Materials & Metallurgical Engineering project ideas

100 projects, from a first build to a final-year capstone. Each lists the skills it teaches and the tools it needs; times and costs are estimates.

Beginner projects

• Alloy Phase Diagram Explorer — Read binary phase diagrams with a moving composition-temperature cursor and lever-rule calculator. Skills: phase diagrams, lever rule, eutectics. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Tensile Test Data Analyzer — Extract yield strength, UTS, elongation and modulus from tensile test data. Skills: stress-strain analysis, mechanical properties. Tools: Python/spreadsheet. Data lab, Up to 15 h, Software only (free tools).
• Grain-Size Measurement Tool — Measure ASTM grain size from micrographs using the intercept method. Skills: grain size, metallography, image analysis. Tools: Python, ImageJ. Data lab, Up to 15 h, Software only (free tools).
• Crystal Structure Viewer — Rotate BCC, FCC and HCP unit cells and compute packing factor and coordination. Skills: crystal structures, APF, coordination. Tools: web app, 3D. Visualizer, Up to 15 h, Software only (free tools).
• Hardness Conversion Calculator — Convert between Brinell, Vickers and Rockwell scales with validity ranges. Skills: hardness scales, conversions. Tools: web calculator. Visualizer, Up to 15 h, Software only (free tools).
• Corrosion of Nails Experiment — Compare rusting of nails in water, salt water and oil over two weeks. Skills: corrosion basics, environments. Tools: nails, jars, camera. Data lab, Up to 15 h, Under $30.
• Thermal Expansion Measurement — Measure linear expansion of metal rods with a dial gauge and compute the coefficient. Skills: thermal expansion, measurement. Tools: rods, dial gauge, hot water. Data lab, Up to 15 h, Software only (free tools).
• Material Density by Archimedes — Measure densities of metal samples by water displacement and identify alloys. Skills: density, Archimedes' principle. Tools: balance, water. Data lab, Up to 15 h, Software only (free tools).
• Material Property Comparison Chart — Plot strength versus density for material families like an Ashby chart. Skills: material selection, Ashby charts. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Work Hardening of Copper Wire — Bend copper wire repeatedly and measure changes in hardness and bend force. Skills: work hardening, dislocations. Tools: copper wire, spring scale. Hardware build, Up to 15 h, Under $30.
• Quench and Temper of Steel Demo — Heat-treat steel samples and compare hardness and brittleness (supervised). Skills: heat treatment, martensite. Tools: samples, furnace (supervised), file. Hardware build, Up to 15 h, Under $30.
• Polymer Melting Behaviour Study — Compare softening of thermoplastics and thermosets on a hot plate. Skills: polymer types, glass transition. Tools: samples, hot plate (supervised). Hardware build, Up to 15 h, Under $30.
