Jordan University of Science and Technology

Engineering collage

Aeronautical Engineering Department

Solution Manual for:

Material Science and Engineering / 8th edition

Ahmed Mustafa El-Khalili

 CHAPTER 8

FAILURE

PROBLEM SOLUTIONS

Principles of Fracture Mechanics

8.1 What is the magnitude of the maximum stress that exists at the tip of an internal crack having a radius
of curvature of 2.5 10 -4 mm (10 -5 in.) and a crack length of 2.5 10 -2 mm (10 -3 in.) when a tensile stress of 170
MPa (25,000 psi) is applied?

Solution

This problem asks that we compute the magnitude of the maximum stress that exists at the tip of an internal
crack. Equation 8.1 is employed to solve this problem, as

a 1/ 2
s m = 2s 0
rt

2.5 10 -2 mm 1/2

= (2)(170 MPa) 2 = 2404 MPa (354, 000 psi)
2.5 10 -4 mm

 8.2 Estimate the theoretical fracture strength of a brittle material if it is known that fracture occurs by the
p ropagation of an elliptically shaped surface crack of length 0.25 mm (0.01 in.) and having a tip radius of
curvature of 1.2 10 -3 mm (4.7 10 -5 in.) when a stress of 1200 MPa (174,000 psi) is applied.

Solution

In order to estimate the theoretical fracture strength of this material it is necessary to calculate sm using
Equation 8.1 given that s0 = 1200 MPa, a = 0.25 mm, and r t = 1.2 10-3 mm. Thus,

a 1/ 2
s m = 2s 0
rt

0.25 mm 1/2
= (2)(1200 MPa) = 3.5 10 4 MPa = 35 GPa ( 5.1 10 6 psi)
1.2 10 -3 mm
 8.3 If the specific surface energy for soda-lime glass is 0.30 J/m2, using data contained in Table 12.5,
compute the critical stress required for the propagation of a surface crack of length 0.05 mm.

Solution

We may determine the critical stress required for the propagation of an surface crack in soda-lime glass
XVLQJ ( TXDW
LRQ W
DNLQJ W
KHYDOXHRI * 3D Table 12.5) as the modulus of elasticity, we get

2E g 1/ 2
sc = s

pa

1/ 2
9 N / m2 ) (0.30 N/m)
=
(2) ( 69 10 = 16.2 10 6 N/m2 = 16.2 MPa

(
(p) 0. 05 10 )
-3 m

 8.4 A polystyrene component must not fail when a tensile stress of 1.25 MPa (180 psi) is applied.
Determine the maximum allowable surface crack length if the surface energy of polystyrene is 0.50 J/m2 (2.86 10 -
3
in.-lb f/in.2). Assume a modulus of elasticity of 3.0 GPa (0.435 10 6 psi).

Solution

7 KH P D[LP XP DOORZDEOH VXUIDFH FUDFN OHQJ W

K IRUSRO\ VW
\ UHQH P D\ EHGHW
HUP LQHG XVLQJ ( TXDW
LRQ W
DNLQJ
3.0 GPa as the modulus of elasticity, and solving for a, leads to

2 E gs (2) (3 10 9 N/m2 ) (0.50 N/m)

a = 2
= 2
p sc (p) (1.25 10 6 N/m2 )

= 6.1 10-4 m = 0.61 mm (0.024 in.)

 8.5 A specimen of a 4340 steel alloy having a plane strain fracture toughness of 45 MPa m ( 41 ksi in. )
is exposed to a stress of 1000 MPa (145,000 psi). Will this specimen experience fracture if it is known that the
largest surface crack is 0.75 mm (0.03 in.) long? Why or why not? Assume that the parameter Y has a value of 1.0.

Solution

This problem asks us to determine whether or not the 4340 steel alloy specimen will fracture when exposed
to a stress of 1000 MPa, given the values of KIc, Y, and the largest value of a in the material. This requires that we
solve for sc from Equation 8.6. Thus

KIc 45 MPa m
sc = = = 927 MPa (133, 500 psi)
Y pa (1.0) (p)(0.75 10 -3 m)

Therefore, fracture will most likely occur because this specimen will tolerate a stress of 927 MPa (133,500 psi) before
fracture, which is less than the applied stress of 1000 MPa (145,000 psi).
 8.6 Some aircraft component is fabricated from an aluminum alloy that has a plane strain fracture
toughness of 35 MPa m (31.9 ksi in. ). It has been determined that fracture results at a stress of 250 MPa
(36,250 psi) when the maximum (o r critical) internal crack length is 2.0 mm (0.08 in.). For this same component
and alloy, will fracture occur at a stress level of 325 MPa (47,125 psi) when the maximum internal crack length is
1.0 mm (0.04 in.)? Why or why not?

Solution

We are asked to determine if an aircraft component will fracture for a given fracture toughness (35
MPa m ), stress level (325 MPa), and maximum internal crack length (1.0 mm), given that fracture occurs for the
same component using the same alloy for another stress level and internal crack length. It first becomes necessary to
solve for the parameter Y, using Equation 8.5, for the conditions under which fracture occurred (i.e., s = 250 MPa and
2a = 2.0 mm). Therefore,

K Ic 35 MPa m
Y= = = 2.50
s pa 2 10 -3 m
(250 MPa) (p)
2

Now we will solve for the product Ys pa for the other set of conditions, so as to ascertain whether or not this
value is greater than the KIc for the alloy. Thus,

1 10 -3 m
Ys p a = (2.50)(325 MPa) (p)
2

= 32.2 MPa m (29.5 ksi in.)

