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Part: ____________________________
K c a 0.003
a) For the aluminium fuselage: = 400 =38.8 MPa m1/2,
which is lower than the fracture toughness of the alloy, therefore it wont fail by
fast fracture. [6 marks]
b) Miners Rule determines the fatigue failure under cumulative loading modes. If
there are k different stress levels of cyclic loading and the number of cycles to
failure at a stress is Nfi, then the damage fraction at this cyclic is Ni / Nfi, where
Ni is the number of cycles at this stress level. Failure occurs when the sum of
the damage fraction reaches 1. [4 marks]
c)
10 5 106
(I) + =0.12<1
10 6 5 107
therefore the alloy will not experience fatigue fracture under the
situation (I)
[5 marks]
4 5 5
10 10 10
(I) 6
+ 7
+ 4
=5.01>1
10 5 10 2 10
therefore the alloy will experience fatigue fracture under the situation
(II)
[5 marks]
Setter: __________HD________________
Assessor: __________________________
1
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2
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(a)
[3 marks]
Ceramic shows an elastic-brittle response. It has higher yield stress when it is under
compression
Metal shows elastic-plastic response with ductile necking to the final failure.
Polymer shows ductile response with considerable necking and alignment of polymer
before final extension and failure.
[3 marks]
(b)
3
a2 + a2 = (4r)2
X = a - 2r = 0.351-20.1244 = 0.1032 nm
So the radius of atom that fits into the largest hole is half of the X, = 0.0516nm
[3 marks]
c) Force at the horizontal plane is F, and the shear force (// to the plane) on the
plane at angle is Fsin. Area of the ellipse (plane at angle ) is A/cos.
Hence the shear stress on the plane at angle is
4
stress on the inclined plane is at a maximum when is 45
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5
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(a)
liquidus
Solidus
Max
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6
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(c) reading from the phase diagram; solid forms at ~650 C and is ~ 1 wt.% Cu.
[2 marks]
(d) Draw in tie line on phase diag in Al + L phase field.
CS = 3 wt.% Cu
CL = 13.5 wt.% Cu
C0= 4 wt.% Cu
C SC 0 34
F L= = =0.10
C S C L 313.5
C 0C L 413.5
F S= = =0.90
C SC L 313.5
solid
liquid
[4 marks]
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
7
__________________ Year Examinations Solution No: ___3_____________
Part: ____________________________
(e)
[2 marks]
(log time)
y
Initially solution strengthened. In region a of above figure, initially drops due
to Cu atoms out of solution, thus reducing solid solution strengthening. Then GP
zones are nucleated and grow. Strength increases due to coherency strains. (Under
aged)
In region b of above figure, GP zones dissolve and '' precipitates nucleate and
grow. As particles grow bigger, they are less easy to cut so strength increases.
(Peak aged)
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8
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
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Dislocations will cut though small hard particles and bow around large well dispersed
particles via Orowan bowing.
[8 marks]
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Part: ____________________________
[ 4 marks]
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
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Part: ____________________________
t
2 a=t a=
(b) If the crack length is 2a and then 2
hence safety is ensured if the stress is always less than or equal to equation 1
C K lc
=
t
2
where C is a constant near unity,
The wall thickness of the pressure vessel is designed to contain the pressure P
without yielding
Pr
h=
t
hence to avoid yielding the hoop stress must be less than the yield stress. To
achieve this, set the thickness in equation 2
Pr
t
y
Pr
2y
Or
2
P ( )
2C 2 K lc
r y
So, the maximum pressure is carried most safely by the material with the greatest
value of
K lc2
M 1= ( )
y
y
This can be maximised by making very small, using say lead, but this would
make the vessel very heavy. Hence, use equation 2. The thinnest wall is the one
y
with the highest so maximise this.
M 2= y
[10 marks]
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11
Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(c)
M2
M1
Suitable materials are carbon and stainless steels and low alloy steels most
favourably. Also, Ni alloys, Cu alloys and Al alloys. Ti alloys.
y
Ni and Ti alloys may be rejected on cost grounds. Al and Cu have lower than
steels and so may be rejected.
