TeachingStaff

MaterialsandManufacturing2(ENB331)
DrTuquaboTesfamichael
(Unit Coordinator)
(UnitCoordinator)
t.tesfamichael@qut.edu.au
Semester2,2011
1

Lectures
Thursdays810aminRoomD101
TextBooks:
W.D.Callister,MaterialsScienceandEngineering:An
Introduction, (2007,7th Edition)
S.KalpakjianandS.R.Schmid,ManufacturingEngineeringand
Technology(2006,5th Edition)

Outline:
Outline:

Failure:Fracture,Fatigue,Creep(wks1,2&8,TT)
MetalCuttingandMachiningEconomics(wks3&4,MR)
CuttingToolTechnology andOperations(wks5&6,WS)
AdvancedManufacturing(wk7,MR)
PolymersandCeramics(wks9&10,MR)
Composites(wk11,TT)
JoiningProcesses(wk12,WS)

Lecturers:
DrMaksymRybachuk:maksym.rybachuk@qut.edu.au
DrWijithaSenadeera:w3.senadeera@qut.edu.au
Project:
DrRabiulAlam:RabiulA@nojapower.com.au
MrJonathanJames:jm.james@qut.edu.au
Tutorials:
MrMarkBroadmeadow:mark.broadmeadow@qut.edu.au
Mr Mark Broadmeadow: mark broadmeadow@qut edu au
MissMaryamShirmohammadi:m.shirmohammadi@qut.edu.au
MrIsuruWlckramasinghe:m.wickramasinghe@qut.edu.au
LabPracticals:
MrPeterGillett:peter.gillett@live.com.au
MrAlexanderMalaver:alexander.malaverrojas@qut.edu.au
Technicalstaff:
MrGregPaterson:g.paterson@qut.edu.au
MrArminLiebhardt:armin.liebhardt@qut.edu.au

Tutorials
Tutorialswillstartinweek3.
Youwillhave8tutorialsduringthesemester.
Pleasehavealooktheweekbyweektimetablein
theunitinformation.

All
AllocationtotutorialisViaQUTVirtual:
i
i l i Vi QUT Vi
l
https://qutvirtual.qut.edu.au/

Practical

GroupProject

Twopracs(wks46forprac1,wks79forprac2)
AllocationViaPracallocationsystem:
http://www.bee.qut.edu.au/study/current/resources/o
nlinesys/
Pracreportstobesubmittedindividually:
Prac reports to be submitted individually :

4informationclasses(wks2,3,5&7)andallocation
toclassesisViaQUTVirtual.
1demonstrationprac(wk8)thatyouneedto
allocateViaPracallocationsystem.
YouMUSTalsoallocateyourselftoaparticulargroup
of not more than 5 members through the
ofnotmorethan5membersthroughthe
BlackboardwebsiteundertheUsersandGroups
menu.
Groupreporttobesubmittedthroughtwostages
(progressreportinwk6andfinalreportinwk12).
Pleasereadtheprojecthandoutfordetail
information.

Duedatesforprac1isinwk7andprac2inwk102.

Pleasefollowtheformatgivenintheprachandoutsfor
yourpracreports.
Important:youmustwearcoveredshoeandshould
followanysafetyfromthelabdemonstratorand/or
technicalstaff!

Assessment

FailureMechanisms

Twoprac15%
GroupProject35%
Finalexam(50%)
CRAwillbeusedforthethreeassessments.

W.D.Callister,Chapter8
AdditionalReferences
Hertzberg:DeformationandFractureMechanicsof
EngineeringMaterials
g
g
Broek:ElementaryEngineeringFractureMechanics
Barsom &RolfeFractureandfatigueControlin
Structures
Farahmand,FractureMechanicsofMetals,
Composites,Welds,andBoltedJoints Applicationof
LEFM,EPFM,andFMDMTheory

FailuresinEngineeringStructures
MostfailuresinEngineeringstructuresoccurreddueto
propagationofcracksfromdefects.
Thiscanbecancaused:
poordesign,poormaterialselection,imperfections,
processingandfabricationsofmaterials, assemblyandservice
conditions of components, etc.
conditionsofcomponents,etc.

Examplesofcatastrophicfailure:

LibertyShipsandT2Tanker(WorldwarII).
CometAircraft(mid1950s).
Molassestank(1919,1973).
Titanic(1912).
KingsBridgeinMelbourne(1962).

Titanic , April 12, 1912

Improper Materials Selection

Titanic (Poor quality of steel for the hull structure)

10

T-2 Tanker in 1941

Failure due to Processing method

T2 Tanker (weld defects initiated cracks)

11

Oil Tank Barge in 1972

12

Point Pleasant bridge,

December, 19, 1967

De Havilland Comet in
mid-1950

Failure due imperfections in the material and poor

design of the bridge
-

Flaw due to fatigue and stress-corrosion cracking.