Therefore, fracture will not occur since this value (32.3 MPa m ) is less than the KIc of the material, 35 MPa m .
 8.7 Suppose that a wing component on an aircraft is fabricated from an aluminum alloy that has a plane
strain fracture toughness of 40 MPa m (36.4 ksi in. ). It has been determined that fracture results at a stress of
365 MPa (53,000 psi) when the maximum internal crack length is 2.5 mm (0.10 in.). For this same component and
alloy, compute the stress level at which fracture will occur for a critical internal crack length of 4.0 mm (0.16 in.).

Solution

This problem asks us to determine the stress level at which an a wing component on an aircraft will fracture
for a given fracture toughness (40 MPa m ) and maximum internal crack length (4.0 mm), given that fracture

occurs for the same component using the same alloy at one stress level (365 MPa) and another internal crack length
(2.5 mm). It first becomes necessary to solve for the parameter Y for the conditions under which fracture occurred
using Equation 8.5. Therefore,

K Ic 40 MPa m
Y= = = 1.75
s pa 2.5 10 -3 m
(365 MPa) (p)
2

Now we will solve for sc using Equation 8.6 as

KIc 40 MPa m
sc = = = 288 MPa (41, 500 psi)
Y pa 4 10 -3 m
(1.75) (p)
2
 8.8 A large plate is fabricated from a steel alloy that has a plane strain fracture toughness of
55 MPa m (50 ksi in. ). If, during service use, the plate is exposed to a tensile stress of 200 MPa (29,000 psi),
determine the minimum length of a surface crack that will lead to fracture. Assume a value of 1.0 for Y.

Solution

For this problem, we are given values of KIc (55 MPa m ) , s (200 MPa), and Y (1.0) for a large plate and are
asked to determine the minimum length of a surface crack that will lead to fracture. All we need do is to solve for a c

XVLQJ ( TXDW
LRQ W
KHUHIRUH

2 2
1 KIc 1 55 MPa m
ac = = = 0.024 m = 24 mm (0.95 in.)
p Ys p (1.0)(200 MPa)
 8.9 Calculate the maximum internal crack length allowable for a 7075-T651 aluminum alloy (Table 8.1)
component that is loaded to a stress one half of its yield strength. Assume that the value of Y is 1.35.

Solution

This problem asks us to calculate the maximum internal crack length allowable for the 7075-T651 aluminum
alloy in Table 8.1 given that it is loaded to a stress level equal to one-half of its yield strength. For this alloy,
KIc = 24 MPa m (22 ksi in. ) ; also, s = sy/2 = (495 MPa)/2 = 248 MPa (36,000 psi). Now solving for 2a c using

Equation 8.7 yields

2 2
2 KIc 2 24 MPa m
2a c = = = 0.0033 m = 3.3 mm (0.13 in.)
p Ys p (1.35)(248 MPa)
 8.10 A structural component in the form of a wide plate is to be fabricated from a steel alloy that has a
plane strain fracture toughness of 77.0 MPa m (70.1 ksi in. ) and a yield strength of 1400 MPa (205,000 psi).
The flaw size resolution limit of the flaw detection apparatus is 4.0 mm (0.16 in.). If the design stress is one half of
the yield strength and the value of Y is 1.0, determine whether or not a critical flaw for this plate is subject to
detection.

Solution

This problem asks that we determine whether or not a critical flaw in a wide plate is subject to detection
given the limit of the flaw detection apparatus (4.0 mm), the value of KIc (77 MPa m ) , the design stress (sy/2 in
which s y = 1400 MPa), and Y = 1.0. We first need to compute the value of a c XVLQJ ( TXDW
LRQ W
KXV

2
2 77 MPa m
1 K 1
a c = Ic = = 0.0039 m = 3.9 mm (0.15 in.)
p Ys p 1400 MPa
(1.0)
2

Therefore, the critical flaw is not subject to detection since this value of a c (3.9 mm) is less than the 4.0 mm resolution

limit.
 8.11 After consultation of other references, write a brief report on one or two nondestructive test
techniques that are used to detect and measure internal and/or surface flaws in metal alloys.

The student should do this problem on his/her own.

 Impact Fracture Testing

8.12 Following is tabulated data that were gathered from a series of Charpy impact tests on a ductile cast
iron.

Temperature (C) Impact Energy (J)

25 124
50 1 23
75 115
85 100
100 73
110 52
125 26
150 9
175 6

(a) Plot the data as impact energy versus temperature.

(b) Determine a ductile-to-brittle transition temperature as that temperature corresponding to the
average of the maximum and minimum impact energies.
(c) Determine a ductile-to-brittle transition temperature as that temperature at which the impact energy
is 80 J.

Solution

(a) The plot of impact energy versus temperature is shown below.

 (b) The average of the maximum and minimum impact energies from the data is

124 J + 6 J
Average = = 65 J
2

As indicated on the plot by the one set of dashed lines, the ductile-to-brittle transition temperature according to this
criterion is about 105C.
(c) Also, as noted on the plot by the other set of dashed lines, the ductile-to-brittle transition temperature
for an impact energy of 80 J is about 95C.
 8.13 Following is tabulated data that were gathered from a series of Charpy impact tests on a tempered
4140 steel alloy.

