Course syllabus for Component design for disassembly and recyclability

The course syllabus contains changes
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Course syllabus adopted 2025-10-13 by Head of Programme (or corresponding).

Overview

  • Swedish nameKomponentdesign för demontering och återvinningsbarhet
  • CodeTRA530
  • Credits7.5 Credits
  • OwnerTRACKS
  • Education cycleSecond-cycle
  • DepartmentTRACKS
  • GradingTH - Pass with distinction (5), Pass with credit (4), Pass (3), Fail

Course round 1

  • Teaching language English
  • Application code 97252
  • Maximum participants30 (at least 10% of the seats are reserved for exchange students)
  • Minimum participants8
  • Open for exchange studentsYes

Credit distribution

0125 Project 7.5 c
Grading: TH		 3.5 c4 c

In programmes

Examiner

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Eligibility

General entry requirements for Master's level (second cycle)

Specific entry requirements

A degree of at least 180 ECTS within Engineering and/or Technology or the equivalent. English proficiency equivalent to the Swedish upper secondary course English 6.

Course specific prerequisites

In addition to the general requirements to study at the second-cycle level at Chalmers, necessary subject or project specific prerequisite competences (if any) must be fulfilled. Alternatively, the student must obtain the necessary competences during the course. We recommend that students have a background in materials science and engineering, mechanical engineering, applied physics or similar. The examiner will check these prerequisite competences. The student will only be admitted in agreement with the examiner.

Aim

The course provides a platform to work and solve challenging cross-disciplinary authentic problems from different stakeholders in society such as the academy, industry or public institutions. Additionally, the aim is that students from different educational programs practice working efficiently in multidisciplinary development teams.

Module 1, Joining for Disassembly
The module introduces students to a range of joining techniques with a focus on sustainable design and engineering practices that could lead to increased circularity in material flows. Emphasis is placed on non-fusion-based methods such as adhesive bonding, mechanical joining and brazing. Special attention is given to the possibility of disassembly for reuse and recycling for each of the methods introduced. Students will learn how joining techniques influence structural performance, recyclability, and cost efficiency and dwell on the compromises that could be necessary between manufacturability, structural performance, and possibilities for disassembly. The module encourages a critical and practical approach to selecting joining methods based on material properties, mechanical function, and environmental constraints.

Module 2, Weld Design for Sustainability
The module aims to provide students with the knowledge and skills to design sustainable welded components and structures by integrating technical competence, international standards, and sustainability considerations. You will learn to apply principles of weld design, evaluate materials and processes, and make design choices that ensure quality, durability, and resource efficiency. In addition, the module builds a fundamental understanding of welding processes, their physics, and the most common non-destructive testing (NDT) methods. Incorporating sustainability and circularity, students will gain the analytical skills to make informed decisions in weld design and quality assurance.

Module 3, Cast component design for recyclability
The module aims to equip students with advanced knowledge and practical skills for designing cast components that enable efficient recycling and contribute to circular material flows. Casting plays a central role in many industries, yet recyclability is often compromised by material choices, process routes, and design features. This module addresses these challenges by introducing students to the relationships between alloy composition, casting processes, component geometry, and recyclability outcomes.

Students will gain insights into lifecycle thinking and the role of foundries in the circular economy, learning how to evaluate cast products not only for performance and cost but also for their environmental footprint and potential for reuse. The module highlights the critical role of design in enabling high-quality secondary materials and avoiding downcycling, while also addressing current regulations and emerging sustainability standards.

By integrating theoretical principles with case studies and practical design exercises, students will develop the ability to critically assess existing cast components and propose innovative solutions that improve recyclability without compromising functionality. The module thus prepares students to take an active role in advancing sustainable engineering practices and shaping the future of recyclable casting in industrial applications.

Learning outcomes (after completion of the course the student should be able to)

  • master problems with open solutions spaces which includes to be able to handle uncertainties and limited information.
  • lead and participate in the development of new products, processes and systems using a holistic approach by following a design process and/or a systematic development process.
  • work in multidisciplinary teams and collaborate in teams with different compositions
  • show insights about and deal with the impact of engineering solutions in a global, economic, environment and societal context.
  • orally and in writing explain and discuss information, problems, methods, design/development processes and solutions
Additional learning outcomes Module 1, Joining for Disassembly:
  • Discuss joining concepts more suitable for disassembly in design and manufacturing, and contrast them with fusion methods like welding.
  • Evaluate adhesive bonding, mechanical joining, soldering, and brazing in terms of materials, requirements, and cost.
    • Identify suitable adhesive bonding techniques, and discuss surface treatments for different engineering applications.
    • Compare mechanical joining methods (e.g., riveting, clinching, hemming) and assess their pros and cons for sustainable design.
    • Understand basic principles of brazing, including metallurgy and joint design.
  • Select appropriate joining methods for aluminium-to-aluminium and aluminium-to-other-metal applications.
  • Communicate technical choices in multidisciplinary contexts, considering sustainability, manufacturability, performance, and circularity.
Additional learning outcomes Module 2, Weld Design for Sustainability:
  • Compare common welding processes and materials, focusing on weldability, efficiency, and sustainability.
  • Understanding the basic theory of structural systems and strength of materials relevant to weld design.
  • Classify welds and interpret welding drawings for different joint and weld types.
  • Outline weld simulation and how welding affects materials, including internal stresses and their impact on mechanical properties.
  • Describe common non-destructive testing (NDT) methods for finding weld defects.
  • Propose suitable construction and weld design choices under different loading conditions whilst considering quality requirements, durability, and sustainability.
Additional learning outcomes Module 3, Cast component design for recyclability:
  • Explain global recycling trends and their implications for casting industries.
  • Evaluate alloy systems and their recyclability, considering contamination risks, material separation, and remelting behavior.
  • Assess the influence of different casting processes and design features on recyclability and resource efficiency.
  • Apply principles of design for recycling (DfR), including material marking, digital product passports, and eco-design tools.
  • Analyse sector-specific case studies and compare conventional vs. recyclable casting design strategies.
  • Propose cast component solutions that balance manufacturability, performance, cost, and recyclability.
  • Interpret relevant recycling standards, codes, and regulatory frameworks influencing casting design.

