CARLETON UNIVERSITY FINAL, EXAMINATION December 1998 DURATION: 3_ HOURS No. of Students: 60 Department Name & Course Number: Mechanical & Aerospace Engineering 86.412* A Insuvctors) Professor J. Beddoes \UTHORIZED MEMORANDA {Calculators only. Students MUST count the numberof pags in ths examination question paper before beginning to write, and report any discrepancy immediatly toa proctor. This question paper has 7 pages ‘This examination question paper MAY be taken from the examination room. ANSWER ALL EIGHT QUESTIONS 1 (8 marks) (@) Briefly define or explain the difference between the hardness and hardenability of steel. (b) Give one reason why high hardenability of a steel is desirable. (©) Give one reason why high hardenability of a stec! is undesirable. 2. marks) (@) The elastic modulus of a continuous and aligned fibre reinforced composite in the Iongitudinal direction is 20.8 GPa. The elastic modulus of the matrix is 2.4 GPa and the elastic modulus of the fibre is 70 GPa. What is the elastic modulus of the composite in the transverse direction? () _ Inpart (a), the fibres are 0.5 mm in diameter, have an average length of 8 mm anda fracture strength of 1000 MPa. The matrix yield strength is 100 MPa. For these properties, comment on the validity of the elastic moduli of part (a).ca Engineering 86.412* 2 i" Final Exam December 1998 3. (6 marks) Acomponent is manufactured from IN792, a nickel based superalloy. The alloy is to be used in the CAST+HEAT TREAT condition at 1500°F, with an applied stress of 40 ksi. However, to mect the service requirements the creep rupture life of the component must be doubled. Using the attached data, determine if reducing the stress level to 35 ksi will double the creep: life. Note: (i) the equation for the x-axis is for time in hours and temperature in degrees Rankine (degrees Rankine="F-+460) (ii) 1 ksi=1000 pounds per square inch. 600 500 400 aN ‘ssauis STRESS, ksi 200 CAST « HEAT TREAT CAST + HP-A = REAT TREAT CAST + H-8 HEAT TREAT 4 8 4 46 4 50 52 PaTx10° (20+ 1091)Engineering 86.412* Bae Final Exam December 1998 (15 marks) (a) The fatigue data shown is for a steel tested in air at 0.1 to 10 Hz or in a NaCl environment at 0.1 Hz (open triangles), 1 Hz (open circles) and 10 Hz (dark circles). Explain why the frequency influences the fatigue crack growth rate in NaCl but not in air. () The material of part (a) is to be used in an application expected to be exposed to air with a loading frequency of 10Hz. Concem exists about the possibility of pre- existing edge cracks and so the component is inspected by eddy current techniques for which the probability of detection curve is shown below. The steel has a yield stress of 1000 MPa and fracture toughness of 100 MPav/m. To guard against fatigue failure itis decided that the component will be removed from service when the crack length is within 1 mm of the critical crack size that causes unstable fast fracture. It is expected that in service the component cyclic stress will vary between 0 and 150 MPa. If a 90% probability of detection is used how many cycles can the component be left in service? Assume that for the crack geometry K, = 080/na (©) One of the eddy current inspectors does not pay attention to their work and as a consequence the component with a crack of 0.7 mm is put into service, Will this cause failure? ‘Stress-imenety factor ange (AK), KS » © Fatigue rack grow rate (le), mye T TF 10 os] goa Bos 00 01 02 03 04 05 06 07 08 09 4 ‘rack Size (nm) fio Fatigue crack growth ale (dW), neyo ect Probabit ges 700Engineering 86.412* Final Exam December 1998 5, (6 marks) (@) You are designing a structural component 15 mm thick that will carry a maximum tensile stress of 375 MPa. The yield strength and fracture toughness of the three alloys available are listed below. Which would you recommend for the application? Provide a reason for your answer. Alloy Yield Strength (MPa) K,, (MPa‘m’) A 500 30 B 400 40 c 600 30 (©) _Ifitis expected that the 375 MPa stress level may occasionally be slightly exceeded, and edge cracks of 1 mm may be present. Would you change your selection of part (a)? State a reason for your answer. (10 marks) A cylindrical cryogenic pressure vessel used in petrochemical manufacture exploded. The vessel operated at about -130°C and was manufactured from a special fine grained low carbon steel. Failure analysis revealed evidence of fatigue crack growth possibly environmentally assisted. A stress analysis of the vessel was undertaken to evaluate the safe operation of similar vessels till in service with a ‘leak before break’ condition desired. Finite clement stress analysis indicated that the highest hoop stress corresponding to the initiation. of cracking was 80 MPa at the inner wall and 60 MPa at the outer wall. At the service temperature laboratory tests revealed the vessel fracture toughness was 40 MPavm. The critical crack size of an edge crack was estimated as 40 mm. The stress intensity for the crack geometry is: K, = 0.1070/na (@)__ Whyis the vessel fabricated from a fine grained steel? (©) What type of evidence might exist to indicate that fatigue cracking occurred? (©) Are the fracture toughness and critical crack size consistent with the fast fracture? Support your answer. (@)___ Htissuggested that the remaining pressure vessels be fitted with pressure relief valves. that will effectively limit the stress levels to those determined by finite element analysis. If this is done, what is the maximum wall thickness of the pressure vessel that will ensure the leak before break criterion is satisfied? Does this appear to be satisfactory?te Engineering 86.412 5 Final Exam December 1998 7. (7 marks) (@) The plot below provides stress corrosion cracking data for a titanium 6% aluminum alloy in four different metallurgical conditions when tested in potassium chloride. From the data, list the conditions in order from least stress corrosion resistant to most stress corrosion resistant. (6) A thick plate made from the titanium 6% aluminum alloy carries a stress of 40 ksi and is exposed to potassium chloride and contains an edge crack 0.3 inch long. Itcan remain in service until the crack doubles in length and the desired service life is 10 hours. Will any of the conditions for which data is provided in the accompanying figure be satisfactory for this application? STRESS INTENSITY tigi 22) 0 00 150 20 OS OXYGEN. AGED ATazSee 03 OXYGEN. QUENCHED Frou are % ‘STRESS CORROSION CRACK VELOCITY lente) ‘STRESS CONNOSION CRACK VELOCITY tin ow) Frou aie STRESS INTENSITY ss VREngineering 86.412* 6 Final Exam December 1998 8. (10 marks) A sample of mild steel is deformed under states of (a) equal biaxial tension and plane stress, and (b) equal biaxial tension and plane strain. Find the ratio of the yield stress in state (b) to the yield stress in state (a) predicted by the Tresca yield criterion. Assume that Poisson's ration is 0.3. Recall that: Tresca’s yield criterion is: where: Ty, is the maximum shear stress, 9,05, are the largest and smallest principal stresses, respectively. LY‘Z EQUATION SHEET - Srna = z oyna = JEG AG = Ona 6, aoa So R 3 = Ce” &s5 = Bo"exp(-Q/RT) 1k D = D,exp(-Qgy/RT) 6m (rs? D = Dyexp[-(K,+)7,/T] x, \? egghT : + Be 23 | a : 42) x, -—e (2) ent 2 00D" Bw \w kTd’ AT’ YS. = 0,+k,d% L-M = T(C+logT)