PE Metallurgical study plan

Draw and label FCC, BCC, and HCP unit cells, then calculate atomic packing factor, coordination number, and theoretical density for at least three metals

Compute diffusion flux and diffusion distance using Fick's first and second law solutions, and state the temperature dependence of the diffusion coefficient

Sketch a full engineering stress-strain curve and label yield strength, tensile strength, elastic modulus, ductility, resilience, and toughness, computing each from numerical data

Explain the four strengthening mechanisms (solid-solution, grain-boundary, strain-hardening, precipitation) and predict which one dominates in a described alloy condition

Convert among engineering stress/strain and true stress/strain and apply the Hollomon power law to a supplied data set

Interpret binary isomorphous, eutectic, and eutectoid phase diagrams by identifying phases, compositions, and phase fractions with the lever rule

Reproduce the Fe-Fe3C diagram from memory and identify proeutectoid ferrite/cementite, pearlite, bainite, and martensite for six given compositions and cooling histories

Select and sequence heat treatments (anneal, normalize, quench-and-temper, austempering, case hardening) to meet stated hardness and toughness targets

Relate crystal structure and defect content to observed property differences among plain carbon, low-alloy, and tool steels

Diagnose common heat-treatment defects such as decarburization, quench cracking, and retained austenite from described symptoms

Compare stainless steel families, aluminum alloys, copper alloys, titanium alloys, and nickel superalloys on strength, corrosion resistance, and temperature capability

Differentiate thermoplastic from thermoset behavior and predict crystallinity, glass transition, and melting effects on modulus and creep

Select precipitation-hardenable versus solid-solution-strengthened alloys and outline the aging treatment sequence for a stated application

Explain galvanic and pitting corrosion mechanisms and choose a mitigation for each of four described environments

Classify ceramics by bonding type and predict how porosity and flaw size control strength and toughness

Contrast processing and property trade-offs among traditional ceramics, glasses, and advanced structural ceramics

Compute rule-of-mixtures and inverse rule-of-mixtures bounds for a fiber-reinforced composite and identify load-transfer limits

Compare pultrusion, lay-up, filament winding, and injection molding for a composite part with a stated shape and volume

Distinguish conductor, semiconductor, and insulator behavior using band structure and describe doping and dielectric/magnetic material roles

Match casting processes (sand, die, investment, continuous) to part size, tolerance, and volume requirements

Compare fusion welding, solid-state welding, and brazing on heat-affected zone, defect risk, and applicable alloys

Sequence powder metallurgy and additive manufacturing routes and predict resulting porosity and property anisotropy

Explain forming operations (rolling, forging, extrusion, deep drawing) in terms of deformation, texture, and residual stress

Describe shaping methods for polymers and ceramics and identify the defects each method typically produces

Apply property-based material indices and trade-off plots to rank candidate materials for a stiffness-limited and a strength-limited design

Calculate a safety factor against yielding and against fast fracture for a specified load case

Weigh cost, manufacturability, and recyclability alongside mechanical properties in a documented selection decision

Identify how processing choice alters the achievable design allowables and tolerances in a finished component

Select tensile, hardness, impact, fatigue, and creep tests appropriate to a stated property requirement and interpret the reported values and their scatter

Distinguish destructive from non-destructive evaluation methods and choose a method for each of five described flaw scenarios

Apply fracture mechanics concepts (stress intensity, critical flaw size, Paris law, S-N and fatigue limit) to predict failure or remaining life

Explain oxidation, galvanic, crevice, and stress-corrosion degradation mechanisms and prescribe prevention for each

Execute a structured failure analysis sequence: evidence collection, fracture-surface interpretation, mechanism hypothesis, and verification

Re-solve missed items from all prior weeks and reduce the error rate on each to zero

Complete a timed 60-question mixed-domain practice exam under exam conditions

Re-derive the ten highest-frequency formulas from memory and check each against the week 1 reference sheet

State the three highest-risk topics and a specific corrective action for each