Temperature (C) Impact Energy (J)

100 89.3
75 88.6
50 87.6
25 85.4
0 82.9
25 78.9
50 73.1
65 66.0
75 59.3
85 47.9
100 34.3
125 29.3
150 27.1
175 25.0

(a) Plot the data as impact energy versus temperature.

(b) Determine a ductile-to-brittle transition temperature as that temperature corresponding to the
average of the maximum and minimum impact energies.
(c) Determine a ductile-to-brittle transition temperature as that temperature at which the impact energy is
70 J.

Solution

The plot of impact energy versus temperature is shown below.

 (b) The average of the maximum and minimum impact energies from the data is

89.3 J + 25 J
Average = = 57.2 J
2

As indicated on the plot by the one set of dashed lines, the ductile-to-brittle transition temperature according to this
criterion is about 75C.
(c) Also, as noted on the plot by the other set of dashed lines, the ductile-to-brittle transition temperature
for an impact energy of 70 J is about 55C.
 Cyclic Stresses (Fatigue)
The S-N Curve

8.14 A fatigue test was conducted in which the mean stress was 50 MPa (7250 psi) and the stress
amplitude was 225 MPa (32,625 psi).
(a) Compute the maximum and minimum stress levels.
(b) Compute the stress ratio.
(c) Compute the magnitude of the stress range.

Solution

(a) Given the values of sm (50 MPa) and sa (225 MPa) we are asked to compute smax and smin . From

Equation 8.14

s max + s min
sm = = 50 MPa
2
Or,

smax + smin = 100 MPa

Furthermore, utilization of Equation 8.16 yields

s max - s min
sa = = 225 MPa
2

Or,

smax smin = 450 MPa

Simultaneously solving these two expressions leads to

s max = 275 MPa (40, 000 psi)

s min = - 175 MPa (-25, 500 psi)

(b) Using Equation 8.17 the stress ratio R is determined as follows:

s min -175 MPa

R= = = - 0.64
s max 275 MPa
(c) The magnitude of the stress range sr is determined using Equatio n 8.15 as

s r = s max - s min = 275 MPa - (-175 MPa) = 450 MPa (65, 500 psi)
 8.15 A cylindrical 1045 steel bar (Figure 8.34) is subjected to repeated compression-tension stress
cycling along its axis. If the load amplitude is 22,000 N (4950 lb f), compute the minimum allowable bar diameter
to en sure that fatigue failure will not occur. Assume a factor of safety of 2.0.

Solution

From Figure 8.34, the fatigue limit stress amplitude for this alloy is 310 MPa (45,000 psi). Stress is defined in
F
Equation 6.1 as s = . For a cylindrical bar
A0

d 2
A0 = p 0
2

Substitution for A0 into the Equation 6.1 leads to

F F 4F
s = = 2
=
A0 d pd02
p 0
2

We now solve for d 0, taking stress as the fatigue limit divided by the factor of safety. Thus

4F
d0 =
s
p
N

(4)(22, 000 N)
= = 13.4 10 -3 m = 13.4 mm (0.53 in.)
310 10 6 N / m2
(p)
2
 8.16 An 8.0 mm (0.31 in.) diameter cylindrical rod fabricated from a red brass alloy (Figure 8.34) is
subjected to reversed tension-compression load cycling along its axis. If the maximum tensile and compressive
loads are + 7500 N (1700 lb f) and -7500 N (-1700 lb f), respectively, determine its fatigue life. Assume that the
stress plotted in Figure 8.34 is stress amplitude.

Solution

We are asked to determine the fatigue life for a cylindrical red brass rod given its diameter (8.0 mm) and the
maximum tensile and compressive loads (+7500 N and -7500 N, respectively). The first thing that is necessary is to
calculate values of smax and smin using Equation 6.1. Thus

Fmax Fmax
s max = =
A0 d 2
p 0
2

7500 N
= = 150 10 6 N/m2 = 150 MPa (22, 500 psi)
8.0 10 -3 m 2
(p)
2

Fmin
s min =
d 2
p 0
2

-7500 N
= = - 150 10 6 N/m2 = - 150 MPa (-22, 500 psi)
8.0 10 -3 m 2
(p)
2

Now it becomes necessary to compute the stress amplitude using Equation 8.16 as

s max - s min 150 MPa - (-150 MPa)

sa = = = 150 MPa (22, 500 psi)
2 2

From Fig ure 8.34, f for the red brass, the number of cycles to failure at this stress amplitude is about 1 105 cycles.
 8.17 A 12.5 mm (0.50 in.) diameter cylindrical rod fabricated from a 2014-T6 alloy (Figure 8.34) is
subjected to a repeated tension-compression load cycling along its axis. Compute the maximum and minimum
loads that will be applied to yield a fatigue life of 1.0 10 7 cycles. Assume that the stress plotted on the vertical
axis is stress amplitude, and data were taken for a mean stress of 50 MPa (7250 psi).

