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Academic Year 2014/15

ENG782s2 Structural Integrity

Exam
2 hours
Instructions: Answer all Three questions

Additional Information: This is a closed book exam

Provided: Data sheet provided

Calculators: Casio FX 85 Series or Casio FX 83 Series

Examiners: Professor Jie Tong and Dr Sarinova Simandjuntak
 Question 1

A. The effect of mean stresses on the fatigue strength may be described by the rule of
Goodman or Gerber, given as:
n
σa σ 
+  m  = 1
S a  Su 
Where:
n = 1 for Goodman and n = 2 for Gerber, σa is the applied stress amplitude, σm is the
applied mean stress, Sa is the fatigue strength of the material and Su is the ultimate
tensile strength of the material.

Show by sketches the two different rules above and discuss which one is the most
conservative (i.e., gives the lowest life time).
[4 Marks]

B. A component made of material A is safely designed for one million life cycles. The fatigue
strength of material A is 600MPa for one million life cycles and the ultimate tensile strength
of material A is 1100MPa.

(i) If the component is subjected to stress cycles with an amplitude stress of 550MPa and a
mean stress of 240MPa, determine whether the component is safe to operate for one
million cycles.
[6 marks]

(ii) What is the maximum stress amplitude that the component can withstand for 240MPa
mean stress?
[5 marks]

C. A through-the-thickness crack is detected in a cylindrical steel pressure vessel. The internal

diameter of the vessel is 5 m and the thickness of the wall is 20 mm. The vessel is to
sustain a maximum pressure of 4 MPa.

(i) If the crack length is found to be 2 mm and the crack plane is oriented at an angle
90-β with the hoop stress axis, β = 18°. Find the opening and shear stress intensity
factors KI and KII. Indicate the predominant loading mode experienced by the crack.
[10 Marks]

(ii) Find the equivalent mode I stress intensity factor using the maximum tangential
stress (MTS) criterion. If the fracture toughness of the material is 40 MPa√m, the
yield stress of the material is 450MPa, what would be the failure mode?
[5 Marks]

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 Question 2

A. A high temperature superheater pipe used in a power generation plant is made of a

steel alloy and its rupture performance could be determined using the Larson-Miller
equation which is represented by the following relationship:

LMP = T (log t r + 20 ) = −15564 (log σ ) + 58825 log σ − 27309

2

Where:
T is the temperature (Kelvin), tr the rupture time (hour) and σ the applied stress
(MPa).

(i) Estimate the maximum allowable stress to achieve a 25 year operation at

temperature of 650°C.
[8 Marks]

(ii) During the operation, the component could experience temperature fluctuation
which is often raised by 5°C. Consider the calculated maximum allowable stress
of the component (from part (i)), how will this affect the life of the component?
[6 Marks]

B. A hot liquid is passing through a pipe made of a medium carbon steel every now
and then. This event could lead to low cycle fatigue failure.

(i) Calculate the thermal stresses range using the following equation:
∆σ thermal = E.α .∆T
Given that:
The linear thermal expansion coefficient, α of the steel = 10.8 X 10-6 K-1
The internal temperature = 255°C
The external temperature = 100°C
The young’s modulus of the steel = 193 GPa
[4 Marks]

(ii) Estimate the fatigue life of the pipe (considering the mean stress is zero and utilising
the following equation and material data).
1 / n′
σaσ 
εa = + a  ,
E  K′ 
The cyclic strength coefficient, K’ = 450 MPa,
The cyclic strain hardening exponent, n’ = 0.10,
Fatigue strength coefficient σ′f = 1655 MPa,
Fatigue strength exponent b = −0.15,
Fatigue ductility coefficient ε′f = 0.4,
Fatigue ductility exponent c = −0.57.
[12 Marks]

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 Question 3

A. Describe plane stress and plane strain states, give examples of the two stress states.
Comment on the difference between fracture toughness and plane strain fracture toughness.
For critical structural components such turbine engine discs, which fracture toughness value
should be used for safe design purposes?
[10 Marks]

B. A surface crack of 4 mm depth and 10 mm surface length is found in a thick rectangular

component. The component is subjected to variable stresses from -100 to 200 MPa. The
stress intensity factor K is known to vary along the crack front and is given as:

1/ 4
1.12σ πa  2 a2 
K=  sin θ + 2 cos 2 θ 
Φ  c 

3π π a 2
where Φ = + , a is the depth and 2c is the surface crack length.
8 8 c2

10 mm

4 mm C
σ A θ
σ

Figure Q3

(i) Find the maximum and minimum stress intensity factors.

