The course content is designed to systematic understanding on various aspects related with failure such as fundamental sources of failure of mechanical components, industrial engineering tools relevant to failure and failure analysis, general procedure of failure analysis through sample collection, preparation and preservation, testing, macro and microscopic observation of fracture, mode of fracture, metallographic procedure and image analysis, use of fracture mechanics and fracture toughness principles in failure analysis and analysis findings and report/recommendation writing. Presentation will include case studies to communicate concepts and procedures effectively. Case studies will be taken up from failure analysis of weld joints in different sectors.
INTENDED AUDIENCE
UG and PG Student, Research Scholar & Practicing Engineers
PRE-REQUISITES
NIL
UG/PG COURSE
PG/Research
CORE/ELECTIVE COURSE
Elective
INDUSTRY SUPPORT – LIST OF COMPANIES/INDUSTRY THAT WILL RECOGNIZE/VALUE THIS ONLINE COURSE
Heavy engineering and pressure vessel industry, power plants
1225 students have enrolled already!!
COURSE INSTRUCOR
Dr. D. K. Dwivedi obtained BE (mechanical engineering) , in 1993 from
GEC Rewa, ME (welding engineering) Univ. of Roorkee in 1997 and PhD in
Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years
teaching experience at NIT Hamirpur and 12 years at IIT Roorkee of
subjects related with manufacturing at UG level and welding engineering
related subjects at PG level. He has published more than 95 research
papers in SCI/SCIE indexed journals and undertaken 16 sponsored research
and 48 industrial consultancy projects. Instructor has authored one
book entitled “Production and Properties of Cast Al-Si Alloys with New
Age International, New Delhi (2013).
COURSE LAYOUT:
Week1:
1. Introduction: Need and scope of failure analysis and prevention
2.Introduction: Engineering disasters and understanding failures
3.Fundamental sources of failures: Deficient design I
4.Fundamental sources of failures: Deficient design II
5. Fundamentalsources of failures: Deficient design III and upgrading of a part
Week2:
1.Fundamental sources of failures: Imperfections in base metals
2.Fundamental sources of failures: Improper Manufacturing I
3.Fundamental sources of failures: Improper Manufacturing II
4.Fundamental sources of failures: Improper Manufacturing III
5.Fundamental sources of failures: Improper Manufacturing IV and improper service conditions
Week3:
1. Fundamental sources of failures: Poor assembly, service andmaintenance
2.Industrial engineering tools for failure analysis:Pareto diagram
3.Industrial engineering tools for failure analysis:Fishbone diagram and FMEA
4.Industrial engineering tools for
failure analysis: FMEA
5.Industrial engineering tools for failure analysis: Fault tree analysis
Week4:
1.Industrial engineering tools for failure analysis: Reliability-I
2.Industrial engineering tools for failure analysis: Reliability-II
3.General procedure of failure analysis: Steps
4.General procedure of failure analysis: Background information collection
5.General procedure of failure analysis: Preliminary examination
Week5:
1.General procedure of failure analysis: NDT for failure analysis
2.General procedure of failure analysis: Destructive testing
3.General procedure of failure analysis: DT, selection, preservation, cleaning & sectioning of samples
4.General procedure of failure analysis: Macroscopy of fracture surfaces-I
5.General procedure of failure analysis: Macroscopy of fracture surfaces-II
Week6:
1.General procedure of failure analysis: Macroscopy of fracture surfaces-III
2.General procedure of failure analysis: Macroscopy of fracture surfaces-IV
3.General procedure of failure analysis: Microscopy of fracture surfaces
4.General procedure of failure analysis: Metallography of failed components
5.General procedureof failure analysis: Determination of type of fracture I
Week7:
1.General procedure of failure analysis: Determination of type of fracture II
2.General procedure of failure analysis: Determination of type of fracture III and chemical analysis
3.General procedure of failure analysis: Application of fracture mechanics I
4.General procedure of failure analysis: Application of fracture mechanics II
5.General procedure of failure analysis: Simulated test and analysisof evidences/results
Week8:
1.General procedure of failure analysis: Questions for analysis
2.General procedure of failure analysis: Reporting failure analysis and failure analysis of welded joint
3.General procedure of failure analysis: Failure analysis of weld joint
4.General procedure of failure analysis: Examples of failure analysis
5.General procedure of failure analysis: Embrittlement of steels
SUGGESTED READING
Becker et al. Failure analysis and prevention, ASM Handbook (2002) Hutching et al. Failure analysis, ASM International (1981) Besterfield et al. Total quality management, Pearson (2002)Engineering failure analysis, Journal, Elsevier Failure analysisand prevention, Journal, Springer .
CERTIFCATION EXAM :
The exam is optional for a fee.
Date and Time of Exams: April 28 (Saturday) and April 29 (Sunday) : Morning session 9am to 12 noon;
Exam for this course will be available in one session on both 28 and 29 April.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published.
CERTIFCATION:
Final score will be calculated as : 25% assignment score + 75% final exam score
25% assignment score is calculated as 25% of average of Best 6 out of 8 assignments
E-Certificate will be given to those who register and write the exam and score greater than or equal to 40% final score. Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT ROORKEE.It will be e-verifiable at nptel.ac.in/noc.
