Material Failure

Presented by :
I Made Wicaksana Ekaputra
Several cases of failure

Ship-cyclic loading
from waves.
Adapted from chapter-opening
photograph, Chapter 8, Callister 7e. (by
Neil Boenzi, The New York Times.)

Computer chip-cyclic
thermal loading.
Adapted from Fig. 22.30(b), Callister 7e.
(Fig. 22.30(b) is courtesy of National
Semiconductor Corporation.)
Hip implant-cyclic
loading from walking.
Adapted from Fig. 22.26(b),
Callister 7e.

I Made Wicaksana E./ Prodi Teknik Mesin 2

Design Strategy:
Stay Above The DBTT!
• Pre-WWII: The Titanic
Reprinted w/ permission from R.W. Hertzberg,
"Deformation and Fracture Mechanics of Engineering
Materials", (4th ed.) Fig. 7.1(a), p. 262, John Wiley and
Sons, Inc., 1996. (Orig. source: Dr. Robert D. Ballard,
The Discovery of the Titanic.)
• Problem: Steels were used having DBTT’s just below room temperature.
I Made Wicaksana E./ Prodi Teknik Mesin
• WWII: Liberty ships
Reprinted w/ permission from R.W. Hertzberg,
"Deformation and Fracture Mechanics of Engineering
Materials", (4th ed.) Fig. 7.1(b), p. 262, John Wiley and
Sons, Inc., 1996. (Orig. source: Earl R. Parker,
"Behavior of Engineering Structures", Nat. Acad. Sci.,
Nat. Res. Council, John Wiley and Sons, Inc., NY,
1957.)
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Influence of Temperature on
Impact Energy

• Ductile-to-Brittle Transition Temperature (DBTT)...

FCC metals (e.g., Cu, Ni)

Impact Energy

BCC metals (e.g., iron at T < 914ºC)

polymers
Brittle More Ductile

High strength materials ( s y > E/150)

Temperature Adapted from Fig. 8.15,

Callister & Rethwisch 8e.
Ductile-to-brittle
transition temperature

I Made Wicaksana E./ Prodi Teknik Mesin 4

 • Types of material failure
1. Deformation failure

What is a deformation failure ?

Deformation failure is a change in the physical dimensions or shape of a

component that is sufficient for its function to be lost or impaired.

2. Fracture

What is Fracture ?

Fracture is a cracking to the extent that a component is separated into two or

more pieces.

Time independent Static loading

• Elastic • Brittle
• Plastic • Ductile
• Creep rupture
Deformation Fracture
Time dependent
• Creep Fatigue

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• Elastic and Plastic Deformation

σUTS N P
Elastic Plastic

F σy
σy
Upper Yie
Stress, σ

Stress, σ
σ
Lo

0.2%
Strain, ε

Strain, ε
• Elastic deformation is recoverd immediately upon unloading

• Plastic deformation is not recovered upon unloading and is therefore permanent..

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Ideal Vs. Real

• Stress-strain behavior (Room Temp):

s
E/10 perfect mat’l-no flaws TSengineering << TS perfect
materials materials
carefully produced glass fiber

E/100 typical ceramic typical strengthened metal

e
typical polymer
0.1

I Made Wicaksana E./ Prodi Teknik Mesin 7

• Plastic deformation

Ductile failure has extensive plastic deformation in the vicinity of the advancing crack. The

process proceeds relatively slow (stable). The crack resists any further extension unless there is

an increase in the applied stress.

Brittle failure, cracks may spread very rapidly, with little deformation. These cracks are more

unstable and crack propagation will continue without an increase in the applied stress.

Brittle

Ductile
Stress, σ

Strain, ε

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 Fracture Very Moderately
Brittle
behavior: Ductile Ductile

%AR or %EL Large Moderate Small

• Ductile fracture is Ductile: Brittle:

usually more desirable Warning before No
than brittle fracture. fracture warning

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Cup-and-Cone fracture Flat fracture

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• Evolution to failure:

necking void Coalescence Crack

of cavities propagation fracture
nucleation

• Resulting 50
50mm
mm
fracture
surfaces
(steel)
100 mm
particles From V.J. Colangelo and F.A. Heiser, Analysis of Fracture surface of tire cord wire loaded in tension.
Metallurgical Failures (2nd ed.), Fig. 11.28, p. 294, John Courtesy of F. Roehrig, CC Technologies, Dublin, OH.
serve as void Wiley and Sons, Inc., 1987. (Orig. source: P. Thornton, J. Used with permission.
Mater. Sci., Vol. 6, 1971, pp. 347-56.)
nucleation
sites.

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• Ductile:
-- one piece
-- large deformation

• Brittle
-- many pieces
-- small deformations

Figures from V.J. Colangelo and F.A. Heiser, Analysis of

Metallurgical Failures (2nd ed.), Fig. 4.1(a) and (b), p. 66 John
Wiley and Sons, Inc., 1987. Used with permission.

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• Ductile fracture

(a) SEM image showing spherical dimples resulting from a uniaxial

tensile load. (b) SEM image of parabolic dimples from shear loading.

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• Brittle fracture

Arrows indicate point at failure origination

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 • Intergranullar and Transgranullar fracture

I Made Wicaksana E./ Prodi Teknik Mesin 15

 • Fatigue

Fatigue testing apparatus for rotating bending test

 Fatigue is a form of failure that occurs in structures subjected to dynamic stresses over an
extended period.
 Under these conditions it is possible to fail at stress levels considerably lower than tensile or
yield strength for a static load.
 Common failure in bridges, aircraft and machine components.

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• Variation of stress with time that
accounts for fatigue failures.

• The stress may be axial (tension-

compression), flexural (bending) or
torsional (twisting) in nature.

• There are 3 fluctuating stress-time

modes seen in the figure: (a) reversed
stress cycle - symmetrical amplitude
about a mean zero stress level; (b)
repeated stress cycle - asymmetrical
maxima and minima relative to the
zero stress level; (c) variable
(random) stress level

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• Fracture surface with
crack initiation at top.
Surface shows
predominantly dull
fibrous texture where
rapid failure occurred
after crack achieved
critical size.

• Fatigue failure

1. Crack initiation

2. Crack propagation

3. Final failure

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• Creep

At an elevated temperature, creep was occured when a metal is subjected to a

constant tensile load. Since materials have its own different melting point, each will
creep when the homologous temperature > 0.5.

Elastic
Primary

Tertiary
Steady state

Testing _ temperatur e(Tt )

Homogolous _ temp (Th)   0.5
Melting _ temperatur e(Tm)

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 Steam Turbine Power Oil Refinery

Process Plant
Nuclear Power Plant

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21
 Creep curve

s
s,e

0 t

Primary Creep: slope (creep rate) decreases with time.

Secondary Creep: steady-state i.e., constant slope.
Tertiary Creep: slope (creep rate) increases with time, i.e. acceleration of
rate.

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Micrography of creep specimen

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Tugas:

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Kumpulkan: 19 Februari 2018

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