• Impact Toughness With a Mini Pendulum — Build a mini Charpy-style pendulum and compare notched samples. Skills: impact toughness, energy absorption. Tools: pendulum rig, samples. Hardware build, Up to 15 h, Under $30.
• Microscope Sample Preparation Guide — Practise grinding, polishing and etching steps with a checklist. Skills: metallography, sample prep. Tools: checklist, microscope. Workflow, Up to 15 h, Software only (free tools).
• Electrical Conductivity of Metals — Measure resistance of wires of different metals and compute conductivity. Skills: electrical conductivity, measurement. Tools: wires, multimeter. Data lab, Up to 15 h, Under $30.
• Ceramic Tile Strength Test — Load ceramic tiles to failure and observe brittle fracture. Skills: brittle fracture, flexural strength. Tools: tiles, weights. Hardware build, Up to 15 h, Under $30.
• Recycling Symbol Sorting Game — Sort materials by recycling codes and explain processing routes. Skills: recycling, material identification. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Composite Rule of Mixtures Calculator — Estimate composite modulus and strength from fibre and matrix properties. Skills: rule of mixtures, composites. Tools: web calculator. Visualizer, Up to 15 h, Software only (free tools).
• Magnetic Properties of Materials — Classify materials as ferro, para or diamagnetic with a strong magnet. Skills: magnetism, material classes. Tools: magnets, samples. Hardware build, Up to 15 h, Under $30.
• Wood Moisture and Strength Study — Measure how moisture content changes timber bending strength. Skills: wood properties, moisture. Tools: timber samples, scale. Data lab, Up to 15 h, Software only (free tools).
• Galvanic Series Explorer — Predict galvanic corrosion for metal pairs and suggest isolation. Skills: galvanic corrosion, electrochemical series. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Hydrogel Swelling Experiment — Measure swelling of hydrogels in different salt solutions. Skills: polymer swelling, osmotic effects. Tools: gel beads, balance. Data lab, Up to 15 h, Software only (free tools).
• 3D-Print Material Strength Comparison — Compare PLA, PETG and ABS printed coupons in bending. Skills: polymer properties, printing parameters. Tools: 3D printer, test jig. Data lab, Up to 15 h, Under $30.
• Sintering of Clay Demo — Fire clay samples at different temperatures and measure shrinkage. Skills: sintering, densification. Tools: clay, kiln (supervised). Hardware build, Up to 15 h, Under $30.
• Glass Transition Visualizer — Show how polymer stiffness changes across the glass transition. Skills: glass transition, viscoelasticity. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).

