Beruflich Dokumente
Kultur Dokumente
ISSUES TO ADDRESS...
• How do cracks that lead to failure form?
• How is fracture resistance quantified? How do the fracture
resistances of the different material classes compare?
• How do we estimate the stress to fracture?
• How do loading rate, loading history, and temperature
affect the failure behavior of materials?
Chapter 8 - 2
Ductile vs Brittle Failure
• Classification:
Fracture Very Ductile Moderately
(Pure gold, Lead) Brittle
behavior: Ductile
Chapter 8 - 3
Example: Pipe Failures
• Ductile failure:
-- one piece
-- large deformation
• Brittle failure:
-- many pieces
-- small deformations
Chapter 8 - 4
Moderately Ductile Failure
• Failure Stages:
void void growth shearing
necking fracture
nucleation and coalescence at surface
s
• Resulting 50
50mm
mm
fracture
surfaces
(steel)
100 mm
From V.J. Colangelo and F.A. Heiser, Fracture surface of tire cord wire
Analysis of Metallurgical Failures (2nd loaded in tension. Courtesy of F.
ed.), Fig. 11.28, p. 294, John Wiley and Roehrig, CC Technologies, Dublin,
Sons, Inc., 1987. (Orig. source: P. OH. Used with permission.
Thornton, J. Mater. Sci., Vol. 6, 1971, pp.
347-56.) Chapter 8 - 5
Moderately Ductile vs. Brittle Failure
Chapter 8 - 6
Brittle Failure
Arrows indicate point at which failure originated
Chapter 8 - 8
Brittle Fracture Surfaces
• Intergranular
(between grains)
Chapter 8 - 9
Ideal vs Real Materials
• Stress-strain behavior (Room T):
s perfect mat’l-no flaws
E/10 TSengineering << TS perfect
materials materials
carefully produced glass fiber
Chapter 8 - 10
Concentration of Stress at Crack Tip
Chapter 8 - 11
Flaws are Stress Concentrators!
• Griffith Crack
1/ 2
a
sm 2so K t so
t
t where
t = radius of curvature
so = applied stress
sm = stress at crack tip
Chapter 8 - 12
Engineering Fracture Design
• Avoid sharp corners!
s smax
Stress Conc. Factor, K t =
s0
w
smax
2.5
r, h
fillet 2.0 increasing w/h
radius
Adapted from Fig. 1.5
8.2W(c), Callister 6e.
(Fig. 8.2W(c) is from G.H.
Neugebauer, Prod. Eng.
(NY), Vol. 14, pp. 82-87
1943.)
1.0 r/h
0 0.5 1.0
sharper fillet radius
Chapter 8 - 13
1.25 x 10 2
1/ 2
s m 2(170MPa)
2.5 x 10 4
2404 MPa
2404
Stress Conc. Factor, K t = 4
170
Chapter 8 - 14
Crack Propagation
Cracks having sharp tips propagate easier than cracks
having blunt tips
• A plastic material deforms at a crack tip, which
“blunts” the crack.
deformed
region
brittle ductile
Chapter 8 - 15
Criterion for Crack Propagation
Crack propagates if crack-tip stress (sm)
exceeds a critical stress (sc)
1/ 2
2E s
i.e., sm > sc sc
a
where
– E = modulus of elasticity
– s = specific surface energy
– a = one half length of internal crack
Chapter 8 - 16
Criterion for Crack Propagation
A relatively large plate of a glass is subjected to
a tensile stress of 40 Mpa. If the specific
surface energy and modulus of elasticity dor
this glass are 0.3 J/m2 and 69 Gpa,
respectively, determine the maximum length
of a surface flaw that is possible without
fracture.
2 E s
a
sc ^ 2
(2)(69 x10^9N/m^2 )(0.3 N / m)
(40x10^6 N/m^2 )^ 2
8.2 x10^ 6m 0.0082mm Chapter 8 - 17
Fracture Toughness
Y is a dimensionless parameter.
