Unit Outline

The Materials section of Materials and Reliability introduces students to the fundamental methods used to analyse static and fatigue failure in ductile and brittle metals, with the aim of informing the selection of suitable materials for engineering design. The section explores stress, strain, and their interdependencies when determining principal stresses and principal strains; key static failure theories; Marin correction factors for fatigue analysis; the assessment of alternating and non-zero mean stress states using key fatigue failure theories; and the extension of fatigue failure theories to multiaxial loading, varying phase and frequency loading, and cumulative damage.

The Reliability section of Materials and Reliability introduces students to the statistical tools used to analyse the condition of components and systems over their lifecycle. A substantial statistical foundation is established in this section, from which system reliability and maintainability may be carefully and accurately assessed. This section provides comprehensive coverage of data handling, the treatment of measurement uncertainties, and probability concepts and distributions, enabling reliability prediction and modelling, as well as the sustainable operation of systems within uncertain environments.

The unit integrates several practical activities that enable students to apply their developing knowledge of materials and reliability engineering. Practical work includes the use of strain gauges to assess static failure in components, the interpretation of loading histories for fatigue analysis, and uncertainty analysis to quantify instrumentation accuracy. Emphasis is placed on component and system performance and on extending service life, thereby promoting sustainability and climate-responsible engineering practice.

Overall, this unit prepares students for Solid Mechanics by equipping them with essential tools for evaluating component and system performance under static and fatigue loading. The unit also introduces the probabilistic perspectives needed for reliable engineering design and covers the uncertainty analysis tools necessary to determine levels of accuracy in testing undertaken in subsequent units.

Intended Learning Outcomes

As per the Assessment and Results Policy 1.3, your results will reflect your achievement against specified learning outcomes.

On completion of this unit, you will be able to:


1	Analyse static failure in ductile and brittle materials using static failure theories.
2	Analyse fatigue failure using correction factors and fatigue failure theories.
3	Analyse the reliability of engineering components and systems using statistical tools.
4	Solve practical engineering problems relating to product performance, extending product life, and overall climate resilience by extending and employing the concepts of static failure theory, fatigue failure theory, and reliability.
5	Assess operational data and uncertainties from sensors to monitor a condition or control a process.

Alterations as a result of student feedback

Unit is being offered for the first time, hence there are no alterations as yet.

How will I be Assessed?

For more detailed assessment information please see MyLO.

Assessment schedule


ASSESSMENT TASK #	ASSESSMENT TASK NAME	DATE DUE	WEIGHT	LINKS TO INTENDED LEARNING OUTCOMES
Assessment Task 1:	In Semester Test	Week 7	10 %	LO1, LO2
Assessment Task 2:	Field Trip	Week 10	15 %	LO4
Assessment Task 3:	Laboratory	Refer to Assessment Description	35 %	LO1, LO2, LO3, LO4, LO5
Assessment Task 4:	Exam	Exam Period	40 %	LO1, LO2, LO3

Assessment details

Assessment Task 1: In Semester Test

Task Description:

Students will complete a closed-book, mid-semester test to ensure they remain on track to developing high fluency in static and fatigue failure analysis. Students will demonstrate their ability to calculate principal stresses and principal strains, apply and compare static ductile and brittle failure theories, determine corrected endurance limits, and analyse complex fatigue-life problems using various fatigue failure theories. Students will draw on the skills and methods developed through workshops and tutorials in the lead-up to the test. The knowledge and competencies assessed in the test forms essential preparation for the Exam.

Task Length:

100 minutes.

Due Date:

Week 7

Weight:

10 %

CRITERION #

CRITERION

MEASURES INTENDED

LEARNING OUTCOME(S)


1	Calculate principal stresses and principal strains.	LO1
2	Solve static ductile and brittle failure theory problems.	LO1
3	Solve fatigue failure theory problems.	LO2

Assessment Task 2: Field Trip

Task Description:

Students will participate in a field trip to observe mechanical components and systems used in industrial applications. The activity will focus on components and systems that are vulnerable to static and fatigue failure, and that incorporate reliability considerations into their operation and maintenance. During the field trip, students will also engage with industry representatives to deepen their understanding of component design.

To complete the assessment, students must submit engineering calculations and a short engineering report. These should demonstrate how a selected component or system observed during the field trip can be shown to satisfy the material and reliability constraints of its operating environment. In preparing their submission, students will draw on the skills and methods developed in practical sessions, workshops, and tutorials leading up to the assessment.

This experience will strengthen students’ ability to evaluate mechanical designs and incorporate climate-safe engineering practice into the design process. It will also provide a foundation for designing specialised components, with consideration given to manufacturability, installation constraints, and operational requirements. Generative AI use is permitted but must be acknowledged.

Task Length:

Maximum 6 pages excluding appended items

Due Date:

Week 10

Weight:

15 %

CRITERION #

CRITERION

MEASURES INTENDED

LEARNING OUTCOME(S)


1	Evaluate material suitability, component and system reliability, and their combined effect on climate-resilient engineering design practice in mechanical components and systems observed during a field trip.	LO4

Assessment Task 3: Laboratory

Task Description:

This assignment consists of three separate submissions completed during the semester. Across these submissions, students will apply practical engineering techniques to analyse static and fatigue failure in components and evaluate the reliability of experimental data through uncertainty analysis.
Part A (assessing ILO1 and ILO4; released in Week 4; due Week 6; weighting 10%) requires students to perform strain gauge testing on a component, develop an appropriate program for processing and presenting the collected data, and extend this program to incorporate static ductile failure theory analysis. Using their strain gauge data, students will quantify and illustrate how close the component is to failure.
Part B (assessing ILO2 and ILO4; released in Week 7; due Week 9; weighting 15%) requires students to develop a program capable of decoding fatigue loading histories and to use this program to assess the fatigue life of components under a range of loading conditions.
Part C (assessing ILO3 and ILO5; released in Week 10; due Week 12; weighting 10%) requires students to collect experimental data and perform an uncertainty analysis to determine the accuracy of the instrumentation used.
For each part, students will demonstrate successful completion of the required tasks through the submission of an engineering report and, where applicable, the accompanying program file. In preparing each submission, students will draw on the skills and methods developed in practical sessions, workshops, and tutorials.
The knowledge and competencies assessed in this assignment support students in applying their developing understanding of static failure theory, fatigue failure theory, and reliability in a practical engineering context. This work also provides an important foundation for the Solid Mechanics unit and for the experimental and analytical work undertaken in subsequent units. Generative AI use is permitted but must be acknowledged.