[5 Marks]

(ii) If the plane strain fracture toughness, K IC , is known as 80 MPa√m, find a

conservative estimate of the minimum crack length at fast fracture.
[5 Marks]

(iii) Assuming the crack shape (aspect ratio, a/c) remains unchanged under cyclic
loading during crack growth, the material constants for Paris law are C = 3×10-12 and
m = 3, find a conservative estimate of the life of the component to failure. Without
detailed calculation, comment on how life to failure would change if the stress cycle is
from -100 to 300.
[10 Marks]

2014-15 Page 3 of 6
 M.SI Structural Integrity Data Sheet

Advanced Fracture Mechanics

Stress intensity factor

K = σ πa × Y

Plastic zone size

2
1  K 
rP =   (for plane stress)
2π σ 
 ys 

2
1  K 
rP =   (for plane strain)
6π σ 
 ys 

Fatigue crack growth

da
= C (∆K )
m
∆ K = ∆ σ πa × Y ,
dN

m m
1− 1−
1 af 2
− ai 2
Nf = m , (m ≠ 2)
C∆σ π ym m m
2
1−
2

Plane strain fracture toughness – Validity check

a
0.45 ≤ ≤ 0.55
W
2
 KQ 
B, a ≥ 2.5 
σ 
 ys 
Pmax ≤ 1.10PQ

Angled crack stress intensity factor solutions

K I = σ θ cos 2 β πa
K II = σ θ cos β sin β πa

2014-15 Page 4 of 6
Maximum Tangential Stress (MTS) Criterion

Mixed mode crack growth is determined by the formation and propagation of a mode I branch at the tip of the initial
crack:

θ  θ  θ 
k Ieq = K I cos 3   − 3K II cos 2   sin 
 2 2 2

where θ is the initial branch crack direction given by the MTS criterion,

2
 θ  1 KI 1  KI 
tan  = ±   + 8
 2  4 K II 4  K II 

Fatigue & Creep

Cyclic stress

∆σ = σ max − σ min


σ a = σ max − σ min = ∆σ
 2 2

 σ + σ
σ m =
max min

2

R = σ min
 σ max

Goodman's rule:

σa σ m
+ =1
Sa Su

Miner's rule:

n1 n n n
+ 2 + 3 + .... = ∑ i = 1
Nf1 Nf 2 Nf 3 N fi

von Mises effective stress

σe = 1
2
(σ1 − σ2 )2 + (σ1 − σ3 )2 + (σ2 − σ3 )2
or
σe = 1
2
(σ x − σ y ) + (σ x − σ z ) + (σ y − σ z ) + 6(τ2xy + τ2xz + τ2yz )
2 2 2

Monotonic stress-strain curve

1
σ σ n
ε = + 
E K

2014-15 Page 5 of 6
Cyclic stress-strain curve
1
σ σ  n′
εa = a +  a 
E  K′ 

Strain-life relationship

∆ε p
= ε′f (2 N f )
c

2
∆ε σ′f
= (2 N f ) + ε′f (2 N f )
b c

2 E
∆ε σ′f − σ m
= (2Nf )b + ε′f (2 Nf )c
2 E

Neuber's rule

∆S 2
∆σ∆ε = K t
2

Linear rule

∆S
∆ε = K t
E

Masing's hypothesis

1
 1
∆σ  1−  ∆ σ n ′
 
∆ε = + 2 n ′   
E  K′ 

Larson-Miller parameter

LMP = T (log t r + c )

Creep-fatigue interaction
tj ni
∑t +∑
N fi
=1
rj

tj ni
C1 ∑ + C2 ∑ =1
t rj N fi

Thin cylinder under internal pressure

pD σ pD
σH = and σ L = H =
2t 2 4t

2014-15 Page 6 of 6