Lifelong Learning for a Brighter World

Shawn Buchok, McMaster University Continuing Education Metallurgy and Business Administration graduate Shawn Buchok, McMaster University Continuing Education Metallurgy and Business Administration graduate

Metallurgy of Iron & Steel

Iron ore steel?
Know your product.

Gain a comprehensive knowledge of steel.

MET 452 - Steels in Service-Fall 2019

Academic Credit Value:
3 units
Course Delivery Mode:
Hours of Study:
39 hours
Course Prerequisite(s):
Course Anti-requisite(s):
Instructor Name:
Lucas Thung
Course Dates:
09/16/2019 - 12/08/2019

Required Course Materials:
Understanding How Components Fail, Wulpi, Donald. 3rd Edition. ASM Intl. (please order directly from ASM)
Optional Course Materials:
Course Description:
This course provides a review of the various modes through which the performance of steels can be
degraded in service. The primary focus will be on corrosion and environmental effects such as wear, and
on mechanical failure, such as fatigue and stress corrosion cracking.

A detailed study of the mechanisms of these effects will be followed by methods of protection and
avoidance of service failures. Techniques of failure analysis will be reviewed.
Learning Outcomes:
By the end of this course, you will be able to:

•  Describe how to systematically investigate metal failures
•  Identify major causes of metal failure
•  Describe various methods of failure prevention
•  Explain the wide possibilities for failure of steel parts
•  Identify the principles of failure investigation
•  Identify various mechanical tests for steel and their purpose
•  Describe basic principles of corrosion
•  Identify various methods of corrosion management
•  Compare and contrast failures by wear, joints, fatigue and creep
•  Describe methods of corrosion control by design and by coatings
•  Define various mechanical and corrosion interactions
•  Explain methods of failure prevention
Course Evaluation
Participation in Weekly Online Discussions: 20%
Quizzes (4 X 10%): 40%
Final Assignment: 40%

Week #  Assignment Details  % of Total Mark
1-12 Weekly Discussions
3 Quiz #1 (Covers Weeks 1 – 3)
6 Quiz #2 (Covers Weeks 4 – 6)
9 Quiz #3 (Covers Weeks 7 – 9)
11 Quiz #4 (Covers Weeks 10 – 11)
12 Final Assignment
 Total Marks:   100%

Students are required to provide feedback by completing course reaction/evaluation surveys. Course
evaluations are administered through an online resource (Survey Monkey) and are distributed to
students by either the Program Associate or Program Manager. Course instructors are not involved in
the distribution or collection of course evaluations. In all cases, students will remain anonymous.

Course Format:
This course emphasizes student participation through weekly online discussion boards. It is expected
that students will read the assigned chapters per the weekly requirements.
Assignment Submission:
Late Coursework:
Late penalties for assignments: 2% per day up to a maximum of 5 days. If after 5 days an assignment
has not been submitted, the student will receive a zero mark for that assignment.

Policy & Procedures:

Academic Regulations (Attendance, Coursework, Tests/Exams):
In accordance to McMaster University’s General Academic Regulations, “it is imperative that students
make every effort to meet the originally scheduled course requirements and it is a student’s
responsibility to write examinations as scheduled
Therefore, all students are expected to attend and
complete the specific course requirements (i.e. attendance, assignments, and tests/exams) listed in the
course outline on or by the date specified. Students who need to arrange for coursework
accommodation, as a result of medical, personal or family reasons, must contact the course instructor
within 48 hours of the originally scheduled due date. It is the student’s responsibility to contact the
Program Manager/Program Associate at CCE to discuss accommodations and procedures related to
deferred tests and/or examinations within 48 hours of the originally scheduled test/exam, as per
Failure to contact the course instructor, in the case of missed coursework, or the Program
Manager/Program Associate, in the case of a missed test/examination, within the specified 48 hours
window will result in a grade of zero (0) on the coursework/exam and no further consideration will be

*Note: Supporting documentation will be required but will not ensure approval of accommodation(s).
Academic Integrity
(Please note that CCE will adhere to a zero tolerance application of the policy)

You are expected to exhibit honesty and use ethical behaviour in all aspects of the learning process.
Academic credentials you earn are rooted in principles of honesty and academic integrity. Academic
dishonesty is to knowingly act or fail to act in a way that result or could result in unearned academic
credit or advantage. This behaviour can result in serious consequences, e.g. the grade of zero on an
assignment, loss of credit with a notation on the transcript (notation reads: “Grade of F assigned for
academic dishonesty”), and/or suspension or expulsion from the university.

It is your responsibility to understand what constitutes academic dishonesty. For information on the
various types of academic dishonesty please refer to the Academic Integrity Policy, located at

The following illustrates only three forms of academic dishonesty:

  1. Plagiarism, e.g. the submission of work that is not one’s own or for which other credit has been
    obtained, including copying solution sets.
  2. Improper collaboration in group work.
  3. Copying or using unauthorized aids in tests and examinations.
Academic Accommodations:
Students who require academic accommodation should contact Student Accessibility Services (SAS).
Staff at SAS will evaluate your learning needs and, if required, will provide a letter for the course
instructor. It is the student’s responsibility to inform the instructor and Program Manager of any
accommodation requirements at the start of the course. For more information, contact SAS at ext.
28652 or visit
On-line Elements:
Material for this course may be accessed through McMaster's new learning system, Avenue2Learn
(A2L). Your instructor will notify you if, or when, you will be required to login and use the tools and
materials available through this on-line system. Computers are available for use in various locations
across McMaster main campus including all libraries and Computer Labs.

To access Avenue to Learn go to: . You will be required to enter
your MAC ID (login and password). To activate your MAC ID, contact University Technology
Course Changes:

The instructor reserves the right to modify elements of the course and will notify students accordingly.

Course Withdrawal Policy:
Policies related to dropping a course and course withdrawals are posted to the Centre for Continuing Education’s program webpage, FAQs & Policies (
Grading Scale:


Equivalent Grade Point

Equivalent Percentages








































Course Schedule:
Week Date  Topic What's Due?
1 Sep 11 - 17 Introduction: Types of Steel and Product Forms

2 Sep 18 - 24 Mechanical Testing / Material Selection

3 Sep 25 - Oct 1 Steel Failure Mechanisms
Quiz #1 (modules 1-3)
4 Oct 2 - 8 Corrosion: Basics and Forms of Corrosion

5 Oct 9 - 15 Corrosion Protection and Prevention

6 Oct 16 - 22 Designing for Corrosion
Quiz #2 (modules 4-6)
7 Oct 23 - 29 Creep and High Temperature Corrosion

8 Oct 31 - Nov 5 Joint Failure / Non-destructive Examination

9 Nov 6 - 12 Failure by Wear
Quiz #3 (modules 7-9)
10 Nov 13 - 19 Failure by Fatigue

11 Nov 20 - 26 Failure Analysis
Quiz #4 (modules 10-11)
12 Nov 27 - Dec 3 Failure Prevention and Review

13 Dec 4 - 10
Final Assignment