Mechanical Metallurgy

Lecturer
Dr. Tapany Udomphol

Assessment

Assignment 20
(homework, quiz, attendance)

Midterm exam 40

Final exam 40

Total 100
Suranaree University of Technology Tapany Udomphol May-Aug 2007
Mechanical Metallurgy
Subject of interests
Part I Mechanical fundamentals
• Introduction to mechanical metallurgy
• Stress and strain relationships of elastic behaviour
• Elements of the theory of elasticity
Part II Metallurgical fundamentals
• Plastic deformation of single crystals
• Dislocation theory
• Strengthening mechanisms
• Fracture

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Mechanical Metallurgy I
Subject of interests

Part III Applications to materials testing

• Tension test
• Hardness test
• Torsion test
• Fracture mechanics
• Brittle fracture and impact testing
• Fatigue of materials
• Creep and stress rupture

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Objectives
• Interaction of stress and strain on materials in elastic and
plastic manners will be understood.

• Deformation behaviour of metals due to dislocation

interaction as well as strengthening mechanisms of metals
will be addressed.

• Different methods of mechanical testing will be highlighted

along with the interpretation of sensible information from the
obtained data such that mechanical assessments are
appropriately selected for the required applications.

• Metallurgical aspects which affect mechanical properties of

materials will be discussed.

•Finally cause of material failure will be studied and suggested

possible solutions will be discussed.
Suranaree University of Technology Tapany Udomphol May-Aug 2007
Main references
• Dieter, G.E., Mechanical metallurgy, 1988, SI metric edition,
McGraw-Hill, ISBN 0-07-100406-8.
• Hibbeler, R.C. Mechanics of materials, 2005, SI second
edition, Person Prentice Hall, ISBN 0-13-186-638-9.
• Sanford, R.J., Principles of fracture mechanics, 2003,
Prentice Hall, New Jersey, ISBN 0-13-092992-1.
• Rolfe, S.T., Barsom, J.M., Fracture and fatigue control in
structures: Applications of fracture mechanics, 1977,
Prentice Hall, New jersey, ISBN 0-13-329953-8.
• Edwards, H.L., Wanhill, R.J.H., Fracture mechanics, 1986,
Arnold, Australia, ISBN 0-7131-3515-8.
• Smallman, R.E., Bishop, R.J., Modern physical metallurgy &
materials engineering: Science, process, applications, 6th
edition, 1999, Butterworth-Heinemann, ISBN 0-7506-4564-4.

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Main references

• Brick, R.M., Pense, A.W., Gordon, R. B., Materials science

and engineering series, 1977, 4th edition, McGraw-Hill, ISBN
0-07-007721-5.
• Hull, D. Fractography: Observing, measureing,
interpreting, fracture surface topography, 1999, Cambridge,
ISBN 0-521-64684-7.
• Dowling, N.E., Mechanical behaviour of materials:
E,ngineering methods for deformation, fracture, and
fatigue, 2nd edition, 1999, Prentice Hall, New Jersey, ISBN 0-
13-010989-4.
• Suresh, S., Fatigue of materials, 1998, 2nd edition,
Cambridge university press, ISBN 0-521-57847-7.

Suranaree University of Technology Tapany Udomphol May-Aug 2007

 Why failure in materials?

• Seven of the Liberty ships built

during the world war II has
broken completely in two as a
result of brittle fractures.
• Over 1000 of approximately
5000 merchant ships built
during World War II had
developed cracks of
considerable size by 1946.

Failure of Liberty Ships during services in

World War II.

Suranaree University of Technology Tapany Udomphol May-Aug 2007

 Why failure in materials?

• The bridge building industry did

not pay particular attention to the
possibility of brittle failure until the
failure of Point Pleasant bridge in
1967.
• The bridge collapsed without
warning, costing 46 lives.

Collapse of Point Pleasant suspension

bridge, West Virginia, on December 15, 1967.

Suranaree University of Technology Tapany Udomphol May-Aug 2007

 Why failure in materials?

• The aircraft was used for inter-

island transportation for 19 years
before failed.
• Failure has been attributed to
multiple-site-damage.

Failed fuselage of the Aloha 737 aircraft in 1988.