In a nuclear facility, stainless steel should be used as it resists corrosion. Corrosion
would be very dangerous. In fact, nuclear pressure vessels are usually made from
316 stainless steel.
[6 marks]
Setter: _____________________________
12
Assessor: __________________________
Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
a) Fracture strength of ceramics depends on the size of flaw it contains. The nature
of ceramic processing is such that defects of variable size are present in the
ceramic. Therefore there is an inherent uncertainty in the failure stress. The failure of
a ceramic component depends on the probability of there being a flaw of a critical
size. So the strength must be described as statistical terms.
[4 marks]
Setter: _____________________________
13
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
{[ ]}
12
Ps ( V 0 )=10.5=exp
0
{[ ]}
12
50
Ps ( V 0 )=0.5=exp
0
{ [ ]}
12
V max
Ps ( V )=0.99998=exp
V 0 0
6 3 12
0.693147
2.00002 1 0
5
=
1.7 10 m 50
1.13 1 0 m max
4 3 [ ]
12
34657=0.01504
50
[ ]
max
14
Pr 14.75 MPa 0.04 m
h= = =236 MPa
t 0.0025 m
[10 marks]
Setter: ___________DPW______________
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(a) label fine pearlite, coarse pearlite, upper and lower bainite, 0%, 50% and 100%
transformation. Austenite and unstable austenite. [4 marks]
15
Setter: _____________________________
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
(b) (i) as above plus . A mixture of pearlite and ferrite, or normalised steel: laminar
structure of Fe3C and ferrite(bcc) with crystals of pre-eutectoid ferrite.
pearlite
ferrite
[3 marks]
b(ii)
(i). Martensite is formed. Martensite is formed when austenite is quenched at such
a high rate that the C atoms do not have time to diffuse and form Fe3C. It forms
lenticular grains of a highly strained body centred tetragonal structure with a high
dislocation density. This gives very high hardness but very low toughness.
[3marks]
16
Setter: _____________________________
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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT
Part: ____________________________
b (iii) In tempering the martensite is heated to over 200 C and Fe3C begins to
precipitate out of the martensite producing a fine dispersion of cementite
nanoparticles in ferrite
[3 marks]
b(iv) pearlite/ferrite is ductile and can readily be hot worked allowing the shape of the
helmet to be beaten to shape due to a low yield stress. This is too soft to be of much
use as armour. Martensite is hard with high yield stress but very brittle and will
shatter readily making it of little use as armour. Tempered martensite has a lower
yield stress than martensite but higher than pearlite, the nano dispersion hinders
dislocation motion. Toughness is significantly higher than martensite.
[3 marks]
17
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(c)
Mo, Mn, Cr and Ni all shift the bainite nose to longer time. This increases the
HARDENABILITY of the steel. (i.e. Jominy test). This allows thicker sections may be
quenched to martensite.
18
In C In In Incr Fo st
cr o cr cr ease r ab
ea m ea ea s m le
se bi se se hard s ca
s ne s s ena st rbi
st s st to bilit ab de
re wi re ug y le s.
ng th ng hn ca In
th S th es rb cr
bu to s id ea
t m es se
re ak an s
du e d yi
ce le in el
s ss hi d
du br bi str
cti itt ts es
lit le gr s
y ai wh
n ile
gr ret
o ai
wt ni
h. ng
Si du
gn cti
if lity
ca .
nt Hi
to gh
ug te
he m
ne p
r to
ug
hn
es
s.
The German and British armours are of comparable thickness and hardness. The
German armour contains no Mo and this makes the steel less tough. The Germans
had run out of Mo by the end of the war and had increased the C, Cr and V content
of their steel to compensate. While it is possible to heat treat the steel indicated to
give impact resistance, this is not the case and in fact the armour contained
tempered bainite indicating a slack quench.
[4 marks]
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19
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