Intermediate projects

• Heat-Treatment Recipe Predictor — Predict hardness after quenching and tempering from composition and temperature data. Skills: heat treatment, hardenability, regression. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Corrosion Coupon Tracking System — Track coupon weight loss, exposure time and corrosion rate across sites. Skills: corrosion monitoring, databases. Tools: database app. Workflow, 15–45 h, Software only (free tools).
• Microstructure Image Classifier — Classify ferrite, pearlite and martensite micrographs with a CNN. Skills: image classification, metallography. Tools: Python, PyTorch. Data lab, 15–45 h, Software only (free tools).
• Welding Parameter Window Mapper — Map current, voltage and speed ranges that give sound welds. Skills: welding parameters, heat input. Tools: spreadsheet/Python. Visualizer, 15–45 h, Software only (free tools).
• Casting Defect Risk Model — Predict porosity and shrinkage risk from casting design rules. Skills: casting defects, solidification. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Powder Metallurgy Process Planner — Plan compaction pressure and sintering cycles for target density. Skills: powder metallurgy, compaction. Tools: Python/spreadsheet. Workflow, 15–45 h, Software only (free tools).
• Electrochemical Corrosion Monitor — Measure corrosion rate with linear polarisation resistance on a test cell. Skills: LPR, electrochemistry. Tools: potentiostat, electrodes. Hardware build, 15–45 h, $30–150.
• Refractory Life Estimator — Estimate refractory wear from temperature cycles and slag contact. Skills: refractories, wear modelling. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Recycling Alloy Composition Sorter — Sort scrap by composition from spectrometer data into alloy grades. Skills: scrap sorting, classification. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• Composite Laminate Calculator — Compute ABD matrices and stresses for layered composite laminates. Skills: classical laminate theory, ply stresses. Tools: Python. Visualizer, 15–45 h, Software only (free tools).
• Surface Coating Selection Assistant — Recommend coatings by environment, substrate and wear needs. Skills: coatings, selection logic. Tools: web app. Workflow, 15–45 h, Software only (free tools).
• Slag Chemistry Balance Tool — Balance slag basicity and fluxes for steelmaking. Skills: slag chemistry, mass balance. Tools: spreadsheet. Simulator, 15–45 h, Software only (free tools).
• Diffusion Carburising Simulator — Solve Fick's second law for carbon profiles during carburising. Skills: diffusion, Fick's laws, case depth. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Jominy Hardenability Analyzer — Plot Jominy curves and compare steels' hardenability. Skills: hardenability, Jominy test. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• Polymer Rheology Data Fitter — Fit power-law and Cross models to viscosity data. Skills: rheology, model fitting. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• Thermal Analysis DSC Interpreter — Identify melting, crystallisation and Tg from DSC curves. Skills: DSC analysis, thermal transitions. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• Dislocation Motion Visualizer — Animate edge and screw dislocations and slip under shear. Skills: dislocations, slip. Tools: web app. Visualizer, 15–45 h, Software only (free tools).
• Electroplating Thickness Study — Electroplate coupons and relate thickness to current and time with Faraday's law. Skills: electroplating, Faraday's law. Tools: plating cell (supervised). Data lab, 15–45 h, Software only (free tools).
• Fatigue Test Data Workbench — Build S-N curves from fatigue data and estimate endurance limits. Skills: fatigue, S-N curves. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• X-Ray Diffraction Peak Analyzer — Index XRD peaks and estimate crystallite size with Scherrer's equation. Skills: XRD, peak indexing. Tools: Python. Data lab, 15–45 h, Software only (free tools).
• Heat-Affected Zone Hardness Map — Measure hardness across a weld and map the HAZ. Skills: HAZ, hardness mapping. Tools: hardness tester, samples. Data lab, 15–45 h, Software only (free tools).
• Aluminium Precipitation Hardening Study — Age aluminium samples and track hardness versus time. Skills: precipitation hardening, ageing. Tools: samples, oven, hardness tester. Data lab, 15–45 h, Software only (free tools).
• Polymer Recycling Degradation Study — Measure property loss after repeated reprocessing of a plastic. Skills: recycling, degradation. Tools: extruder/printer, test rig. Data lab, 15–45 h, $30–150.
• Cathodic Protection Designer — Size sacrificial anodes for a buried pipe. Skills: cathodic protection, current demand. Tools: spreadsheet. Visualizer, 15–45 h, Software only (free tools).
• Rolling Reduction Calculator — Compute roll forces and strain for flat rolling passes. Skills: metal forming, rolling. Tools: Python. Simulator, 15–45 h, Software only (free tools).