Failure of one of the heat treated-carbon steel eye-bar
allowed the entire connection to rotate and separate

ClassificationofFailureMechanisms
1.Fracture:failureofmaterialsunderstatic
(constant)loading:
Brittlefracture:breakingofmaterialsfollowing
elasticdeformation(fracturedominantfailure).
(
)
Ductilefracture:duetoelongationbeyondpointof
necking(yieldingdominantfailure).

Poor Design

The British De Havilland Comet (very sharp fillet

radii of the window in the passenger cabin)
13

Fracture
YieldingDominantFailure:
Formationofmicrovoidsandcavitiesatgrainboundariesor
interfacesbetweenmaterialandsmallimpurities.
Coalescenceofvoidsandcavitiestoformellipticalcrack.
Indoingthis,extensiveplasticdeformationaroundcracktip
untilcriticalcracklength.
Rapidpropagationofcrackbysheardeformationat~45o to
tensileaxis.

2.Fatigue: timedependentfailuredueto
repeatedstress/strain(cyclic),here<<y.
3.Creep: timedependentstrain(deformation)
understaticloadathightemperature.

YieldingDominantFailure

YieldingDominantFailure

CUPandCONEfracture.
DefectsinYieldingDominantFailurearemicroscopic:

(c)20003 Brooks/Cole, a division of

Thom
mson Learning, Inc. Thomson
Learniing is a trademark used herein
under license.

Dislocations.
Interstitials.
grainboundaries.
Precipitates.

(c)2003 Brooks/Cole, a division of Thomson Learning, Inc.

Thomson Learning is a trademark used herein under license.

Fibrouscentralregionconsistingofmultiple
"dimples"(leftoverfrommicrovoids).
Shearlip(tearing)ofmaterialatouterregion.

FractureDominantFailure

FractureDominantFailures

Crackpropagatesrapidlyandperpendiculartotensile
axis.
Littleplasticdeformationaroundcracktip.
Veryflatfracturesurface(cleavage).

FlawsinFractureDominantFailurearemacroscopic:

Weldflaws.
porosity(holes).
Inclusions.
fatigueandstresscorrosioncracks.

fracture initiation

20
20

FractureMechanics

FractureMechanics
Concernedwithbehaviourofmaterialscontaining
flawsandtheconditionsinwhichtheypropagate.
Fracturemechanicsdeterminerelationshipbetween
materialproperties,defect(flaw)sizeandloads.
Usedasadesigntoolforengineerstoprevent
structuralfailuresifcrackexists.
Whatwewishtoknowisthemaximumstressthata
materialcanwithstandifitcontainsdefects(flaws)
ofcertainsizeandgeometry.

Uncracked sample

Cracked sample

Plastic collapse
(FMDM)

Elastic plastic
fracture mechanics
(EPFM)

Linear elastic
fracture mechanics
(LEFM)

Ductility
Defect size

HistoricaldevelopmentofFracture
Mechanics

StressConcentration
x2/a2 +y2/b2=1

Inglis carriedoutastressanalysis
aheadofanellipticalnotchinan
infiniteplate:
m
2a
1

b
Inglis foundthatstressis
concentratedduetonotchand
themaximumstress,m (fracture
strength)dependsuponthe
radiusofthenotchtip,.

Twoapproaches:
GriffithCrackTheorydevelopedbyA.A.Griffithin1920
basedon Energybalanceapproachofbrittlematerials
(LEFM).
StressAnalysisofcracksapproachbasedonelastictheory
concept
concept.

Ultimatelythesetwoapproachescanbeproved
equivalent.
WewillconsidertheElasticStressanalysisapproach
today.
EnergybalanceapproachwillbeusedinyourFracture
prac.

23

Radius of curvature:

b 2
a

2a
2b

Stressconcentrationfactor,Kt

24

Example

GeometricalEffectofCracks

Estimatethetheoreticalfracturestrengthofabrittlematerial
ifitisknownthatfractureoccursbythepropagationofan
ellipticallyshapedsurfacenotchoflength0.5mmandhaving
atipradiusofcurvatureof5X103mm,whenastressof
1035MPaisapplied.

m 2

Geometricalchangesof
section,defects,flaws,holes,
etcconcentratestress
differently.
e.g.maximumstress,m, ata
circularhole(sayabolthole)
inaplateis3timesthe
nominalstress,Whereas
anellipticalflawconcentrate
higherstresses.

1/ 2
0 .5mm
207 GPa

3 mm
5 x10

m 2 1035 MPa

Whatisthestressconcentrationfactor?

GeometricalEffectofCracks

26

GeometricalEffectofCracks
FromInglisequation,astheellipticalnotchturns
intoacrack, goesto0andm tendstoinfinity!
Thissuggeststhatthestressatthetipofallcracks
is infinite!
isinfinite!
Ifstressatcracktipisinfinite,whydontallcracks
causefractureatverylowstresses?

Reason:materialatthecracktipyields(plastically
deform)andsotheassumptionofelasticityby
Inglis doesnothold.

