Nile University

School of Engineering & Applied Sciences

Mechanical Engineering Program
MENG:301
Mechanical Behavior of Materials
Spring 2020
Sheet#1

Principles of Fracture Mechanics

Q1:
What is the magnitude of the maximum stress that exists at the tip of an internal crack having a radius of
curvature of 1.9 x 10−4 mm (7.5 x 10−6 𝑖𝑛 ) and a crack length of 3.8 x 10−2 𝑚𝑚 (1.5 𝑥 10−3 𝑖𝑛 ) when a
tensile stress of 140 MPa (20,000 psi) is applied ?

Q2:
Estimate the theoretical fracture strength of a brittle material if it is known that fracture occurs by the
propagation of an elliptically shaped surface crack of length 0.5 mm (0.02 in.)
and having a tip radius of curvature of 5 x 10−3 𝑚𝑚(2𝑥10−4 𝑖𝑛 ), when a stress of 1035 MPa (150,000 psi)
is applied.

Q3:
If the specific surface energy for aluminum oxide is 0.90 J/m2, using data contained in Table 12.5, compute
the critical stress required for the propagation of an internal crack of length 0.40 mm.

Q4:
An MgO component must not fail when a tensile stress of 13.5 MPa (1960 psi) is applied. Determine the
maximum allowable surface crack length if the surface energy of MgO is 1.0 J/m2. Data found in Table 12.5
may prove helpful.

Q5:
A specimen of a 4340 steel alloy with a plane strain fracture toughness of 54.8 MPa √𝑚 (50 ksi √𝑖𝑛 ) is
exposed to a stress of 1030 MPa (150,000 psi). Will this specimen experience fracture if it is known that the
largest surface crack is 0.5 mm (0.02 in.) long? Why or why not? Assume that the parameter Y has a value of
1.0.

Q6:
Some aircraft component 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 300 MPa (43,500 psi)
when the maximum (or critical) internal crack length is 4.0 mm (0.16 in.). For this same component and
alloy, will fracture occur at a stress level of 260 MPa (38,000 psi) when the maximum internal crack length
is 6.0 mm (0.24 in.)? Why or why not?

Q7:
Suppose that a wing component on an aircraft is fabricated from an aluminum alloy that has a plane strain
fracture toughness of 26MPa √𝑚 (23.7 ksi √𝑖𝑛 ). It has been determined that fracture results at a stress of
112 MPa (16,240 psi) when the maximum internal crack length is 8.6 mm (0.34 in.). For this same
component and alloy, compute the stress level
at which fracture will occur for a critical internal crack length of 6.0 mm (0.24 in.).

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Q8:
A large plate is fabricated from a steel alloy that has a plane strain fracture toughness of 82.4 MPa √𝑚 (75
ksi √𝑖𝑛 ) If, during service use, the plate is exposed to a tensile stress of 345 MPa (50,000 psi), determine
the minimum length of a surface crack that will lead to fracture. Assume a value of 1.0 for Y.

Q9:
Calculate the maximum internal crack length allowable for a Ti-6Al-4V titanium alloy (Table 8.1)
component that is loaded to a stress one-half of its yield strength. Assume that the value of Y is 1.50.

Q10:
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 98.9 MPa √𝑚 (90 ksi √𝑖𝑛 ) and a yield strength of 860 MPa (125,000 psi). The
flaw size resolution limit of the flaw detection apparatus is 3.0 mm (0.12 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.

Impact Fracture Testing

Q11:
Following is tabulated data that were gathered from a series of Charpy impact tests on a commercial low-
carbon steel alloy.

(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 20
J.

Cyclic Stresses (Fatigue)

The S–N Curve

Q12:
A 6.4 mm (0.25 in.) diameter cylindrical rod fabricated from a 2014-T6 aluminum alloy (Figure 8.34) is
subjected to reversed tension compression load cycling along its axis. If the maximum tensile and
compressive loads are +5340 N (+1200 lbf) and -5340 N(-1200 lbf), respectively, determine its fatigue life.
Assume that the stress plotted in Figure 8.34 is stress amplitude.

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Q13:
The fatigue data for a brass alloy are given as follows:

(a) Make an S–N plot (stress amplitude versus logarithm cycles to failure) using these data.
(b) Determine the fatigue strength at 4*106 cycles.
(c) Determine the fatigue life for 120 MPa.
(d) Suppose that the fatigue data for the brass alloy were taken from 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 1800
revolutions per minute. Give the maximum torsional stress amplitude possible for each of the following
lifetimes of the rod:
(1) 1 year, (2) 1 month, (3) 1 day, and (4) 1 hour.

Q14:
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.

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

Creep
Q15:
The following creep data were taken on an aluminum alloy at 480°𝐶 (900°𝐹) and a constant stress of 2.75
MPa (400 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.

Q16:
A cylindrical component constructed from a
low carbon–nickel alloy (Figure 8.30) has a
diameter of 19.1 mm (0.75 in.). Determine
the maximum load that may be applied for it
to survive 10000 h at 538°𝐶 (1000°𝐹)

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Q17 :
For a cylindrical low carbon–nickel alloy specimen (Figure 8.31) originally19 mm (0.75 in.) in diameter and
635 mm (25 in.) long, what tensile load is necessary to produce a total elongation of 6.44 mm (0.25 in.) after
5000 h at 538°𝐶 (1000°𝐹) Assume that the sum of instantaneous and primary creep elongations is 1.8 mm
(0.07 in.).

Q18 :
A specimen 1015 mm (40 in.) long of a low carbon–nickel alloy (Figure 8.31) is to be exposed to a tensile
stress of 70 MPa (10,000 psi) at 427 °𝐶 (800°𝐹) Determine its elongation after 10,000 h. Assume that the
total of both instantaneous and primary creep elongations is 1.3 mm (0.05 in.).

Q19 :
For a cylindrical low carbon–nickel alloy specimen (Figure 8.31) originally 19 mm (0.75 in.) in diameter
and 635 mm (25 in.) long, what tensile load is necessary to produce a total elongation of 6.44 mm (0.25 in.)
after 5000 h (Considering that we didn’t reach tertiary region) at 538 °𝐶 (1000°𝐹) Assume that the sum of
instantaneous and primary creep elongations is 1.8 mm (0.07 in.).

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Figures

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