Advanced projects

• Fracture Toughness Data Workbench — Compute KIC from test data and check validity criteria. Skills: fracture mechanics, validity checks. Tools: Python. Data lab, 45–100 h, Software only (free tools).
• Creep-Life Estimation Model — Estimate creep life with Larson-Miller parameters. Skills: creep, LMP, life prediction. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Non-Destructive Testing Dashboard — Combine ultrasonic, eddy current and radiography findings per component. Skills: NDT, data integration. Tools: dashboard. Dashboard, 45–100 h, $30–150.
• Shape-Memory Alloy Actuator Demo — Drive an SMA wire actuator and measure stroke versus temperature. Skills: shape memory, phase transformation. Tools: NiTi wire, power supply. Hardware build, 45–100 h, $150+.
• Thermo-Mechanical Process Simulator — Simulate microstructure evolution during hot rolling and cooling. Skills: thermomechanical processing, recrystallisation. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Additive Metal Build Monitor — Monitor melt-pool and layer images to flag defects during metal AM. Skills: process monitoring, AM defects. Tools: camera data, Python. Dashboard, 45–100 h, $30–150.
• Fatigue Crack Growth Calculator — Integrate Paris-law crack growth to predict inspection intervals. Skills: Paris law, damage tolerance. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Phase-Field Solidification Model — Simulate dendritic growth with a simple phase-field model. Skills: phase-field modelling, solidification. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Hydrogen Embrittlement Study — Compare ductility of charged and uncharged steel samples. Skills: hydrogen embrittlement, testing. Tools: samples, test rig (supervised). Data lab, 45–100 h, $30–150.
• Residual Stress Measurement — Estimate residual stress with hole-drilling strain gauges. Skills: residual stress, strain gauges. Tools: rosette gauges, drill. Hardware build, 45–100 h, $150+.
• Battery Electrode Material Study — Compare electrode coatings by capacity retention over cycles. Skills: electrode materials, cycling. Tools: coin cells (supervised), cycler. Data lab, 45–100 h, Software only (free tools).
• Wear-Resistant Coating Evaluation — Compare hardfacing coatings in abrasion tests. Skills: wear testing, coatings. Tools: abrasion rig. Data lab, 45–100 h, $30–150.
• Biodegradable Polymer Degradation Model — Model mass loss of a biodegradable polymer over time. Skills: degradation kinetics, mass-loss modelling. Tools: Python, lab data. Simulator, 45–100 h, Software only (free tools).
• High-Entropy Alloy Screening — Screen alloy compositions with empirical phase-formation rules. Skills: HEA design rules, screening. Tools: Python. Data lab, 45–100 h, Software only (free tools).
• Ceramic Matrix Composite Design — Select fibre, interphase and matrix for a high-temperature part. Skills: CMCs, design trade-offs. Tools: spreadsheet. Workflow, 45–100 h, Software only (free tools).
• Stress Corrosion Cracking Risk Map — Map SCC risk by material, stress and environment. Skills: SCC, risk mapping. Tools: Python. Visualizer, 45–100 h, Software only (free tools).
• Superplastic Forming Simulation — Simulate superplastic forming thickness distribution. Skills: superplasticity, forming. Tools: FEA. Simulator, 45–100 h, Software only (free tools).
• Machine Learning Alloy Property Predictor — Predict yield strength from composition and processing. Skills: materials informatics, ML. Tools: Python. Data lab, 45–100 h, Software only (free tools).
• Electron Microscopy Image Analysis — Measure particle sizes and phase fractions from SEM images. Skills: SEM analysis, segmentation. Tools: Python, ImageJ. Data lab, 45–100 h, Software only (free tools).
• Thermal Barrier Coating Life Model — Estimate TBC spallation life from thermal cycles. Skills: TBCs, oxidation, life models. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Friction Welding Joint Study — Study joint strength versus forge pressure in friction welding. Skills: solid-state welding, process parameters. Tools: test data. Data lab, 45–100 h, Software only (free tools).
• Polymer Composite Recycling Route Comparison — Compare mechanical, thermal and chemical recycling of composites. Skills: composite recycling, LCA. Tools: spreadsheet. Workflow, 45–100 h, Software only (free tools).
• Magnetic Material Hysteresis Analyzer — Measure B-H loops and compute core losses. Skills: hysteresis, magnetic losses. Tools: coil setup, scope. Data lab, 45–100 h, Software only (free tools).
• Corrosion Inhibitor Screening Rig — Screen inhibitors with electrochemical tests in parallel cells. Skills: inhibitors, electrochemistry. Tools: multi-channel potentiostat. Hardware build, 45–100 h, $150+.
• Sintered Gear Density Optimisation — Optimise compaction to reach target density in PM gears. Skills: PM, density, DOE. Tools: Python. Simulator, 45–100 h, Software only (free tools).

