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MatS 2001 - Fall 2012

Problem Set 3 Solutions: Assigned 09/14/12

3-1 A Ni-Cr steel beam is designed to support a load at 50% of the yield stress. The beam is
bolted to a bridge truss using a hole drilled through the center. What is the maximum
allowable hole diameter? Assume Y = 1.4. Note, given more than one set of material data,
choose conservatively.

3-2 A poly(methyl methacrylate) (PMMA) window (1 m by 1 m by 2 mm thick), hangs freely
(vertically) from a frame (clamped at the top). It is pierced cleanly at the center by a 22
caliber steel jacketed bullet. Does the window fracture? Assume the stress at any vertical
location in the window results from the mass hanging below that level. Also, the density of
PMMA is 1 g/cm
3
. Give analysis to support your answer.





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3-3 Fatigue data for a brass alloy are given as follows:

Stress Amplitude (MPa) Cycles to failure
170 3.7x10
4

148 1.0x10
5
130 3.0x10
5
114 1.0x10
6
92 1.0x10
7

80 1.0x10
8

74 1.0x10
9


Make an S-N plot using these data. (A) Determine the fatigue strength at 4x10
6

cycles
(B) Determine the fatigue life in number of cycles for 120 MPa.




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3-4 The following fatigue data were acquired for a new metal alloy.

AK (MPam
1/2
) da/dN (m/cycle)

0.03 10
-7

0.10 10
-6

0.30 10
-5


Using an appropriate plot determine the constants A and m.



m=1.99, A= 1.07x10
-4



3-5 Consider a flat plate of some metal alloy that is to be exposed to repeated tensile-
compressive cycling in which the mean stress is 25 MPa. If the initial and critical surface
crack lengths are 0.15 and 4.5 mm, respectively, and the values of m and A are 3.5 and 2
x 10
14
, respectively (for Ao in MPa and a in m), estimate the maximum tensile stress to
yield a fatigue life of 2.5 x10
7
cycles. Assume the parameter Y has a value of 1.4, which is
independent of crack length.

Estimate the maximum tensile stress that will yield a fatigue life of 2.5 x 10
7

cycles, given values of a
o
, a
c
, m, A, and Y. Use the following equation:
N
f
=
1
A
m/2
(Ao)
m
Y
m
]
(
a
o
a
c
a
-m/2
da
For m = 3.5
y = 1.9986x - 3.9709
-8
-7
-6
-5
-4
-3
-2
-1
0
-2 -1.5 -1 -0.5 0
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N
f
=
1
A
1.75
(Ao)
3.5
Y
3.5
]
(
a
o
a
c
a
-1.75
da
= -
1.33
A
1.75
(Ao)
3.5
Y
3.5

(
(
1
a
c
0.75
-
1
a
o
0.75

Solving for Ao yields:
Ao =

)
`

1.33
N
f
A
1.75
Y
3.5

(
(
1
a
o
0.75
-
1
a
c
0.75

1/3.5


=

)
`

1.33
(2.5 x 10
7
)(2 x 10
-14
)()
1.75
(1.4)
3.5

(
(
1
( ) 1.5 x 10
-4 0.75
-
1
( ) 4.5 x 10
-3 0.75

1/3.5

= 178 MPa
This 178 MPa will be the maximum tensile stress since we can show that the
minimum stress is a compressive one--when o
min
is negative, Ao is taken to be
o
max
. If we take o
max
= 178 MPa, and since o
m
is stipulated in the problem to
have a value of 25 MPa, then from Equation (8.21)
o
min
= 2o
m
- o
max
= 2(25 MPa) -178 MPa = -128 MPa
Therefore o
min
is negative and we are justified in taking o
max
to be 178 MPa.


3-6 Give the approximate temperature at which creep deformation becomes an important
consideration for each of the following metals:
Creep becomes important at 0.4T
m
, T
m
being the absolute melting temperature of the
metal.
For Ni, 0.4T
m
= (0.4)(1455 + 273) = 691

K or 418C
For Cu, 0.4T
m
= (0.4)(1085 + 273) = 543

K or 270C
For Fe, 0.4T
m
= (0.4)(1538 + 273) = 725

K or 450C
For W, 0.4T
m
= (0.4)(3410 + 273) = 1473

K or 1200C
For Pb, 0.4T
m
= (0.4)(327 + 273) = 240

K or -33C
For Al, 0.4T
m
= (0.4)(660 + 273) = 373

K or 100C

3-7 The following creep data were taken on an aluminum alloy at 400C and a constant stress
of 25 MPa. Plot the data as strain versus time, then determine the steady-state or
minimum creep rate. Note: The initial and instantaneous strain is not included.

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40 30 20 10 0
0.0
0.1
0.2
0.3
0.4
T i m e ( m i n )
S
t
r
a
i
n


The steady-state creep rate (Ac/At) is the slope of the linear region as

Ac
At
=
0.230 - 0.09
30 min - 10 min
= 7.0 x 10
-3
min
-1



3-8 Consider a thin metal plate 20 mm wide which contains a centrally positioned, through-
thickness crack. This plate is to be exposed to reversed tensile-compressive cycles of
stress amplitude 125 MPa. If the initial and critical crack lengths are 0.20 and 8.0 mm,
respectively, and the values of m and A are 4 and 5x10
-12
, respectively (for Ao in MPa and
a in m), estimate the fatigue life of this plate.

