Alloy Design Engineering Course

Lesson 1 • Diffusion in Solid Alloys

Explains Fick's laws, diffusion mechanisms, and temperature dependence in metallic systems. Underpins understanding of heat treatment and phase transformation kinetics.

Lesson 2 • Mechanical Properties Overview

Introduces stress-strain behaviour, elastic modulus, yield strength, and fracture toughness. Connects atomic-scale structure to measurable engineering properties.

Lesson 3 • Crystal Defects and Their Effects

Examines point, line, and planar defects and their influence on mechanical behaviour. Links defect density to strength, ductility, and diffusion rates.

Lesson 4 • Atomic Structure and Metallic Bonding

Covers electron configuration, metallic bonding mechanisms, and crystal lattice formation. Establishes the atomic basis for all subsequent alloy property discussions.

Lesson 1 • Reading Binary Phase Diagrams

Teaches lever rule, liquidus/solidus lines, and invariant reactions in binary systems. Enables accurate microstructure prediction at any composition and temperature.

Lesson 2 • CALPHAD Method Introduction

Presents the CALPHAD approach to computing multicomponent phase diagrams from assessed databases. Enables students to use computational tools for alloy thermodynamic prediction.

Lesson 3 • Solid-State Phase Transformations

Examines nucleation and growth, spinodal decomposition, and ordering reactions. Connects thermodynamic driving forces to microstructural evolution during processing.

Lesson 4 • Thermodynamic Fundamentals for Alloys

Covers Gibbs free energy, enthalpy of mixing, and entropy contributions to phase stability. Provides the thermodynamic framework for interpreting phase diagrams.

Lesson 1 • Precipitation and Dispersion Hardening

Covers coherent precipitate formation, Orowan bypassing, and particle coarsening kinetics. Links ageing heat treatment parameters to peak hardness and overageing behaviour.

Lesson 2 • Combined and Synergistic Strengthening

Evaluates additive and non-additive interactions amongst multiple strengthening mechanisms. Guides alloy designers in balancing strength, ductility, and toughness simultaneously.

Lesson 3 • Grain Boundary Strengthening

Applies the Hall-Petch relationship to predict yield strength from grain size. Examines grain refinement processing routes and their practical limits.

Lesson 4 • Work Hardening and Dislocation Interactions

Analyses dislocation multiplication, forest hardening, and the Taylor equation. Connects cold-working schedules to achievable strength and residual ductility.

Lesson 1 • Iron-Carbon Phase Diagram Mastery

Analyses the Fe-C diagram including austenite, ferrite, cementite, and pearlite fields. Provides the foundation for all ferrous heat treatment and microstructure control.

Lesson 2 • Heat Treatment of Carbon Steels

Covers annealing, normalising, quenching, and tempering cycles and their microstructural outcomes. Connects TTT and CCT diagrams to practical heat treatment schedule design.

Lesson 3 • Tool Steels and Wear-Resistant Alloys

Covers high-speed steels, cold-work, and hot-work tool steel compositions and heat treatment. Addresses carbide volume fraction, red hardness, and wear resistance optimisation.

Lesson 4 • Alloying Elements in Steels

Examines how Cr, Mn, Mo, Ni, and V shift phase boundaries and improve hardenability. Enables selection of alloying additions to meet specific mechanical and corrosion targets.

Lesson 1 • Nickel Superalloy Fundamentals

Analyses gamma-prime and gamma-double-prime strengthening, creep resistance, and oxidation behaviour. Prepares students to design alloys for gas turbine and high-temperature service.

Lesson 2 • Aluminium Alloy Design

Covers wrought and cast aluminium series, age-hardening sequences, and temper designations. Connects alloy chemistry to strength, corrosion resistance, and weldability trade-offs.

Lesson 3 • Copper and Copper-Based Alloys

Reviews brass, bronze, and cupronickel systems, their phase diagrams, and processing routes. Links electrical conductivity, strength, and corrosion resistance to composition choices.

Lesson 4 • Titanium Alloy Systems

Examines alpha, beta, and alpha-beta titanium alloys, phase stability, and heat treatment. Addresses specific strength, biocompatibility, and elevated-temperature performance.

Lesson 1 • Surface and Case Hardening Processes

Covers carburising, nitriding, induction hardening, and shot peening for surface property enhancement. Links case depth, residual stress profile, and surface hardness to fatigue life improvement.

Lesson 2 • Solidification and Casting Processes

Covers nucleation during solidification, dendrite formation, segregation, and casting defects. Links solidification rate and mould design to final ingot or casting microstructure.

Lesson 3 • Powder Metallurgy and Additive Routes

Introduces sintering, hot isostatic pressing, and powder-bed fusion for near-net-shape alloy production. Addresses porosity control, microstructural homogeneity, and post-processing requirements.

Lesson 4 • Thermomechanical Processing

Examines hot and cold rolling, forging, and extrusion and their effects on grain structure. Connects deformation temperature, strain rate, and reduction ratio to microstructural outcomes.

Lesson 1 • High-Temperature Oxidation and Hot Corrosion

Covers parabolic oxidation kinetics, protective oxide scale formation, and sulphidation attack. Enables alloy composition selection for oxidation resistance in combustion environments.

Lesson 2 • Stress Corrosion and Hydrogen Embrittlement

Analyses stress corrosion cracking, corrosion fatigue, and hydrogen-assisted cracking mechanisms. Connects alloy microstructure, stress state, and environment to crack initiation thresholds.

Lesson 3 • Electrochemical Corrosion Principles

Covers galvanic cells, mixed potential theory, and Pourbaix diagrams for alloy systems. Provides the electrochemical foundation for predicting and preventing aqueous corrosion.

Lesson 4 • Protective Coatings and Inhibition Strategies

Reviews thermal barrier coatings, bond coats, anodising, and corrosion inhibitor chemistry. Links coating selection to substrate alloy, service temperature, and expected degradation mode.

Lesson 1 • Experimental Alloy Development Workflow

Covers alloy melting, casting, thermomechanical processing, and characterisation at laboratory scale. Connects computational predictions to physical trial results through structured experimental design.

Lesson 2 • Computational Alloy Design Tools

Applies CALPHAD, first-principles calculations, and machine learning models to screen alloy compositions. Reduces experimental iteration by predicting phase stability, properties, and processing windows.

Lesson 3 • Characterisation Techniques for Alloy Design

Reviews XRD, SEM/EDS, TEM, and atom probe tomography for phase and composition analysis. Selects appropriate techniques to validate computational predictions and resolve microstructural questions.

Lesson 4 • Alloy Optimisation and Scale-Up

Applies statistical optimisation, sensitivity analysis, and pilot-scale trials to refine alloy compositions. Addresses scale-up challenges including segregation, processing variability, and qualification testing.