Solution

This problem asks that we compute the maximum and minimum loads to which a 12.5 mm (0.50 in.) diameter
2014-T6 aluminum alloy specimen may be subjected in order to yield a fatigue life of 1.0 107 F\ FOHV ) LJ XUH LVW
R
be used assuming that data were taken for a mean stress of 50 MPa (7250 psi). Upon consultation of Figure 8.34, a
fatigue life of 1.0 107 cycles corresponds to a stress amplitude of 160 MPa (23,200 psi). Or, from Equation 8.16

s max - s min = 2s a = (2)(160 MPa) = 320 MPa (46, 400 psi)

Since sm = 50 MPa, then from Equation 8.14

s max + s min = 2s m = (2)(50 MPa) = 100 MPa (14, 500 psi)

Simultaneous solution of these two expressions for smax and smin yields

smax = +210 MPa (+30,400 psi)

smin = 110 MPa ( 16,000 psi)

F d 2
Now, inasmuch as s = (Equation 6.1), and A0 = p 0 then
A0 2

2
s max p d 20 (210 10 6 N / m2 ) (p) (12.5 10 -3 m)
Fmax = = = 25, 800 N (6000 lb f )
4 4

2
s min p d 20 (-110 10 6 N / m2 ) (p) (12.5 10 -3 m)
Fmin = = = - 13, 500 N (-314 0 lb f )
4 4
 8.18 The fatigue data for a brass alloy are given as follows:

Stress Amplitude (MPa) Cycles to Failure

310 2 10 5
223 1 10 6
191 3 10 6
168 1 10 7
153 3 10 7
143 1 10 8
134 3 10 8
127 1 10 9

(a) Make an SN plot (stress amplitude versus logarithm cycles to failure) using these data.
(b) Determine the fatigue strength at 5 10 5 cycles.
(c) Determine the fatigue life for 200 MPa.

Solution

(a) The fatigue data for this alloy are plotted below.

(b) As indicated by the A set of dashed lines on the plot, the fatigue strength at 5 105 cycles [log (5
105) = 5.7] is about 250 MPa.
 (c) As noted by the B set of dashed lines, the fatigu e life for 200 MPa is about 2 106 cycles (i.e., the log
of the lifetime is about 6.3).
 8.19 Suppose that the fatigue data for the brass alloy in Problem 8.18 were taken from torsional tests, and
that a shaft of this alloy is to be used for a coupling that is attached to an electric motor operating at 1500 rpm.
Give the maximum torsional stress amplitude possible for each of the following lifetimes of the coupling: (a) 1
year, (b) 1 month, (c) 1 day, and (d) 2 hours.

Solution

For each lifetime, first compute the number of cycles, and then read the corresponding fatigue strength from
the above plot.
(a) Fatigue lifetime = (1 yr)(365 days/yr)(24 h/day)(60 min/h)(1500 cycles/min) = 7.9 108 cycles. The stress
amplitude corresponding to this lifetime is about 130 MPa.
(b) Fatigue lifetime = (30 days)(24 h/day)(60 min/h)(1500 cycles/min) = 6.5 107 cycles. The stress
amplitude corresponding to this lifetime is about 145 MPa.
(c) Fatigue lifetime = (24 h)(60 min/h)(1500 cycles/min) = 2.2 106 cycles. The stress amplitude
corresponding to this lifetime is about 195 MPa.
(d) Fatigue lifetime = (2 h)(60 min/h)(1500 cycles/min) = 1.8 105 cycles. The stress amplitude
corresponding to this lifetime is about 315 MPa.
 8.20 The fatigue data for a ductile cast iron are given as follows:

Stress Amplitude
Cycles to Failure
[MPa (ksi)]

248 (36.0) 1 10 5
236 (34.2) 3 10 5
224 (32.5) 1 10 6
213 (30.9) 3 10 6
201 (29.1) 1 10 7
193 (28.0) 3 10 7
193 (28.0) 1 10 8
193 (28.0) 3 10 8

(a) Make an SN plot (stress amplitude versus logarithm cycles to failure) using these data.
(b) What is the fatigue limit for this alloy?
(c) Determine fatigue lifetimes at stress amplitudes of 230 MPa (33,500 psi) and 175 MPa (25,000 psi).
(d) Estimate fatigue strengths at 2 10 5 and 6 10 6 cycles.

Solution

(a) The fatigue data for this alloy are plotted below.

(b) The fatigue limit is the stress level at which the curve becomes horizontal, which is 193 MPa (28,000 psi).
 (c) As noted by the A set of dashed lines, the fatigue lifetime at a stress amplitude of 230 MPa is about 5
105 cycles (log N = 5.7). From the plot, the fatigue lifetime at a stress amplitude of 230 MPa (33,500 psi) is about
50,000 cycles (log N = 4.7). At 175 MPa (25,000 psi) the fatigue lifetime is essentially an infinite number of cycles
since this stress amplitude is below the fatigue limit.
(d) As noted by the B set of dashed lines, the fatigue strength at 2 105 cycles (log N = 5.3) is about 240
0 3D SVL and according to the C set of dashed lines, the fatigue strength at 6 106 cycles (log N = 6.78) is
about 205 MPa (30,000 psi).
 8.21 Suppose that the fatigue data for the cast iron in Problem 8.20 were taken for bending-rotating tests,
and that a rod of this alloy is to be used for an automobile axle that rotates at an average rotational velocity of
750 revolutions per minute. Give maximum lifetimes of continuous driving that are allowable for the following
stress levels: (a) 250 MPa (36,250 psi), (b) 215 MPa (31,000 psi), (c) 200 MPa (29,000 psi), and (d) 150 MPa
(21,750 psi).