This problem asks that we estimate the fatigue life of a flat plate that has a
centrally positioned through-thickness crack, given that W = 20 mm, 2a
o
= 0.20
mm, 2a
c
= 8.0 mm, m = 4.0, and A = 5 x 10
-12
. Furthermore, inasmuch as
reverse stress cycling is to be used Ao = 125 MPa. For this plate and crack
geometry, the parameter Y=1. Hence, the equation for N
f
takes the form
N
f
=
( )
0
/ 2
/ 2
1
c
a
m m
m
a
da
a
At o A
}

=
( )
0
4 2
12 2
1
5 10
c
a
a
da
a
t o

A
}

Which, upon integration, leads to the solution
( )
| |
1 1
4
12 2
1
1 2 0.004 0.0001
5 10 125

( =

f
N
t

= 8.09 x 10
5
cycles
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3-9 For an 18-8 Mo stainless steel (Figure 8.43), predict the time to rupture for a component
that is subjected to a stress of 80 MPa at 700C.

Determine, for an 18-8 Mo stainless steel, the time to rupture for a component that is
subjected to a stress of 80 MPa at 700C (973 K). From Figure 8.43, the value of the
Larson-Miller parameter at 80 MPa is about 23.5 x 10
3
, for T in K and t
r
in h. Therefore,
23.5 x 10
3
= T(20 + log t
r
)
= 973(20 + log t
r
)
And, solving for t
r

24.15 = 20 + log t
r
which leads to t
r
= 1.42 x 10
4
h = 1.6 yr.

3-10 Consider an 18-8 Mo stainless steel component (Figure 8.43) that is exposed to a
temperature of 500C. What is the maximum allowable stress level for a rupture
lifetime of 5 years? 20 years?

Calculate the stress levels at which the rupture lifetime will be 5 years and 20 years
when an 18-8 Mo stainless steel component is subjected to a temperature of 500C (773
K). It first becomes necessary, using the specified temperature and times, to calculate
the values of the Larson-Miller parameter at each temperature. The values of t
r

corresponding to 5 and 20 years are 4.38 x 10
4
h and 1.75 x 10
5
h, respectively.
Hence, for a lifetime of 5 years
T(20 + log t
r
) = 773[20 + log (4.38 x 10
4
)] = 19.05 x 10
3

And for t
r
= 20 years
T(20 + log t
r
) = 773[20 + log (1.75 x 10
5
)] = 19.51 x 10
3

Using the curve shown in Figure 8.43, the stress values corresponding to the five-
and twenty-year lifetimes are approximately 260 MPa and 225 MPa, respectively.
3-11 (a) Estimate the activation energy for creep (i.e., Qc in
2
exp
n C
S
Q
K
RT
c o
| |
=
|
\ .
) for the
low carbon nickel alloy having the steady-state creep behavior shown in Figure 8.39.
Use data taken at a stress level of 55 MPa and temperatures of 427C and 538C.
Assume that the stress exponent n is independent of temperature. (b) Estimate
S
c at
649C.
(a) Estimate the activation energy for creep for the low carbon-nickel alloy having the
steady-state creep behavior. Since o is a constant, the equation takes the form

c
.

s
= K
2
o
n
exp
\

|
.
|
|
-
Q
c
RT
= K
2
' exp
\

|
.
|
|
-
Q
c
RT

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where K
2
' is now a constant. (Note: the exponent n has about the same value at
these two temperatures Problem 22.) Taking natural logarithms of the above expression
ln c
.

s
= ln K
2
' -
Q
c
RT

For the case in which we have creep data at two temperatures (denoted as T
1
and
T
2
) and their corresponding steady-state creep rates (c
.

s
1
and c
.

s
2
), it is possible to set
up two simultaneous equations of the form as above, with two unknowns, namely K
2
'
and Q
c
. Solving for Q
c
yields
Q
c
= -
R
\

|
.
|
|
ln c
.
s
1
- ln c
.
s
2

(
(
1
T
1
-
1
T
2


Let us choose T
1
as 427C (700 K) and T
2
as 538C (811 K); then from Figure
8.39, at o = 55 MPa, c
.

s
1
= 0.01%/1000 h = 1 x 10
-7
(h)
-1
and c
.

s
2
= 0.8%/1000 h = 0.8
x 10
-5
(h)
-1
. Substitution of these values into the above equation leads to

Q
c
= -
(8.31 J/mol-K)[ ] ln( ) 10
-7
- ln( ) 0.8 x 10
-5

(
1
700 K
-
1
811 K

= 186,200 J/mol
(b) We are now asked to calculate c
.

s
at 649C. It is first necessary to determine
the value of K
2
' , which is accomplished using the first expression above, the value of
Q
c
, and one value each of c
.

s
and T (say c
.

s
1
and T
1
). Thus,
K
2
' = c
.

s
1
exp
\

|
.
|
|
Q
c
RT
1


= [ ] 10
-7
(h)
-1
exp

(
186200 J/mol
(8.31 J/mol-K)(700 K)
= 8.0 x 10
6
(h)
-1

Now it is possible to calculate c
.

s
at 922 K as follows:
c
.

s
= K
2
' exp
\

|
.
|
|
-
Q
c
RT


= [ ] 8.0 x 10
6
(h)
-1
exp

(
-
186200 J/mol
(8.31 J/mol-K)(922 K)

= 2.23 x 10
-4
(h)
-1
= 22.3 %/1000 h