Effect of Stress Risers on Tensile Tests

Eileen OByrne-Hudson Mario Trinchero Jessica Enos Shawna Enos

SRJC Engineering 45 December 9, 2009

Great Failures From Poor Design

Failure around an escape hatch

DH.106 in flight

The de Havilland Comet:

Problems with explosive cabin decompression due to poor window design Punch riveting around the windows and escape hatches caused stress risers that induced failure

Great Failures From Poor Design

Liberty Ships
Ships had a tendency to break in half when in cold waters and overloaded Stress risers occurred where sharp corners on hatches met weld seams, and the welded design allowed cracks to propagate easily through the entire vessel

The S.S. Schenectady, A T2 tanker Liberty Ship

S.S. John W. Brown

1045 Steel
1045 is a medium carbon steel is used when greater strength and hardness is desired than in the "as rolled" condition. Extreme dimensional accuracy, straightness and concentricity combine to minimize wear in high speed applications. Turned, ground and polished bars can be machined asymmetrically with minimal distortion.

Properties of Steel
Chemical Composition: C=0.45%, Mn=0.75%, P=0.04% max, S=0.05% max Density : 7.872* 10 kg/m Modulus of elasticity : 201 GPa Thermal expansion (20 C) : 11.7*10-6 C Specific heat capacity : 486 J/(kg*K) Thermal conductivity : 50.9 W/(m*K) Electric resistivity: 1.62*10-7 Ohm*m Tensile strength (hot rolled) : 565 MPa Yield strength (hot rolled) : 310 MPa Elongation (hot rolled) : 16% Hardness (hot rolled) : 84 RB

Testing of Steel with Fractures

This is an image of the stress at the tip of a fracture Stress at the crack tip can be approximated by the formula A very small crack radius will result in a tip stress many times that of the applied stress

Sample Preparation
Each sample started as a standard 1045 tensile specimen, with a length of 2 and a diameter of 0.5. A crack was machined around the circumference of each sample. All cracks have a depth of 0.005. The three crack diameters are 0.002, 1/64 (0.0156), and 1/32 (0.0313). These diameters are at the very tip of the crack. The diameter of the smallest crack is a best estimation, as there were no tools available to measure the actual diameter.

Setup
We used a standard tensile testing setup for our tests.
Top Left: Tester with loaded sample; Bottom Left: Strain gauge on sample

Results
Stress- Strain Plot For 1045 Steel With C racks
140000 120000 100000

Stress (psi)

80000 60000 40000 20000 0 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Strain (in/in)

1/64" .002" 1/32" Standard 1045

Fracture Surfaces

0.002 fracture surface

1/64 fracture surface

1/32 fracture surface

Standard 1045 fracture surface

o vs. m
The following graphs are of the maximum stress at the crack tip compared to the value of the applied stress.

1/32
Stress- Strain Plot of Nnormal Stress and Stress at C rack Tip for 1/32" C rack
250000

200000

Stress (psi)

150000 100000

Normal At Stress Riser

50000

0 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Strain (in/in)

1/64
Stress- Strain Plot of Normal Stress and Stress at C rack Tip for 1/64" C rack
250000

200000

Stress (psi)

150000 100000

Normal At Stress Riser

50000

0 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Strain (in/in)

0.002
Stress- Strain Plot of Normal Stress and Stress at C rack Tip for 0.002" C rack
500000 450000 400000

Stress (psi)

350000 300000 250000 200000 150000 100000 50000 0 0 0.01 0.02 0.03 Strain (in/in) 0.04 0.05 0.06 Normal At Stress Riser

Interpretation of Results:
None of the samples exhibited the necking of the standard sample
Cracks induced a brittle failure instead of ductile

0.002 crack radius failed much earlier

Sharper stress risers effectively make material more brittle, indicating why rounded joints and seams are favored in many designs.

Work Cited
Kopeliovich, Dmitri. "Carbon steel SAE 1045." Subs Tech- Substances and Technology. 16 May 2008. Subs Tech, Web. 5 Dec 2009. <http://www.substech.com/dokuwiki/doku.php?id=carbon_steel_sae_1045>. "properties of 1045." metal supplies online. 2009. Web. 5 Dec 2009. <http://www.metalsuppliersonline.com/Research/Property/metals/845.asp>. Bureau of Labor Statistics, U.S. Department of Labor, Career Guide to Industries, 2008-09 Edition, Steel Manufacturing, on the Internet at <http://www.bls.gov/oco/cg/cgs014.htm> (visited December 05, 2009 ). Riveros, Guillermo A. "Numerical Evaluation of Stress Intensity Factors (KI) J-Integral Approach." Sep 2006. US Army Corps of Engineers, Web. 5 Dec 2009. <http://chl.erdc.usace.army.mil/library/publications/chetn/pdf/chetn-ix-16.pdf>. Liberty Ship. Wikipedia. 2009. Web. 7 Dec 2009. <http://en.wikipedia.org/wiki/Liberty_ship>. "Engineering Stress and Fatigue Experts - Summer 2007 News." Engineering Stress and Fatigue Experts - Home. Web. 07 Dec. 2009. <http://www.stressandfatigue.co.uk/alpha_omega_news.html>. "Stress concentration -." Wikipedia, the free encyclopedia. Web. 07 Dec. 2009. <http://en.wikipedia.org/wiki/Stress_risers>. "De Havilland Comet -." Wikipedia, the free encyclopedia. Web. 08 Dec. 2009. <http://en.wikipedia.org/wiki/De_Havilland_Comet>. "SS Schenectady -." Wikipedia, the free encyclopedia. Web. 08 Dec. 2009. <http://en.wikipedia.org/wiki/SS_Schenectady>. Greenwood, John T., ed. Milestones Of Aviation. [Westport]: Hugh Lauter Levin Associates, 1995. Print.