipitation hardening, dispersion hardening, cold working, grain refinement, texture hardening
o Fracture behavior: crack formation and propagation, ductile, mixed and brittle fractures, dependence of fracture work on metallic lattice structure and temperature, dependence of transition temperature on chemical composition, grain size and strain rate
o Fatigue failures: oscillating types of loading, fatigue hardening and crack formation, crack propagation, fatigue failure surface, dependence of the strain amplitude or stress amplitude on the number of cycles, behavior of cold-worked components under cyclic loading, dependence of the crack growth rate on the stress intensity factor range, Paris Law and material characteristics, Wöhler curve, low cycle, high cycle and very high cycle fatigue
o Creep fractures
• Aluminum materials
o Properties of aluminum
o Natural hard aluminum alloys of the AlMg type
o Heat-treatable aluminum alloys: precipitation hardening, “hardening” heat treatment, alloying concept, technically important alloys
o Aluminum casting alloys without Si
o Aluminum casting alloys with Si: Alloying concept, refining, technically important alloys and their properties
• Ferrous materials
o Repetitorium on unalloyed steels
o Low-alloy steels: Designation, mode of action of the alloying elements (solid solution hardening, inhibition of the transformation of austenite to ferrite and perlite, ferrite stabilization, austenite stabilization, tempering resistance through Si and special carbide formers)
o High-alloy steels: alloys based on Fe-Ni, Fe-Cr and Fe-Cr-Ni, in particular corrosion-, scale- and wear-resistant Cr steels and corrosion-resistant and heat-resistant austenitic CrNi steels
o Steels used in mechanical and automotive engineering: construction, tempering, case-hardening, spring, dual-phase, deep-drawing and advanced high-strength steels, steels for screw connections
Introduction to Manufacturing Engineering:
• industrial production technology, tasks and interrelations of manufacturing technology, product development process, classification of manufacturing processes
• Manufacturing accuracy: definition of “accuracy”, true value, correct value, empirical value, selection of the appropriate manufacturing process based on order data, geometry, technology and time values, factors influencing accuracy, quality requirements and assurance, quality-oriented manufacturing, manufacturing metrology, systematic and random error, measurement data acquisition, dimensional, form and positional accuracy, surface quality, design deviations, roughness parameters, achievable roughness of manufacturing processes, functional and machine accuracy taking into account static, dynamic and thermal disturbances, tribological wear on tools
• Complex 21st-century manufacturing chains: linking metallurgy, materials and production technology, overview of metallurgical processes for the production of raw metal, production of the final metal by molding (ingot casting, continuous casting) and forming (rolling, forging, extrusion), followed by further manufacturing processes for the production of the finished component, practical examples
• Primary processing: definition, classification and process overview, casting defects in pure metals and alloys, metallic casting materials, guidelines for the design of castings suitable for casting, technology of the melting shop (tasks and functioning of cupola, induction, , arc, rotary drum, resistance and electron beam furnaces), casting technology (continuous casting, sand casting, gravity and low-pressure die casting, pressure die casting, centrifugal casting)
• Forming: definition, production of semi-finished products, production of workpieces, advantages of forming, cold forming, hot forming, dependence of formability on state of stress, temperature, strain rate and material, friction (real material surface, influencing variables, friction laws, wear, lubricants), massive (rolling, forging, extruding, wire drawing, , extrusion molding) and sheet metal forming (deep drawing, stretch forming)
• Cutting: definition, classification and process overview, consideration of machining processes in terms of productivity and quality, chip formation, cutting and chip sizes in drilling and turning, cutting edge geometry, chip types, built-up edge, number and class of chip spaces, influence of cutting speed, cutting depth, feed and tool geometry on chip shape, chip grooves on tools, heat generation during and distribution of heat to coolant, chip, workpiece and tool, stability, sizes, conditions and criteria, machining processes with geometrically defined cutting edge (chiseling, filing, turning, drilling, countersinking, reaming, milling, broaching) and with geometrically undefined cutting edge (grinding, honing, lapping)
“Fertigungs- und Werkstofftechnik” lab
The “Fertigungs- und Werkstofftechnik” lab is used for practical exercises and to apply the knowledge acquired and explained in the lectures “Struktur und Eigenschaften von Werkstoffen” and “Einführung in die Fertigungstechnik” using the following experiments/exercises/tests:
• Destructive material testing: tensile testing, hardness test, Charpy impact test
• Metallography
• Machining processes (turning, milling)
[updated 08.04.2025]
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