Expert projects

• Microstructure-Property ML Explorer — Link microstructure images to properties with deep learning and explain features. Skills: materials informatics, XAI. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Circular Metallurgy Material Passport — Track alloy composition and history through reuse and recycling. Skills: material passports, traceability. Tools: database. Workflow, 100 h+, Software only (free tools).
• Materials Selection Pareto Tool — Find Pareto-optimal materials for multiple conflicting requirements. Skills: multi-objective selection, Pareto fronts. Tools: Python. Visualizer, 100 h+, Software only (free tools).
• Integrated Computational Materials Engineering Case — Chain process, microstructure and property models for a part. Skills: ICME, model chaining. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Autonomous Materials Discovery Loop — Use Bayesian optimisation to select the next experiment for a target property. Skills: autonomous experimentation, Bayesian optimisation. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Atomistic Simulation of Grain Boundaries — Simulate grain boundary energies with molecular dynamics. Skills: MD simulation, interfaces. Tools: LAMMPS. Simulator, 100 h+, Software only (free tools).
• Self-Healing Polymer Study — Make a self-healing polymer and measure strength recovery. Skills: self-healing materials, testing. Tools: lab materials (supervised). Data lab, 100 h+, Software only (free tools).
• Additive Manufacturing Microstructure Control — Tailor AM scan strategy to control grain texture. Skills: AM, solidification control. Tools: literature/process data. Simulator, 100 h+, Software only (free tools).
• Digital Twin of a Heat-Treatment Furnace — Mirror furnace temperatures and predict part properties live. Skills: digital twins, heat treatment. Tools: Python, sensor data. Digital twin, 100 h+, $150+.
• Lightweight Alloy Crash Absorber — Design an aluminium crash box and predict energy absorption. Skills: crashworthiness, FEA. Tools: FEA tool. Simulator, 100 h+, Software only (free tools).
• Corrosion Digital Twin for Pipelines — Predict corrosion growth along a pipeline from inspection data. Skills: corrosion modelling, inspection data. Tools: Python. Digital twin, 100 h+, Software only (free tools).
• Nanostructured Steel Processing Study — Evaluate severe plastic deformation for strength gains. Skills: SPD, nanostructures. Tools: literature, data. Data lab, 100 h+, Software only (free tools).
• Solid-State Battery Electrolyte Screening — Screen electrolytes by conductivity and stability data. Skills: electrolytes, screening. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Thermodynamic CALPHAD Calculation — Compute phase equilibria with CALPHAD-style databases. Skills: CALPHAD, thermodynamics. Tools: pycalphad. Simulator, 100 h+, Software only (free tools).
• Fatigue of Additively Manufactured Parts — Relate porosity in AM parts to fatigue life scatter. Skills: AM fatigue, defects. Tools: CT data, Python. Data lab, 100 h+, Software only (free tools).
• Green Steel Process Comparison — Compare hydrogen DRI, EAF and blast furnace routes for emissions. Skills: decarbonisation, process comparison. Tools: spreadsheet. Dashboard, 100 h+, Software only (free tools).
• Smart Coating With Damage Sensing — Design a coating that changes colour when damaged. Skills: smart coatings, sensing. Tools: lab materials. Data lab, 100 h+, Software only (free tools).
• Uncertainty in Material Allowables — Derive A- and B-basis allowables from test scatter. Skills: statistics, allowables. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Rare-Earth-Free Magnet Study — Compare magnet alternatives without rare earths for motors. Skills: magnetic materials, trade-offs. Tools: data analysis. Data lab, 100 h+, Software only (free tools).
• Weld Microstructure Prediction — Predict weld microstructure from cooling rates. Skills: weld metallurgy, CCT diagrams. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Bio-Based Composite Development — Develop a natural-fibre composite and benchmark it against glass fibre. Skills: bio-composites, testing. Tools: lab materials. Data lab, 100 h+, Software only (free tools).
• Lifetime Prediction of Polymer Seals — Predict seal life from accelerated ageing and Arrhenius models. Skills: polymer ageing, Arrhenius. Tools: Python, test data. Data lab, 100 h+, Software only (free tools).
• Multi-Scale Composite Failure Model — Link micro-scale damage to laminate failure predictions. Skills: multi-scale modelling, failure. Tools: FEA, Python. Simulator, 100 h+, Software only (free tools).
• Critical Raw Material Substitution Planner — Identify substitutes for critical materials in a product. Skills: material criticality, substitution. Tools: database. Workflow, 100 h+, Software only (free tools).
• In-Situ X-Ray Tomography Analysis — Track damage growth in 3D tomography data during loading. Skills: tomography, image analysis. Tools: Python. Data lab, 100 h+, Software only (free tools).

Project ideas for every branch · Materials & Metallurgical Engineering roadmap