Solution

For each stress level, first read the corresponding lifetime from the above plot, then convert it into the
number of cycles.
(a) For a stress level of 250 MPa (36,250 psi), the fatigue lifetime is approximately 90,000 cycles. This
translates into (9 104 cycles)(1 min/750 cycles) = 120 min.
(b) For a stress level of 215 MPa (31,000 psi), the fatigue lifetime is approximately 2 106 cycles. This
translates into (2 106 cycles)(1 min/750 cycles) = 2670 min = 44.4 h.
(c) For a stress level of 200 MPa (29,000 psi), the fatigue lifetime is approximately 1 107 cycles. This
translates into (1 107 cycles)(1 min/750 cycles) = 1.33 104 min = 222 h.
(d) Fo r a stress level of 150 MPa (21,750 psi), the fatigue lifetime is essentially infinite since we are below the
fatigue limit [193 MPa (28,000 psi)].
 8.22 Three identical fatigue specimens (denoted A, B, and C) are fabricated from a nonferrous alloy. Each
is subjected to one of the maximum-minimum stress cycles listed below; the frequency is the same for all three tests.

Specimen smax (MPa) smin (MPa)

A + 450 350
B + 400 300
C + 340 340

(a) Rank the fatigue lifetimes of these three specimens from the longest to the shortest.
(b) Now justify this ranking using a schematic SN plot.

Solution

In order to solve this problem, it is necessary to compute both the mean stress and stress amplitude for each
specimen. Since from Equation 8.14, mean stresses are the specimens are determined as follows:

s max + s min
sm =
2

450 MPa + (-350 MPa)

s m (A) = = 50 MPa
2

400 MPa + (-300 MPa)

s m ( B) = = 50 MPa
2

340 MPa + (-340 MPa)

s m (C ) = = 0 MPa
2

Furthermore, using Equation 8.16, stress amplitudes are computed as

s max - s min
sa =
2

450 MPa - (-350 MPa)

s a (A) = = 400 MPa
2

400 MPa - (-300 MPa)

s a ( B) = = 350 MPa
2

340 MPa - (-340 MPa)

s a (C ) = = 34 0 MPa
2

On the basis of these results, the fatigue lifetime for specimen C will be greater than specimen B, which in turn will be
greater than specimen A. This conclusion is based upon the following S-N plot on which curves are plotted for two
sm values.
 8.23 Cite five factors that may lead to scatter in fatigue life data.

Solution

Five factors that lead to scatter in fatigue life data are (1) specimen fabrication and surface preparation, (2)
metallurgical variables, (3) specimen alignment in the test apparatus, (4) variation in mean stress, and (5) variation in
test cycle frequency.
 Crack Initiation and Propagation
Factors That Affect Fatigue Life

8.24 Briefly explain the difference between fatigue striations and beachmarks both in terms of (a) size and
(b) origin.

Solution

(a) With regard to size, beachmarks are normally of macroscopic dimensions and may be observed with the
naked eye; fatigue striations are of microscopic size and it is necessary to observe them using electron microscopy.
(b) With regard to origin, beachmarks result from interruptions in the stress cycles; each fatigue striation is
corresponds to the advance of a fatigue crack during a single load cycle.
 8.25 List four measures that may be taken to increase the resistance to fatigue of a metal alloy.

Solution

Four measures that may be taken to increase the fatigue resistance of a metal alloy are:
(1) Polish the surface to remove stress amplification sites.
(2) Reduce the number of internal defects (pores, etc.) by means of altering processing and fabrication
techniques.
(3) Modify the design to eliminate notches and sudden contour changes.
(4) Harden the outer surface of the structure by case hardening (carburizing, nitriding) or shot peening.
 Generalized Creep Behavior

8.26 Give the approximate temperature at which creep deformation becomes an important consideration
for each of the following metals: nickel, copper, iron, tungsten, lead, and aluminum.

Solution

Creep becomes important at about 0.4Tm, Tm being the absolute melting temperature of the metal. (The

melting temperatures in degrees Celsius are found inside the front cover of the book.)

For Ni, 0.4Tm = (0.4)(1455 + 273) = 691 K or 418C (785F)

For Cu, 0.4Tm = (0.4)(1085 + 273) = 543 K or 270C (518F)
For Fe, 0.4Tm = (0.4)(1538 + 273) = 725 K or 450C (845F)
For W, 0.4Tm = (0.4)(3410 + 273) = 1473 K or 1200C (2190F)
For Pb, 0.4Tm = (0.4)(327 + 273) = 240 K or -33C (-27F)
For Al, 0.4Tm = (0.4)(660 + 273) = 373 K or 100C (212F)
 8.27 The following creep data were taken on an aluminum alloy at 400C (750F) and a constant stress
of 25 MPa (3660 psi). 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.

Time (min) Strain Time (min) Strain

0 0.000 16 0.135
2 0.025 18 0.153
4 0.043 20 0.172
6 0.065 22 0.193
8 0.078 24 0.218
10 0.092 26 0.255
12 0.109 28 0.307
14 0.120 30 0.368

Solution

These creep data are plotted below

The steady-state creep rate (De/Dt) is the slope of the linear region (i.e., the straight line that has been
superimposed on the curve) as

De 0.230 - 0.09
= = 7.0 10 -3 min -1
Dt 30 min - 10 min
 Stress and Temperature Effects

8.28 A specimen 750 mm (30 in.) long of an S-590 alloy (Figure 8.31) is to be exposed to a tensile stress of
80 MPa (11,600 psi) at 815C (1500F). Determine its elongation after 5000 h. Assume that the total of both
instantaneous and primary creep elongations is 1.5 mm (0.06 in.).