Task Length:

Maximum 6 pages excluding appended items.

Due Date:

Refer to Assessment Description

Weight:

35 %

CRITERION #

CRITERION

MEASURES INTENDED

LEARNING OUTCOME(S)


1	Use a strain rosette to obtain experimental strain data that supports practical assessment of component failure and climate-resilient component design.	LO4
2	Process and translate strain gauge data into principal strains and principal stresses.	LO1
3	Use principal stresses from strain gauge testing to evaluate static component failure against the Maximum Shear Stress and Distortion Energy failure theories.	LO1
4	Decode fatigue loading histories using the rain-flow counting method to support practical fatigue assessment and climate-resilient product-life evaluation.	LO4
5	Analyse multiaxial fatigue problems, varying phase and frequency fatigue problems, accumulative damage fatigue problems, and a combination of the above using Marin correction factors and a range of fatigue failure theories.	LO2
6	Perform experimental work in a manner that facilitates uncertainty analysis.	LO5
7	Apply theoretical analysis to develop mathematical expressions for measurement uncertainty.	LO5
8	Solve statistical problems involving reliability concepts, using appropriate methods and statistical techniques to draw logical conclusions.	LO3
9	Present practical static failure theory, fatigue failure theory, and reliability results.	LO1, LO2, LO3, LO5

Assessment Task 4: Exam

Task Description:

This closed-book examination ensures that, upon completion of the unit, students have developed a high fluency in static and fatigue failure analysis and reliability. Students will demonstrate their ability to calculate principal stresses and principal strains, apply and compare static failure theories, determine corrected endurance limits, analyse complex fatigue-life problems using various fatigue failure theories, and assess component and system reliability. Students will draw on the skills and methods developed through class workshops and tutorials. The knowledge and competencies assessed in this exam are used in the fourth-year Solid Mechanics unit and subsequent engineering design units.

Task Length:

3 hours

Due Date:

Exam Period

Weight:

40 %

CRITERION #

CRITERION

MEASURES INTENDED

LEARNING OUTCOME(S)


1	Calculate principal stresses and principal strains.	LO1
2	Solve static ductile and brittle failure theory problems.	LO1
3	Solve fatigue failure theory problems.	LO2
4	Solve statistical problems involving reliability concepts, using appropriate methods and statistical techniques to draw logical conclusions.	LO3

How your final result is determined

To pass this unit, you need to demonstrate your attainment of each of the Intended Learning Outcomes, achieve a final unit grade of 50% or greater, and pass any hurdle tasks.

To pass ILO1 your aggregate mark on the components of the Test and Exam assessing ILO1 weighted according to their contribution to the final mark, must be greater than or equal to 50%.

To pass ILO2 your aggregate mark on the components of the Test and Exam assessing ILO2 weighted according to their contribution to the final mark, must be greater than or equal to 50%.

To pass ILO3 your aggregate mark on the components of the Laboratories and Exam assessing ILO3 weighted according to their contribution to the final mark, must be greater than or equal to 50%.

To pass ILO4 you must demonstrate a pass grade on all criteria associated with that ILO on either the Laboratories (Part A and B) or Field Trip.

To pass ILO5 you must demonstrate a pass grade on at least 1 out of 2 criteria associated with that ILO on the Laboratories (Part C).

Academic progress review

The results for this unit may be included in a review of your academic progress. For information about progress reviews and what they mean for all students, see Academic Progress Review in the Student Portal.

Submission of assignments

Where practicable, assignments should be submitted to an assignment submission folder in MYLO. You must submit assignments by the due date or receive a penalty (unless an extension of time has been approved by the Unit Coordinator). Students submitting any assignment in hard copy, or because of a practicum finalisation, must attach a student cover sheet and signed declaration for the submission to be accepted for marking.

Academic integrity

Academic integrity is about acting responsibly, honestly, ethically, and collegially when using, producing, and communicating information with other students and staff members.

In written work, you must correctly reference the work of others to maintain academic integrity. To find out the referencing style for this unit, see the assessment information in the MyLO site, or contact your teaching staff. For more detail about Academic Integrity, see Important Guidelines & Support.

Requests for extensions

If you are unable to submit an assessment task by the due date, you should apply for an extension.

A request for an extension should first be discussed with your Unit Coordinator or teaching support team where possible. A request for an extension must be submitted by the assessment due date, except where you can provide evidence it was not possible to do so. Typically, an application for an extension will be supported by documentary evidence: however, where it is not possible for you to provide evidence please contact your Unit Coordinator.

The Unit Coordinator must notify you of the outcome of an extension request within 3 working days of receiving the request.

Late penalties

Assignments submitted after the deadline will receive a late penalty of 5% of the original available mark for each calendar day (or part day) that the assignment is late. Late submissions will not be accepted more than 10 calendar days after the due date, or after assignments have been returned to other students on a scheduled date, whichever occurs first. Further information on Late Penalties can be found on the Assessments and Results Procedure.