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MatS 2001 - Exam #1 Solution

October 7, 2011
Question 1 True/False (15 Points)
Circle True (T) or False (F) (Do not guess: +1 points for correct answer, 0 points if no answer is
provided, -1 point for incorrect answer).
a) T F The strain hardening exponent in the relationship o
T
= Kc
T
n
is equal to the true
strain at the point where necking begins.
b) T F A stiff material has a low modulus of elasticity.
c) T F Poissons ratio is based on constant volume in the elastic region
d) T F If Internal and surface cracks are initially the same size, the internal crack will
cause fatigue failure before the external crack.
e) T F The Larson Miller Parameter directly relates creep failure time to applied stress.
f) T F Typical yield stresses for metals are in the range of 10-300 GPa.
g) T F The most important factor in determining a materials resistance to fracture is the
number of cracks in it.
h) T F Crack growth rate in fatigue decreases as the crack length increases.
i) T F Ceramics have higher K
IC
values than metals.
j) T F K
IC
is small for metals because they have some ductility.
k) T F Plastic deformation results in a permanent change in shape.
l) T F Crack propagation in brittle failure becomes easier as the crack length increases.
m) T F Fracture can happen before the yield stress is reached.
n) T F For a brittle material, yield stress and tensile strength can be the same
o) T F True stress is always smaller than Engineering stress.
Question 2 Creep (15 Points)
The hook shown to the right will support a container of molten steel and must carry a load of 40,000 lb.
The hook operates continuously at a temperature of 5
Larson Miller parameter is shown below:
( ) L-M T 38.316 1.796log 10
day
t x = +
common log, base 10.
a) (10) If the useful life of the hook, with a
factor of 2), is to be 10 years of continuous operation, what must be
indicated portion of the hook?
( L-M 583+273 38.316 1.796log3650 10
From graph stress 2,000 psi, or with sa
design stress = 1,000 psi
, or 40 in , 40 50.93
7.14 in.
F lb
A d
d
o t
= +
= = = =
=
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right will support a container of molten steel and must carry a load of 40,000 lb.
The hook operates continuously at a temperature of 583 C. The relationship between stress and
Miller parameter is shown below:
3
L-M T 38.316 1.796log 10
day
t x

when T is in Kelvin and rupture time is in days.
If the useful life of the hook, with an applied stress the maximum calculated stress (
, is to be 10 years of continuous operation, what must be the diameter (in inches) of the
indicated portion of the hook?
)( )
( )
3
2 2
L-M 583+273 38.316 1.796log3650 10
From graph stress 2,000 psi, or with safety factor,
design stress = 1,000 psi
40,000 4
, or 40 in , 40 50.93
1,000 psi
7.14 in.
x
F lb
A d
o t

= + =
~
= = = =
right will support a container of molten steel and must carry a load of 40,000 lb.
C. The relationship between stress and
Kelvin and rupture time is in days. Note: log is
n applied stress the maximum calculated stress (safety
the diameter (in inches) of the
3
L-M 583+273 38.316 1.796log3650 10 38.28
From graph stress 2,000 psi, or with safety factor,
, or 40 in , 40 50.93
=
= = = =
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b) (5) Calculations by a new engineer stated that the diameter should be 3.5 (not the answer to part
a). If a hook of this size was used, what would be its useful life (in years)?
( )
( )( )
3
2
L-M 535+273 38.316 1.796log t 10
40,000
( ) stress = 4,157 psi
3.5
4
Design stress = Working stress x safety factor = 4,157 x 2 = 8300 psi
From the graph: L-M 32.8 or,
32.8
log t
days
days
x
Applied working
t

= +
=
~
=
=
4
32.8 1
38.316 9.7829 10
.856 1.796
1, or years = 0.0027
days
x
t

| |
=
|
\ .
=
Question 3 Poissons Ratio (5 Points)
A cylindrical specimen of an alloy, 8 mm in diameter, is stressed elastically in tension. A force of 15,700
N produces a reduction in specimen diameter of 5x10
-3
mm. Compute Poissons ratio for this material if
its modulus of elasticity is 140 GP
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Question 4 Fracture/Fatigue (35 Points)
An aluminum rod is used as a support in a critical application. The rod is subjected to stress cycling
between 50 MPa compression and 320 MPa tension. The material from which the rod is made can have
no flaw larger than 0.10 mm. Two alloys are being considered:
Yield Strength [MPa] Elastic Modulus [GPa]
K
IC
[MPa m
1/2
]
Al 7075 495 71.0 24
Al 2024 345 72.4 50
Both alloys follow the Paris Equation: da/dN =A (K)
m
where A=1.0x10
-13
, m=3.1, and Y=1.73. These
values give crack growth in meters/cycle when K is in MPa-m
1/2
.
a) (5) Will either alloy fail upon initial loading? If so, which one(s) and why? If not, why not?
b) (5) What is the critical crack length for fatigue failure for each alloy?
c) (5) Without actually calculating cycles to failure, which rod will fail first in continuous operation?
Why?
Alloy 7075 will fail first
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d) (10) What is the service life, in cycles to failure, of the rod that will fail first?
e) (10) If the rod with the shortest service life is inspected every 100,000 cycles and cracks of 0.5mm or
larger can be detected, can a crack be detected before failure occurs? (Hint: how large would a
crack have been at the last inspection before failure?)
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Question 5 Stress/Strain (30 Points)
A stainless steel eye-bolt was installed through a support plate that is 145
mm thick and the nut was tightened so that the bolt was under no tensile
load.
Material properties are:
E = 193 GPa

y
= 205 MPa

UTS
= 515 MPa
% elongation at fracture 40%
strain hardening exponent 0.22
A stress of 295 MPa was applied to test the bolt resulting in a strain of 0.038. The 295 MPa stress was
then removed.
Next, a weight was hung from the same bolt, such that the total load was 35,000 N and the bolt
experienced a true strain of 0.12.
a) (5) What was the length of the bolt while under a stress of 295 MPa?
b) (5) What was the length of the bolt when the 295 MPa stress is removed?
c) (10) What is the engineering stress in the rod when supporting the load?
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d) (5) What was the length of the rod when supporting the 35,000 N load?
e) (5) What is the length of the rod when the 35,000 N load is removed?