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Material property assessments

Hardness Micro/Macro hardness tests

Strength
Ductility (elongation, area Tension tests
of reduction)

Creep (elevated-
Creep tests
temperature strength)

Torsion Torsion tests

Toughness (resistance Impact tests

to failure) Fracture toughness tests

Fatigue S-N fatigue tests

Fatigue crack growth tests
Suranaree University of Technology Tapany Udomphol May-Aug 2007
Hardness tests

• Hardness is a property
which is a measure of a
resistance to permanent or
plastic deformation.
• Using difference
indenters, i.e., ball,
diamond.

Parameters:
• Brinell hardness (BHN)
• Meyer hardness
Macro-microhardness (Vickers) instrument
• Vickers hardness (VHN)
• Rockwell hardness

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Tensile tests
σ A
• Provide basic design
information on the strength
of materials.
• Acceptance test for the σο
specification of the
materials.
ε2 ε1 ε
Parameters: Ture stress-strain curve of a ductile
metal under uniaxial tensile loading.
• Tensile strength σTS Tensile testing
configuration
• Yield stress σy
• Young’s Modulus of
elasticity E
• %Elongation
• Area of reduction

Plate specimens Round specimens

Suranaree University of Technology Tapany Udomphol May-Aug 2007
Torsion test

Torsion testing
• Applying twisting moment machine
to the specimen and measure
the torque.
• has not been standardized.

Parameters:
• Shear Modulus
• Torsional yield strength
• Modulus of rupture

Ultimate torsion test results

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Creep test

• Creep is high temperature

progressive deformation of a
material at constant stress.
• A tensile specimen is loaded
at a constant (elevated)
temperature. Strain is
measured with time.

Parameters:
• Creep strength
• Creep rate
Typical creep curve

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Impact tests
• Measure toughness of materials in terms of
energy absorption.
• Specimen is impacted by a hammer and the
energy absorbed during fracture is measured
in Joul.
• Easy and practical.
• Establish Ductile to Brittle Transition
Temperature (DBTT).
• Not a standard material parameter, should
be used in conjunction with other material
properties such as strength and fracture
toughness for materials determination. www.twi.co.uk

Parameters: Charpy impact testing

• Impact energy
• Ductile to brittle transition temperature

Suranaree University of Technology Tapany Udomphol May-Aug 2007

Fracture mechanics Clip gauge

• Resistance of materials to crack

propagation (to failure).
• Crack propagation can be
predicted before failure.
• Material will fail when the
stress intensity factor K
Fracture toughness testing
reaches the critical value KIC.

Parameters:
• Fracture toughness KIC
• Crack tip opening
displacement CTOD
• J-integral J
Failed fracture toughness
specimens.
Suranaree University of Technology Tapany Udomphol May-Aug 2007
 +

Fatigue tests σa
∆σ

σmax σm
• Material is subjected to a
repetitive or fluctuating stress
(cyclic loading) and will fail at σmin

a stress level much lower than _ cycles

that causes failure in statistic

loading. Stresses in fatigue loading

• S-N fatigue test and fatigue

crack growth resistance.

Parameters:
• Fracture life (fatigue strength)
• Fatigue crack growth resistance
• Paris exponent (m)
• Fatigue threshold (Kth)
Fatigue striations on fatigue
fracture surface
Suranaree University of Technology Tapany Udomphol May-Aug 2007
To improve properties of metals

Materials assessment Improvement of materials properties

WE NEED TO

Understand mechanical aspects

• Stress and strain relationships of elastic behaviour
• Elements of the theory of plasticity.

Understand Metallurgical aspects

• Plastic deformation
• Dislocation theory
• Strengthening mechanisms
• Fracture
Suranaree University of Technology Tapany Udomphol May-Aug 2007
References

• www.ndsu.nodak.edu
• www.kockums.se
• www.indentec.com
• www.enduratec.com
• www.bactechnologies.com
• www.twi.co.uk
• www.jaeri.go.jp
• www.hghouston.com
• www.minton.co.uk
• www2.umist.ac.uk
• www.materialsengineer.com

Suranaree University of Technology Tapany Udomphol May-Aug 2007