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PLANT MATERIAL PROBLEMS Material Science Volume 2 of 2 Creep
PLANT MATERIAL PROBLEMS DOE-HDBK-1017/2-93 Plant
Materials Fundamental requirements during design and
manufacturing for avoiding fatigue failure are different for
different cases. For a pressurizer, the load variations are fairly low,
Web but the cycle frequency is high; therefore, a steel of high fatigue
strength and of high ultimate tensile strength is desirable. The
www.tpub.com reactor pressure vessel and piping, by contrast, are subjected to
Bottom of Form large load variations, but the cycle frequency is low; therefore, high
ductility is the main requirement for the steel. Thermal sleeves are
Home used in some cases, such as spray nozzles and surge lines, to
minimize thermal stresses. Although the primary cause of the
phenomenon of fatigue failure is not well known, it apparently arises
from the initial formation of a small crack resulting from a defect or
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... Administration microscopic slip in the metal grains. The crack propagates slowly at
. Advancement first and then more rapidly when the local stress is increased due to a
Aerographer decrease in the load-bearing cross section. The metal then fractures.
Automotive Fatigue failure can be initiated by microscopic cracks and notches,
Aviation and even by grinding and machining marks on the surface;
Combat
Construction therefore, such defects must be avoided in materials subjected to
Diving cyclic stresses (or strains). These defects also favor brittle fracture,
Draftsman which is discussed in detail in Module 4, Brittle Fracture. Plant
Engineering operations are performed in a controlled manner to mitigate the
Electronics effects of cyclic stress. Heatup and cooldown limitations, pressure
Food and Cooking
Math limitations, and pump operating curves are all used to minimize
Medical cyclic stress. In some cases, cycle logs may be kept on
Music various pieces of equipment. This allows that piece of equipment
Nuclear to be replaced before fatigue failure can take place. Work (Strain)
Fundamentals Hardening W ork hardening is when a metal is strained beyond
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the yield point. An increasing stress is required to produce
 Religion additional plastic deformation and the metal apparently becomes
USMC stronger and more difficult to deform. Stress-strain curves are
discussed in Module 2, Properties of Metals. If true stress is
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plotted against true strain, the rate of strain hardening tends to
ROM's become almost uniform, that is, the curve becomes almost a straight
Printed Manuals line, as shown in Figure 1. The gradient of the straight part of the
Downloadable Books line is known as the strain hardening coefficient or work hardening
coefficient, and is closely related to the shear modulus (about
proportional). Therefore, a metal with a high shear modulus will
have a high strain or work hardening coefficient (for example,
molybdenum). Grain size will also influence strain hardening. A
material with small grain size will strain harden more rapidly than the
same material with a larger grain size. However, the effect only
applies in the early stages of plastic deformation, and the influence
disappears as the structure deforms and grain structure breaks down.
Work hardening is closely related to fatigue. In the example on
fatigue given above, bending the thin steel rod becomes more difficult
the farther the rod is bent. This is the result of work or strain
hardening. Work hardening reduces ductility, which increases the
chances of brittle failure. MS-05 Page 28 Rev. 0

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