Solution

From the 815C line in Figure 8.31, the steady state creep rate es is about 5.5 10-6 h -1 at 80 MPa. The
steady state creep strain, e , therefore, is just the product of es and time as
s

es = es x (time)

= (5.5 10 -6 h -1) (5, 000 h) = 0.0275

Strain and elongatiRQ DUHUHODW

HG DVLQ ( TXDW
LRQ VROYLQJ IRUW
KHVW
HDG\ VW
DWHHORQJ DW
LRQ Dls, leads to

Dls = l0 es = (750 mm) (0.0275 ) = 20.6 mm (0.81 in.)

Finally, the total elongation is just the sum of this Dls and the total of both instantaneous and primary creep

elongations [i.e., 1.5 mm (0.06 in.)]. Therefore, the total elongation is 20.6 mm + 1.5 mm = 22.1 mm (0.87 in.).
 8.29 For a cylindrical S-590 alloy specimen (Figure 8.31) originally 10 mm (0.40 in.) in diameter and
500 mm (20 in.) long, what tensile load is necessary to produce a total elongation of 145 mm (5.7 in.) after 2,000 h
at 730C (1350F)? Assume that the sum of instantaneous and primary creep elongations is 8.6 mm (0.34 in.).

Solution

It is first necessary to calculate the steady state creep rate so that we may utilize Figure 8.31 in order to
determine the tensile stress. The steady state elongation, Dls, is just the difference between the total elongation and

the sum of the instantaneous and primary creep elongations; that is,

Dls = 145 mm - 8.6 mm = 136.4 mm (5.36 in.)

Now the steady state creep rate, es is just

D ls 136.4 mm
. De l 500 mm
es = = 0 =
Dt Dt 2, 000 h

= 1.36 10-4 h -1

Employing the 730C line in Figure 8.31, a steady state creep rate of 1.36 10-4 h -1 corresponds to a stress s of about
200 MPa (or 29,000 psi) [since lo g (1.36 10-4 ) = -3.866]. From this we may compute the tensile load using Equation
6.1 as

d 2
F = sA0 = sp 0
2

10.0 10 -3 m 2
= (200 10 6 N/m 2 ) (p) = 15, 700 N (3645 lb f )
2
 8.30 If a component fabricated from an S-590 alloy (Figure 8.30) is to be exposed to a tensile stress of 300
MP a (43,500 psi) at 650C (1200F), estimate its rupture lifetime.

Solution

This problem asks us to calculate the rupture lifetime of a component fabricated from an S-590 alloy exposed
to a tensile stress of 300 MPa at 650C. All that we need do is read from the 650C line in Figure 8.30 the rupture
OLIHW
LP HDW 0 3D W
KLVYDOXHLVDERXW K
 8.31 A cylindrical component constructed from an S-590 alloy (Figure 8.30) has a diameter of 12 mm
(0.50 in.). Determine th e maximum load that may be applied for it to survive 500 h at 925C (1700F).

Solution

We are asked in this problem to determine the maximum load that may be applied to a cylindrical S-590 alloy
component that must survive 500 h at 925C. From Figure 8.30, the stress corresponding to 500 h is about 50 MPa
d 2
(7,250 psi). Since stress is defined in Equation 6.1 as s = F/A0, and for a cylindrical specimen, A0 = p 0 , then
2

d 2
F = sA0 = sp 0
2

12 10 -3 m 2
= (50 1 0 6 N/m 2 ) (p) = 5655 N (1424 lb f )
2
 8.32 From Equatio n 8.19, if the logarithm of es is plotted versus the logarithm of , then a straight line

should result, the slope of which is the stress exponent n. Using Figure 8.31, determine the value of n for the S-590
alloy at 925C, and for the initial (i.e., lower-temperature) straight line segments at each of 650C, 730C, and
815C.

Solution

The slope of the line from a log es versus log s plot yields the value of n LQ ( TXDW
LRQ W
KDWLV

D log es
n=
D log s

We are asked to determine the values of n for the creep data at the four temperatures in Figure 8.31 [i.e., at 925C, and
for the initial (i.e., lower-temperature) straight line segments at each of 650C, 730C, and 815C]. This is
accomplished by taking ratios of the differences between two log es and log s values. (Note: Figure 8.31 plots log s
versus log es ; therefore, values of n are equal to the reciprocals of the slopes of the straight-line segments.)

Thus for 650C

D log es log (10 -1) - log (10 -5 )

n= = = 11.2
D log s log (545 MPa) - log (240 MPa)

While for 730C

D log es log (1) - log (10 -6 )

n= = = 11.2
D log s log (430 MPa) - log (125 MPa)

And at 815C

D log es log (1) - log (10 -6 )

n= = = 8.7
D log s log (320 MPa) - log (65 MPa)

And, finally at 925C

n=
D log es
=
( )
log 10 2 - log (10 -5 )
= 7.8
D log s log (350 MPa) - log (44 MPa)
 8.33 (a) Estimate the activation energy for creep (i.e., Qc in Equation 8.20) for the S-590 alloy having the
steady-state creep behavior shown in Figure 8.31. Use data taken at a stress level of 300 MPa (43,500 psi) and
temperatures of 650C and 730C . Assume that the stress exponent n is independent of temperature. (b) Estimate
e at 600C (873 K) and 300 MPa.
s

