Course detail

Causes of Defects and Their Diagnostics

FSI-WPVAcad. year: 2011/2012

The basic information about physical, metallurgical and technological causes of defects of the metal materials and alloys, especially unalloyed steel, low alloy and high alloy steels, grey and white cast iron. Is given the basic information about the classification systems of the defects. The example of the classification systems of cast metals, wrought metals and welded metals - namely steels. The defects of cast and wrought steel and the defects of welded steels are explained in detail. It means that is given: - the possibilities of identification of the defect, - its technological causes, - and the possibilities of its prevention. Than are explained the following problems:
- The significance and basic principles of the statistical control of defects in the factory.
- The diagnostic of the defects by means of non-destructive method of testing.
- The problems of non-destructive testing of semi-product and final-product from different metal materials and alloy in the industry.
- The problems and main principles of quality inspection.
- The principles and using of capillary method, electrical and magnetically methods, X-ray methods, ultrasonic methods.
- And the problem: How to use the statistical and analytical methods of the identification of defects to their prevention?

Language of instruction

Czech

Number of ECTS credits

5

Mode of study

Not applicable.

Guarantor

prof. Ing. Karel Stránský, DrSc.

Department

Institute of Materials Science and Engineering (ÚMVI)

Learning outcomes of the course unit

The course gives the possibility to obtain the knowledge: about the defects in the metallurgical processes, about the casting defects, about the defects in tempering of different materials, about the defects in welding processes – then about the systems of defect classification, about their causes, diagnostic methods and also about their prevention in different production processes and technologies.

Prerequisites

The foundation knowledge of the technological processes of iron and non-iron metals and their alloys, it means: foundation knowledge of metallurgy, foundry, welding, cutting, forming and heat treatment of metals and alloys. The foundation knowledge of processes of the physical and chemical metallurgy. The knowledge from the following regions of materials: the structure of metals and alloys, composite materials, constructional ceramics and materials for electronics. The knowledge of the mechanical, physical and technological properties of these materials. The foundation knowledge of the using and behavior of materials in the technical practice. The knowledge of mathematical-statistical tests and their applications.

Co-requisites

Not applicable.

Planned learning activities and teaching methods

Teaching methods depend on the type of course unit as specified in the article 7 of BUT Rules for Studies and Examinations.

Assesment methods and criteria linked to learning outcomes

Condition for awarding the course unit credit: Having done all the assigned topics in exercises and prepared the respective written individual tasks. Examination has a written and an oral part – the student answers three questions.

Course curriculum

Not applicable.

Work placements

Not applicable.

Aims

The aim of course is following: to explain the problems of evidence, evaluation, classification, causes and prevention of material and technological defects in the material and technological processes in factories; to know the diagnostic of material defects, namely in metallurgical and another technological processes.

Specification of controlled education, way of implementation and compensation for absences

Compulsory attendance at exercises, preparing written reading a paper on an assigned topics. Absence from exercises is resolved individually.

Recommended optional programme components

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

Elbel T., Havlíček F., Jelínek P., Levíček P., Rous J., Stránský K. Vady odlitků ze slitin železa (klasifikace, příčiny a prevence). 1. vyd. Brno: MATECS, 1992. 339 s. (CS)
Míšek B., Ptáček L. Defektoskopie a provozní diagnostika. 1. vyd. Brno: VUT v Brně, 1992. 174 s. ISBN 80-214-0425-6. (CS)

Recommended reading

Not applicable.

Classification of course in study plans

  • Programme M2A-P Master's

    branch M-MTI , 2. year of study, winter semester, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

Ing. Martin Juliš, Ph.D.
prof. Ing. Karel Stránský, DrSc.

Syllabus

1) The definition of defects in technical praxis; the classification systems of defects in the production of metallic materials.
2) The record – keeping of defects in material production; the using of the mathematical and statistical methods.
3) The type of defects: chemical heterogeneity, gas holes, blowholes, superficial blowholes, pinholes; their effect on the properties; causes, identification and prevention.
4) The type of defects: slag inclusions, slag – gas defects, sand inclusion, oxide inclusion, lustrous carbon film, decarburization, oxidation; their effect on the properties; causes, identification and prevention.
5) The type of defects: physical segregation, A segregate, V segregate, cold shots, metallic inclusion, defect fracture; their effect on the properties; causes, identification and prevention.
6) The type of defect: incorrect chemical composition, deviations from mechanical properties, deviation from physical properties, wrong homogeneity; their causes, identification and possibility of prevention.
7) The defects of shape, dimension and mass – their effect their effect on the properties; causes, identification and prevention.
8) The diagnostic of defects by means of acoustical methods – their principals, possibilities and limiting.
9) The diagnostic of defects by means of X – ray methods – their principals, possibilities and limiting.
10) The another methods of defect diagnostic. Inspection (acceptance) of the material production (quality, dimensional and another inspection).

labs and studios

26 hours, compulsory

Teacher / Lecturer

Ing. Martin Juliš, Ph.D.
prof. Ing. Karel Stránský, DrSc.

Syllabus

1) The examples of the type of the single classification defect systems – casting, welding, forming of metals, metal cutting.
2) The methods and examples of the using of the classification defect systems – the creating and planning of the quality inspection conditions.
3) The definition and examples of the following type of defects: overt defect, cover defect, admissible defect, inadmissible defect, removed defect, repaired defect.
4) The examples of the type of defects (examples of the describing, identification, calculation and evaluation from another point of view): chemical heterogeneity, gas holes, blowholes, superficial blowholes, and pinholes.
5) The examples of the type of defects: slag inclusions, slag – gas defects, sand inclusion, oxide inclusion, lustrous carbon film, decarburization (it means the inadmissible decreasing of carbon in the surface layers of steel), oxidation.
6) The examples of the type of defects: A – segregate, V – segregate, cold shots, metallic inclusion, and defects of fractures.
7) The examples of the type of defects: incorrect chemical composition, deviations from mechanical properties and deviation from physical properties, wrong homogeneity.
8) The examples of the diagnostic of the defects due to acoustical, capillary and electro–magnetic methods.
9) The examples of the diagnostic of the defects due to X – ray and another methods.
10) The methodology of an analyzing of metallurgical, casting, forming, welding, heat treatment and post-weld thermal treatment defects.