Cracksizeconvention:
2aifthereare2tips(e.g.internalflaw)
aifonly1tip(e.g.edgeorsurfacecrack)

28

StressDistributionaroundcracktip

Crackmodesofloading

InModeI,stressisappliedatinfinitedistancealonethey
axisandlocalizedtensileandshearstressesareinduced
aroundcracktipsaloneyandxaxes.

Threemodesofcracktipopeninghavebeenidentified:
y
x
y

(Opening mode)

((sliding
g mode))

(tearing mode)

2a

y
r
x
xy

Mostfracturesinactualengineeringsituationsoccur
underconditionsofModeIloading.

biaxial stress field

29

30

LinearElasticFractureMechanics(LEFM)

K I
cos
2 r

sin

K I

cos
sin
1 sin
2
2
2 r

xy

K I
sin
2 r

1 sin
2

cos

sin

Stressintensity
Stressdistributionaroundanycrackinstructureis
similaranddependsonlyontheparametersrand

Relatesthestressfieldmagnitude (Localstresses)and
distribution aheadofacracktip.
Stressanalysisiscomplicated,butsolutionsformodeI
crackingare:

Thesearelocalized
cracktiptensile
andshearstresses

3
2

ij

r ,

K I.

1
. f ij
2 r

Thedifferencebetweenvariouscracksliesinthe
magnitudeofthestressfieldparameter,K
it d f th t
fi ld
t K calledthe
ll d th
stressintensityfactor.
KI isstressintensityfactorinModeIandhasaunitofMPa m

Kdescribestheintensityofthestressfieldaheadofa
sharpcrackinanystructuralmember:
plates,beams,airplanewings,pressurevessels,etc.
32

Stressintensity

Stressintensity

Thestressofprimaryinterestandinmostpractical
applicationsisy.
Fory tobeamaximum,

KI

2r

Forathroughthicknesscrack(central
crack)infiniteplateoflength 2a,the
stressintensityfactorcanberelated
totheappliedexternalstressas:

K I y 2r

2a

Effect of applied stress

KI

y
r
x
xy

Stressintensity
Stress
intensity
factor

2r

Effect of crack size

a
2r

Constant of proportionality

Comparethiswithstress
concentrationfactorbyInglis.

K t

a
2r
For infinite plate

y C

a
2r
Comparison leads to :

K I a

Notesonstressintensity

DeviationsfromGeometry

Solutiondeterminedabovewasonlyfora
centrecrackedplateloadeduniaxiallyandin
planestress.
g
Solutioncanbeextendedtoothergeometries
withsomemodifications.
Solutionassumesthatalmostallofthe
materialbehaveselastically (smallscale
yieldingonly).

Deviationsfromthegeometrydescribedcan
beincorporatedinthestressanalysis.
Usualtoincorporatethemasafactor,Yinthe
stress intensity equation:
stressintensityequation:

KI Y a
35

36

 KI valuesforthree
crackgeometries

Example effectofspecimenwidth

2a

Assumetheplatehasafinite
width,W.
KI dependsuponWandthisis
f
factoredintotheequation.
d
h

a
K I f a
W

Stress,

For central crack infinite

plate Y=1.

Q=Flaw shape parameter

Anumberofsolutionshavebeen
proposedforf(a/W)

38

Example:Cracksgrowingfromaroundhole

a
K I f

a , where

a
a
a
f
1 0 . 256
1 . 152

W
W
W

KI

1
2a

1
W

a
12 . 200

Comparison of correction factors

whena/rapproacheszero,f(a/r)
h
/
h
f( / )
becomes3.
whena/r approachesinfinite,
f(a/r)becomes1andthusKI
approachesthatofathrough
thicknesscrackinaninfiniteplate.

2.5

KI

f(a/W)

Series1

a
ta n

Series2
Series3

Series4

a
1.5

KI

a
sec

a/W

Manysolutions,buttheyallcomeout
tomoreorlessthesame.
39

FractureToughness(KIC)
Thestressintensityfactor(KI)dependsonboththe
magnitudeofappliedstressandcracklength.
WhenKI reachesacriticalvaluefractureoccurs!
Thiscriticalstressintensityfactorisdefinedasfracture
toughness, KIC.
toughness,K
IC
KIC isameasureofamaterialsresistancetoBRITTLE
fracturewhenacrackispresent.

K IC Y a
Material
Selection

Design
Stress

Designwithfracturemechanics
Example:AircraftWing
The7075T651highstrengthaluminumalloyis
generallyusedforaircraftwings.Thematerialhasa
fracturetoughnessof26.DuringNDT(non
MPa m
destructivetesting),thelargestflawsizemonitoredon
the wing of an aircraft was an edge crack of 9 mm in
thewingofanaircraftwasanedgecrackof9mmin
length.Whatisthemaximumallowableload(pressure)
sothatanycatastrophicfailurecanbeavoided?
c

Allowable Flow size or

NDT flaw detection

K IC
Y amax

26 MPa m
1.12 0.009m

138MPa

Allowableloadshouldbelessthan138MPa.
42