Content

Contents Module 1, Joining for Disassembly:

The module introduces metal component joining as an aspect of sustainable design focusing on alternatives to high-temperature processes such as fusion welding.
  • Adhesive bonding in terms of joint design, adhesive types, bond configurations, and necessary surface treatments.
  • Mechanical joining methods such as clinching, hemming, riveting, mechanical interlocking, and threaded fasteners are examined with respect to material compatibility, structural performance, cost, and recyclability - particularly for aluminium-to-aluminium and aluminium-to-other-metal connections.
  • Fundamentals of soldering and brazing, including basic definitions, joint design considerations, and key metallurgical principles relevant to low-temperature joining.
Across all topics, the focus is on evaluating joining strategies in terms of material properties, sustainability, and real-world application.

Contents Module 2, Weld Design for Sustainability:

Students are introduced to commonly used welding processes, materials, and their weldability, with particular emphasis on selecting sustainable and efficient solutions. The module covers the competences required of weld coordinators, weld engineers, and weld designers in accordance with ISO 14731. Different types of weld imperfections are examined, and the importance of quality requirements in welding is addressed based on ISO 3834.

Fundamental concepts of statics and strength of materials relevant to weld design are included, together with design considerations that promote durability and resource efficiency. The module also discusses weld quality classes in line with ISO 5817, various joint and weld types, and the interpretation of welding drawings.

A central part of the module is weld design under both static and fatigue loading, highlighting how design choices influence product lifetime and sustainability. Learning is reinforced through practical examples and assignments, while guest lectures from industry provide additional perspectives on sustainable practices in weld design.

The module introduces weld defects and non-destructive testing techniques, as well as thermal modelling and residual stress.

Contents Module 3, Cast component design for recyclability:

The module is structured into five sections.
  • Section 1 Introduction to Recyclability in Casting, which covers global recycling trends, lifecycle thinking, alloy classifications, circular economy principles, key sustainability metrics, and case studies.
  • Section 2 Material Selection and Alloy Compatibility, which talks about alloying elements and recyclability, contamination risks, low-alloy vs. multi-phase systems, mono-material design, recycling codes, and international standards.
  • Section 3 Casting Process Influence on Recyclability, which covers comparison of processes, role of sand, binders and coatings, core design, defect control, remelting energy, and challenges of large-scale castings.
  • Section 4 Design for Recycling: Methods and Tools, which talks about DfR vs. reuse, material marking and tracking, digital product passports, eco-design software, and hybrid recycling strategies.
  • Section 5 Integrated Case Studies and Future Trends, which includes sector-specific analyses, regulatory landscape, emerging recycling technologies, and visions for circular casting ecosystems

Organisation

The course is run by a teaching team and project tasks to be solved in a group. The course is supplemented by on-demand teaching and learning of the skills necessary for the project. The project team includes university examiners, a pole of university supervisors and external co-supervisors and guest lecturers from industry.

The course emphasizes active dialogue both among participants and between participants and lecturers. It integrates theory with professional practice through a blend of in-person sessions, online workshops, and self-paced study via the Canvas learning platform. Between the sessions and workshops, participants engage in lectures, literature studies, analyses, and reflective exercises while networking and collaborating with peers.

Literature

Additional selected articles from international journals will be provided on Canvas. With input from the teaching team, students will be encouraged to identify and acquire relevant literature throughout their projects.

Examination including compulsory elements

Module 1, Joining for Disassembly, 2.5 HEC
  • Participation including preparatory quizzes
  • Project presentations
  • Oral examination
Module 2, Weld Design for Sustainability, 2.5 HEC
  • Participation including preparatory quizzes
  • Project presentations
  • Oral examination
Module 3, Cast component design for recyclability, 2.5 HEC
  • Participation
  • Project presentations
  • Home assignments

The course examiner may assess individual students in other ways than what is stated above if there are special reasons for doing so, for example if a student has a decision from Chalmers about disability study support.

The course syllabus contains changes

  • Changes to course rounds:
    • 2025-11-04: Examinator Examinator Johan Ahlström (jnah) added by UOL
      [Course round 1]