279LAB3
279LAB3
279LAB3
PROCEDURE
Fatigue test the smooth and notched specimens (cold rolled mild steel) and record the number of stress
cycles to failure. Note: the minimum daimeter (6.35 mm) is the same for both.
Determine the Charpy impact energy (Joules) for the 0.40%C steel specimens at the specified
temperatures. Examine the fracture surface for each test and estmate the % shear (ductile) failure.
Use the ballistic pendulum to determine the angular deflection for the 0.11% C steel specimens (BCC
structure) over the temperature range -196C to +20C. Perform the same test on aluminum specimens
(FCC structure) at -196C, +20C and one intermediate temperature.
Use ultrasonic, magnetic and die penetrant techniques to locate cracks within each of the steel test
specimens. Record the specimen number, the type of flaw detected (surface or internal) and the
position (distance from the numbered end in mm).
Examine the fracture characteristics of the various failed industrial components on display.
THE REPORT
A clean copy of the data sheets with all data and calculations must be included. The report should also
include responses to the following :
1. Use the data given in the handout to plot an S-N (stress vs log cycles) diagram for the mild steel.
Determine the fatigue limit in MPa and compare this to its UTS which is 700 MPa. Be sure to also
show your data on the plot.
Plotting the data of Stress Vs. Log cycles we get:
2. Why is the data point for the notched specimen so far from the S-N curve? Use the S-N diagram to
determine the actual stress at the notch and calculate the stress concentration factor (defined as the
ratio of actual stress to calculated stress).
Actual stress at notch: around 525 MPa
Calculated stress: 445.47 MPa
Stress concentration factor = 525/445 = 1.18
3. In designing a structure subject to fluctuating stresses, how you would utilize the information derived
from an S-N diagram? If made from aluminum can this structure have an infinite service life?
To design a structure subject to fluctuating stress, we need to make sure that we do not apply
stress more than the fatigue limit from the S-N diagram. If material were made from aluminum,
this structure will still not going to gain infinite service life.
The graph below is the S-N graph for aluminum, we can see that the graph below
5. For the ballistic pendulum test, plot versus T for both the steel and aluminum. Calculate the DBTT
for each. Above the transition to brittle fracture, increases as temperature decreases. Explain why
including a sketch of the stress-strain curve at various temperatures to to support your answer.
the DBTT for steel is between -102 and -115 degree celcius (~ 109 degree celcius)
There is no DBTT for aluminum
Above the transition to brittle fracture (the ductile region), we see increase as temperature
decreases. increases mean more energy is absorbed by the material. As temperature
decreases, the yielding strength of the material increases, the area under the stress-strain
curves elastic region increases, so the material can absorb more energy. However, when the
yielding strength exceed certain point, the area under the stress-strain curves elastic region
start to decrease (that mean the slope angle is higher than 45 degree) and that is when the
transition between the ductile and brittle occur.
6. Based on the % shear values estimated during the lab, sketch the fracture surfaces for the Charpy
specimens. With increasing % shear does the energy absorbed in fracture increase or decrease?
Explain why.
The % shear increase the energy absorbed in the fracture increases because during shear, the
energy is absorbed to cause plastic deformation. If we look at the graph below, we will see that
the area under the stress strain curve is greater, which mean that the material is more tough, and
more tough means being able to absorb more energy.
NON-DESTRUCTIVE TESTING
It is clearly useful to detect flaws and fatigue cracks in parts before sudden failure occurs. For this purpose
a number of non-destructive techniques can be used, including dye penetrants, magnetic particles, x-rays
and ultrasonic testing.
Leakage Flux
Fe Powder
Oscilloscpope
readout
% Shear
100 oC
93
88
21 oC
30
-190oC
Cycles to Failure
Smooth
25500
Notched
11500
Diameter d 6.35 mm
Load 11 lbs 48.9 N
M 229mm x Load 11198.1
32 M
Stress Amplitude @ Surface S
445.47
d3
Moment
N - mm
MPa
Flaw Type
(Surface or Internal)
Location
(mm from #-end)
Detected By*
(method)
Surface
15
DPF, US
Internal
US, MP
11
None
US, DP
*DP=Dye Penetrant
MP=Magnetic Particle
US=Ultrasonic
Aluminum
(degrees)
Temperature
(oC)
(degrees)
24.6
4.4
24.7
1.8
-182
2.2
-187.2
2.4
-165.2
2.6
-151.8
2.5
-134
2.5
-94.2
5.4
-115
2.6
-102
5.6
(N)
33.4
35.6
37.8
37.8
40.0
42.3
44.5
48.9
48.9
51.1
53.4
53.4
57.8
62.3
66.7
Cycles
> 108
> 108
15,725,000
5,870,000
2,700,000
758,000
397,000
192,000
127,000
173,500
18,200
37,000
13,000
4,500
3,320