Chapter 8 - 18
Chapter 8 - 19
Fracture Toughness Ranges
Graphite/
Metals/ Composites/
Ceramics/ Polymers
Alloys fibers
Semicond
100
C-C(|| fibers) 1
70 Steels
60 Ti alloys
50
40
Al alloys
30 Mg alloys Based on data in Table B.5,
K Ic (MPa · m0.5 )
s c amax s
A c amax B
Chapter 8 - 24
Influence of Temperature on
Impact Energy
Chapter 8 - 25
Design Strategy:
Stay Above The DBTT!
• Pre-WWII: The Titanic • WWII: Liberty ships
Reprinted w/ permission from R.W. Hertzberg, Reprinted w/ permission from R.W. Hertzberg,
"Deformation and Fracture Mechanics of Engineering "Deformation and Fracture Mechanics of Engineering
Materials", (4th ed.) Fig. 7.1(a), p. 262, John Wiley and Materials", (4th ed.) Fig. 7.1(b), p. 262, John Wiley and
Sons, Inc., 1996. (Orig. source: Dr. Robert D. Ballard, Sons, Inc., 1996. (Orig. source: Earl R. Parker,
The Discovery of the Titanic.) "Behavior of Engineering Structures", Nat. Acad. Sci.,
Nat. Res. Council, John Wiley and Sons, Inc., NY,
1957.)
S = stress amplitude
• Fatigue limit, Sfat: case for
--no fatigue if S < Sfat unsafe steel (typ.)
Sfat
10 3 10 5 10 7 10 9
N = Cycles to failure
S = stress amplitude
• For some materials, case for
there is no fatigue unsafe Al (typ.)
limit!
safe Adapted from Fig.
8.19(b), Callister &
Rethwisch 8e.
10 3 10 5 10 7 10 9
N = Cycles to failure
Chapter 8 - 28
Rate of Fatigue Crack Growth
• Crack grows incrementally
typ. 1 to 6
da
K
m
dN
~ s a
increase in crack length per loading cycle
crack origin
• Failed rotating shaft
-- crack grew even though
Kmax < Kc
-- crack grows faster as
• s increases Adapted from
Fig. 8.21, Callister &
• crack gets longer Rethwisch 8e. (Fig.
• loading freq. increases. 8.21 is from D.J.
Wulpi, Understanding
How Components Fail,
American Society for
Metals, Materials Park,
OH, 1985.)
Chapter 8 - 29
Improving Fatigue Life
S = stress amplitude
1. Impose compressive Adapted from
surface stresses Fig. 8.24, Callister &
Rethwisch 8e.
(to suppress surface near zero or compressive sm
cracks from growing) moderate tensile sm
Larger tensile sm
N = Cycles to failure
Chapter 8 - 30
Creep
Sample deformation at a constant stress (s) vs. time
s
s,e
0 t
tertiary
primary
secondary
elastic
Chapter 8 - 32
Secondary Creep
• Strain rate is constant at a given T, s
-- strain hardening is balanced by recovery
stress exponent (material parameter)
Qc
e s K 2s exp
n
activation energy for creep
strain rate RT (material parameter)
material const. applied stress
Adapted from
• Strain rate 200 Fig. 8.31, Callister 7e.
Stress (MPa)
g.b. cavities
applied
stress
Chapter 8 - 34
Prediction of Creep Rupture Lifetime
• Estimate rupture time
S-590 Iron, T = 800ºC, s = 20,000 psi
data for
S-590 Iron
12 16 20 24 28
1 (1073 K )( 20 log tr ) 24x103
103 L (K-h)
Adapted from Fig. 8.32, Callister & Rethwisch
8e. (Fig. 8.32 is from F.R. Larson and J. Ans: tr = 233 hr
Miller, Trans. ASME, 74, 765 (1952).)
Chapter 8 - 35
Estimate the rupture time for
S-590 Iron, T = 750ºC, s = 20,000 psi
• Solution:
Core Problems:
Self-help Problems:
Chapter 8 - 38