Solution

(a) We are asked to estimate the activation energy for creep for the S-590 alloy having the steady-state
creep behavior shown in Figure 8.31, using data taken at s = 300 MPa and temperatures of 650C and 730C. Since s
is a constant, Equation 8.20 takes the form

Q Q
es = K 2s nexp - c = K2' exp - c
RT RT

where K2' is now a constant. (Note: the exponent n has about the same value at these two temperatures per Problem

8.32.) Taking natural logarithms of the above expression

Qc
ln es = ln K2' -
RT

For the case in which we have creep data at two temperatures (denoted as T and T ) and their corresponding
1 2
steady-state creep rates ( es and es ), it is possible to set up two simultaneous equations of the form as above, with
1 2
two unknowns, namely K2' and Qc. Solving for Qc yields

R ln es - ln es
1 2
Qc = -
1 1
-
T1 T2

-5
Let us choose T1 as 650C (923 K) and T2 as 730C (1 . W
KHQ IURP ) LJ XUH DWs = 300 MPa, es = 8.9 10
1
-2
h -1 and es = 1.3 10 h -1. Substitution of these values into the above equation leads to
2

Qc = -
[
(8.31 J / mol - K) ln (8.9 10 -5 ) - ln (1.3 10 -2 ) ]
1 1
923 K - 1003 K

= 480,000 J/mol
 (b) We are now asked to estimate es at 600C (873 K) and 300 MPa. It is first necessary to determine the

value of K2' , which is accomplished using the first expression above, the value of Qc, and one value each of es and T
(say e and T1). Thus,
s1

Q
K2' = es exp c
1 RT1

480, 000 J / mol

( )
= 8.9 10 -5 h-1 exp 23 -1
= 1.34 10 h
(8.31 J / mol - K)(923 K)

Now it is possible to calculate es at 600C (873 K) and 300 MPa as follows:

Q
es = K 2' exp - c
RT

480, 000 J/mol

( )
= 1.34 10 23 h-1 exp -
(8.31 J/mol - K)(873 K)

= 2.47 10-6 h -1
 8.34 Steady-state creep rate data are given below for nickel at 1000C (1273 K):

es (s1) s [MPa (psi)]

10 4 15 (2175)
6
10 4.5 (650)

If it is known that the activation energy for creep is 272,000 J/mol, compute the steady-state creep rate at a
temperature of 850C (1123 K) and a stress level of 25 MPa (3625 psi).

Solution

Taking natural logarithms of both sides of Equation 8.20 yields

Qc
ln es = ln K2 + n ln s -
RT

With the given data there are two unknowns in this equation--namely K2 and n. Using the data provided in the

problem statement we can set up two independent equations as follows:

272, 000 J / mol

(
ln 1 10 -4 s-1 )= ln K2 + n ln (15 MPa) -
(8.31 J/mol - K)(1273 K)

272, 000 J / mol

(
ln 1 10 -6 s-1 )= ln K2 + n ln (4.5 MPa) -
(8.31 J/mol - K)(1273 K)

Now, solving simultaneously for n and K2 leads to n = 3.825 and K2 = 466 s -1 . Thus it is now possible to solve for es

at 25 MPa and 1123 K using Equation 8.20 as

Q
es = K2s nexp - c
RT

272, 000 J/mol

( )
= 466 s-1 (25 MPa) 3.825exp -
(8.31 J/mol - K)(1123 K)

2.28 10-5 s -1
 8.35 Steady-state creep data taken for a stainless steel at a stress level of 70 MPa (10,000 psi) are given
as follows:

es (s1) T (K)

1.0 10 5 977
2.5 10 3 1089

If it is known that the value of the stress exponent n for this alloy is 7.0, compute the steady-state creep rate at 1250
K and a stress level of 50 MPa (7250 psi).

Solution

Taking natural logarithms of both sides of Equation 8.20 yields

Q
ln es = lnK2 + n lns - c
RT

With the given data there are two unknowns in this equation--namely K2 and Qc. Using the data provided in the

problem statement we can set up two independent equations as follows:

Qc
(
ln 1.0 10 -5 s-1 )= ln K2 + (7.0) ln (70 MPa) -
(8.31 J/mol - K)(977 K)

Qc
(
ln 2.5 10 -3 s-1 )= ln K2 + (7.0) ln (70 MPa) -
(8.31 J/mol - K)(1089 K)

Now, solving simultaneously for K2 and Qc leads to K2 = 2.55 105 s -1 and Q = 436,000 J/mol. Thus, it is now
c
possible to solve for es at 50 MPa and 1250 K using Equation 8.20 as

Q
es = K2s nexp - c
RT

436, 000 J/mol

( )
= 2.55 10 5 s-1 (50 MPa) 7.0 exp -
(8.31 J/mol - K)(1250 K )

0.118 s -1
 Alloys for High-Temperature Use

8.36 Cite three metallurgical/processing techniques that are employed to enhance the creep resistance of
metal alloys.

Solution

Three metallurgical/processing techniques that are employed to enhance the creep resistance of metal alloys
are (1) solid solution alloying, (2) dispersion strengthening by using an insoluble second phase, and (3) increasing
the grain size or producing a grain structure with a preferred orientation.
 DESIGN PROBLEMS

8.D1 Each student (or group of students) is to obtain an object/structure/component that has failed. It
may come from your home, an automobile repair shop, a machine shop, etc. Conduct an investigation to determine
the cause and type of failure (i.e., simple fracture, fatigue, creep). In addition, propose measures that can be taken
to prevent future incidents of this type of failure. Finally, submit a report that addresses the above issues.

