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MS 115b: Fundamentals of Materials Science

Solutions 2 (60pts)
13.2 (10pts) A large thick plate of steel is examined by X-ray methods, and found to contain no detectable cracks. The equipment can detect a single edge-crack of depth a = 5mm or greater. The steel has a fracture toughness
-3/2 -2

KC

of 40MNm and a yield strength of 500 MNm . Assuming that the plate contains cracks on the limit of detection, determine whether the plate will undergo general yield or will fail by fast fracture before general yielding occurs. What is the stress at which fast fracture would occur? Calculate the stress for failure by (a) general yield and (b) fast fracture. (a) (b)

= 500MNm 2
=

for general yield.

KC 40 = = 319MNm 2 , a 0.005

for fast fracture, assuming that a crack on the limit of detection is present. The plate will fail by fast fracture before it fails by general yield. Answer : Failure by fast fracture at 319MNm-2

13.3 (10pts) The fuselage of a passenger aircraft can be considered to be an internally pressurized thin walled tube of diameter 7 m and wall thickness 3 mm. It is made from aluminum alloy plate with a fracture toughness
-3/2 -2

K C of

100MNm . At cruising altitude, the internal gauge pressure is 0.06MNm . Multiple fatigue cracks initiated at a horizontal row of rivet holes, and linked to form a single long axial through thickness crack in the fuselage. Estimate the critical length at which this crack will run, resulting in the break-up of the fuselage.

pr 0.06MNm 2 0.5 7000mm = = 70MNm 2 , t 3mm

KC = Y a , Y = 1
1K 1 100MNm 3/ 2 a= C = = 0.65m 70MNm 2
2 2

r
t

Answer : 0.65m.

16.3 (10pts) In order to test the strength of a ceramic, cylindrical specimens of length 25 mm and diameter 5mm are put into axial tension. The tensile stress which causes 50 percent of the specimens to break is 120MNm-2. Cylindrical ceramic components of length 50 mm and diameter 11 mm are required to withstand an axial tensile stress

with a survival probability of 99 percent. Given that m=5, use equation (16.7) to determine

1.

V m V (11/ 2) 2 mm 2 50mm = = 9.7 PS (V ) = exp , V0 0 V0 (5 / 2) 2 mm 2 25mm


For the test specimens, eqn (16.7) gives

1 120MNm 2 5 120MNm 2 , 0 = = 129MNm 2 PS (V0 ) = 0.5 = exp 1/ 5 1 0 ( ln 0.5)


For the components, eqn (16.7) gives
5 1/ 5 1 1 2 ln 0.99 2 PS (V ) = 0.99 = exp 9.7 , = 129MNm = 32.6MNm 129MNm 2 9.7

Answer : 32.6 MNm-2 17.1 (10pts) A component is made of a steel for which K C = 54MNm
3/ 2

. Non-destructive testing by ultrasonic

methods shows that the component contains cracks of up to 2a = 0.2mm in length. Laboratory tests show that the crack-growth rate under cyclic loading is given by

da 4 = A ( K ) dN
where

A = 4 1013 (MNm 2 ) 4 m 1 . The component is subjected to an alternating stress of range


= 180MNm 2

about a mean tensile stress of /2 . Given that Catastrophic failure will occur when

K = a , calculate the number of cycles to failure.

180MNm -2 a f = 54MNm -2 ,
Now

a f = 0.029m

da 1 1 4 = A ( K ) = A( ) 4 2 a 2 , dN = 2 da , B A( )4 2 = 4.14 103 m 1 4 2 dN A( ) a

Nf

dN = N f 0 =

1 1 2 da a0 B a 1 11 1 1 1 6 = = 3 = 2.4 10 B a f a0 4.14 10 0.029 0.0001


af

Answer :

2.4 106 cycles

17.2 (10pts) An aluminum alloy for an airframe component was tested in the laboratory under an applied stress which varied sinusoidally with time about a mean stress of zero. The alloy failed under a stress range, , of 280MNm-2 after 105 cycles; under a range of 200MNm-2, the alloy failed after 107 cycles. Assuming that the fatigue behaviour of the alloy can be represented by

( N f ) = C
a

where a and C are material constants, find the number of cycles to failure. stress range of 150MNm-2.

N f for a component subjected to a

280MNm 2 (105 ) = C , 200MNm 2 (107 ) = C


a a

a=

0.073 1 1 280 = 649MNm 2 , C = 280MNm 2 (105 ) log = 0.073 = 2 200 13.7


1/ a

C Nf =
Answer :

649 = 150

13.7

= 5.2 108

5.2 108 cycles

20.2 (10pts) An alloy tie bar in a chemical plant has been designed to withstand a stress
12 1

of

25MNm-2 at 620C.

Creep tests carried out on specimens of the alloy under these conditions indicated a steady-state creep rate,

, of

3.110 s . In service it was found that, for 30 percent of the running time, the stress and temperature increased to 30MNm-2 and 650C. Calculate the average creep rate under service conditions. It may be assumed that the alloy creeps according to the equation

= A 5 e Q / RT
where A and 160 kJ mol .
-1

Q are constants, R is the universal gas constant and T is the absolute temperature. Q has a value of

5 160kJ/mol A = 1 15 exp ( Q / RT ) = 3.1 1012 s 1 ( 25MNm 2 ) exp 8.314J/K mol (620 + 273)K

= 7.26 1010 s 1 ( MNm 2 )


5

12 1 2 = A ( 30MNm 2 ) exp = 15.5 10 s 8.314J/K mol (650 + 273)K

160kJ/mol

= 0.71 + 0.3 2 = ( 0.7 3.1 + 0.3 15.5 ) 1012 s 1 = 6.82 1012 s 1


Answer :

6.82 1012 s 1

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