Each student or group of students is to submit their own report on a failure analysis investigation that was
conducted.
 Principles of Fracture Mechanics

8.D2 (a) For the thin-walled spherical tank discussed in Design Example 8.1, on the basis of critical
crack size criterion [as addressed in part (a)] , rank the following polymers from longest to shortest critical crack
length: nylon 6,6 (50% relative humidity), polycarbonate, poly(ethylene terephthalate), and poly(methyl
methacrylate). Comment on the magnitude range of the computed values used in the ranking relative to those
tabulated for metal alloys as provided in Table 8.3. For these computations, use data contained in Tables B.4 and
B.5 in Appendix B.
(b) Now rank these same four polymers relative to maximum allowable pressure according to the leak-
before-break criterion, as described in the (b) portion of Design Example 8.1. As above, comment on these values
in relation to those for the metal alloys that are tabu lated in Table 8.4.

Solution

(a) This portion of the problem calls for us to rank four polymers relative to critical crack length in the wall
of a spherical pressure vessel. In the development of Design Example 8.1, it was noted that critical crack length is
proportional to the square of the KIcsy ratio. Values of KIc and sy as taken from Tables B.4 and B.5 are tabulated
below. (Note: when a range of sy or KIc values is given, the average value is used.)

Material KIc (MPa m ) sy (MPa)

Nylon 6,6 2.75 51.7

Polycarbonate 2.2 62.1
Poly(ethylene terephthlate) 5.0 59.3
Poly(methyl methacrylate) 1.2 63.5

On the basis of these values, the four polymers are ranked per the squares of the KIcsy ratios as follows:

K 2
Material Ic (mm)
s
y

PET 7.11
Nylon 6,6 2.83
PC 1.26
PMMA 0.36
These values are smaller than those for the metal alloys given in Table 8.3, which range from 0.93 to 43.1 mm.

2 - s ratio is used. The four polymers are ranked

(b) Relative to the leak-before-break criterion, the KIc y

according to values of this ratio as follows:

2
KIc
Material (MPa - m)
sy

PET 0.422
Nylon 6,6 0.146
PC 0.078
PMMA 0.023

These values are all smaller than those for the metal alloys given in Table 8.4, which values range from 1.2 to 11.2
MPa-m.
 Data Extrapolation Methods

8.D3 An S-590 alloy component (Figure 8.32) must have a creep rupture lifetime of at least 100 days at
500C (773 K). Compute the maximum allowable stress level.

Solution

This problem asks that we compute the maximum allowable stress level to give a rupture lifetime of 100 days
for an S-590 iron component at 773 K. It is first necessary to compute the value of the Larson-Miller parameter as
follows:

T (20 + log t r ) = (773 K){20 + log [(100 days)(24 h/day)

]}

= 18.1 103

From the curve in Figure 8.32, this value of the Larson-Miller parameter corresponds to a stress level of about 530
MPa (77,000 psi).
 8.D4 Consider an S-590 alloy component (Figure 8.32) that is subjected to a stress of 200 MPa ( 29,000
psi). At what temperature will the rupture lifetime be 500 h?

Solution

We are asked in this problem to calculate the temperature at which the rupture lifetime is 500 h when an S-
590 iron component is subjected to a stress of 200 MPa (29,000 psi). From the curve shown in Figure 8.32, at 200
MPa, the value of the Larson-Miller parameter is 22.5 103 (K-h). Thus,

22.5 10 3 (K - h) = T (20 + log tr )

= T [20 + log (500 h) ]

Or, solving for T yields T = 991 K (718C).

 8.D5 For an 18-8 Mo stainless steel (Figure 8.35), predict the time to rupture for a component that is
subjected to a stress of 80 MPa (11,600 psi) at 700C (973 K).

Solution

This problem asks that we determine, for an 18-8 Mo stainless steel, the time to rupture for a component that
is subjected to a stress of 80 MPa (11,600 psi) at 700C (973 K). From Figure 8.35, the value of the Larson-Miller
parameter at 80 MPa is about 23.5 103, for T in K and tr in h. Therefore,

23.5 10 3 = T (20 + log t r )

= 973(20 + log t r )

And, solving for tr

24.15 = 20 + log t r

which leads to tr = 1.42 104 h = 1.6 yr.

 8.D6 Consider an 18-8 Mo stainless steel component (Figure 8.35) that is exposed to a temperature of
500C (773 K). What is the maximum allowable stress level for a rupture lifetime of 5 years? 20 years?

Solution

We are asked in this problem to 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 to calculate the value of the Larson-Miller parameter for each time. The values of tr corresponding to 5

and 20 years are 4.38 104 h and 1.75 105 h, respectively. Hence, for a lifetime of 5 years

[ ]
T (20 + log t r ) = 773 20 + log (4.38 10 4 ) = 19.05 10 3

And for tr = 20 years

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

Using the curve shown in Figure 8.35, the stress values corresponding to the five- and twenty-year lifetimes
are approximately 260 MPa (37,500 psi) and 225 MPa (32,600 psi), respectively.