CARLETON UNIVERSITY FINAL EXAMINATION December 1999 DURATION: 3_ HOURS No.of Students: 65 Department Name & Course Number: Mechanical & Aerospace Engineering 86.412*A. Instructor(s) Professor J.C. Beddoes SUTHORIZED MEMORANDA Iculators Only Students MUST count the number of pages in this examination question paper before beginning to write, and report any discrepancy immediately toa proctor. This question paper has 7 ages. ‘This examination question paper MIAYY be taken from the examunation oom. DO ALL EIGHT QUESTIONS - Equation Sheet is Attached To This Exam Question 1 (6 marks) A certain material has a modulus of elasticity of 100 GPa. If the material cracks in a brittle fashion the resulting crack has a surface energy of 1 J/m:. If the material cracks plastically the resulting crack has a surface energy of 300 J/m*. If a through thickness centre crack of 1 mm length exists in a large plate of this material, calculate: (@ the breaking strength if failure occurs elastically, and (©) the breaking strength if failure occurs plastically. Question 2 (7 marks) A polymer matrix composite is reinforced with 10 pm diameter alumina fibres. Ifthe strength of the alumina fibres is 1 GPa and the fibre/matrix shear strength is 10 MPa, (@ — Whatis the critical fibre length? (©) Whatis the average stress in the alumina fibre if the composite is made with 1 cm long alumina fibres that are all aligned in the load direction?Engineering 86.412*A. 2 Final Exam December 1999 Question 3 (8 marks) ‘A structural element is to be made from steel with a plane strain fracture toughness of 50 MPavm and a plane stress fracture toughness that is 3 times the plane strain fracture toughness. The steel has a yield stress of 600 MPa and the expected applied stress during service is 300 MPa. During the preliminary design the thickness of this structural element is not well known. For this problem you may assume the equation for a small crack in an infinite plate is a reasonable approximation. (a) Ifthe thickness is going to be 20 mm, what is the critical crack length? (b) Ifthe thickness of the structural element is reduced to 2 mm, and the applied stress remains the same, will the critical crack length change? Support your answer. Question 4 (12 marks) (@) Creep tests on a metallic alloy give the following results: Temperature (°C) Stress (MPa) Steady State Strain Rate (s") 650 50 2x10" 650 200 2x10” 750, 200 1.6x10* For this alloy the activation energy for diffusion is 165 ki/mole. Based on this data, what creep mechanism do you think is occurring? Justify your answer. The universal gas constant is 8.413 Jimole-K. (b) If the constant B in the power law creep equation for this alloy is 7.4x10, estimate the steady state strain rate for a creep test of this alloy at 250 MPa and 700°C.Ww Engineering 86.412*A 3 Final Exam December 1999 Question 5 (15 marks) In this course one of the fracture case studies involved failure of engine fan disk on a DC-10 resulting in the crash at Sioux City, Iowa. The fan disk was fabricated from Ti-6AI-4V, which has the following typical properties: Yield strength = 880 MPa Plane strain fracture toughness = 91 MPa‘m”* da Paris Law fatigue crack growth according to: le 48x 10° AK? where AK is in MPa‘m* and da/dN is in mm/cycle. ‘The fan disk contained a hard alpha defect, the details of which were thoroughly characterized as part of the post-crash investigation. This defect can be modelled as a surface thumbnail crack, the size of which was as follows: Initial Size After Fan Disk Fabrication: a=0.38mm 2c = 1.4mm Last NDT Inspection, 760 cycles prior to failure: a= 6.35 mm 2e= 12.7 mm Size at Failure: a=127mm 2c =25.4 mm For this defect geometry the following equation provides a reasonable approximation: K = Yoyna .95 for a/2c = 0. 4 where a and 2c are defined -> ‘The fan disk experienced 15,503 cycles (start up and shutdown being one cycle) before failure. Given this information: (@) estimate the stress level across the crack when the fan disc failed, () assuming that your answer to part (a) represents the normal operating stress level, estimate the stress intensity associated with the hard alpha defect at the beginning of engine service, (©) whats the average fatigue crack growth rate in the direction along the a dimension, (@ inthe direction along the a dimension, estimate the fatigue striation spacing at a time near the beginning of service when a = 0.38 mm, (assume that when the engine is not operating the stress level is zero), (©) __ inthe direction along the a dimension, estimate the fatigue striation spacing corresponding to the crack length at the last NDT inspection (assume that when the engine is not operating the stress level is zero).Engineering 86.412*A 4 Final Exam December 1999 Question 6 (7 marks) (a) __Inthis course four different techniques for "Design Against Fatigue" were introduced. During the design of the fan disc of the previous question it was determined that the fatigue life of a defect free disc would be 54,000 engine cycles (start up and shutdown being one cycle). Certification authorities applied a % safety factor multiplier to this life, giving a certified life of 18,000 cycles. What "Design Against Fatigue” technique does this information imply. Briefly explain your answer. () Asa result of the Sioux City crash the investigation authorities made the following recommendation: “Develop ... an alternate method of inspecting the ... rotor disks for the presence of cracks: issue an Airworthiness Directive to require that these disks be inspected with this method on an expedited basis, and that the inspection be repeated at a cyclic interval based upon the crack size detectable by the inspection method, the stress level in the applicable area ... , and the crack ‘What "Design Against Fatigue” technique does this recommendation imply for continued service of the fan disks? Briefly explain your answer.Engineering 86.412*A 5 Final Exam ‘December 1999 Question 7 (8 marks) ‘The plot below illustrates the stress corrosion cracking behaviour for a Cr-stee! for a rotating component in a steam turbine. The normal operating stress in this component is 1000 MPa at a temperature of 288°C. During a regular inspection of the component a 3 mm crack is found. (@) Ifthe partis put back into normal service without repair, estimate the stress corrosion. crack growth rate of this crack. (Assume that the stress intensity relationship for an infinite plate is a reasonable approximation for this geometry.) (b) Since a replacement component will take several months to obtain, the component must be operated in a manner that minimizes the risk of failure. Two choices are available 1) reduce the rotational speed so that the stress is only 400 MPa, or 2) reduce the component temperature to 160°C. Which choice will extend the life of the part the most? Justify your answer.Engineering 86.412*A 6 Final Exam December 1999 Question § For Aerospace Engineering Students Only (7 marks) The figure below illustrates the aluminum alloys specified for various structural applications on Boeing commercial aircraft. Comparing the alloy selected for wing applications, its apparent that lower wing structures are fabricated from 2xxx alloys (Al-Cu) while upper wing structures are fabricated from 7xxx alloys (Al-Zn-Mg). (@) Realizing that the upper wing is predominantly a tensile structure and the lower wing is predominantly a compressive structure, what is the reason for the different alloy selection for these two applications. () _ Briefly explain why the difference in toughness and strength between the 2xxx and 7xxx alloys occurs. 8 Fracture toughness (Kapp), kel vin 3 Question 8 For Mechanical Engineering Students Only (7 marks) In this course the "Failure of a Highway Bridge” fracture case study several problems associated with the welding procedure contributed to the failure. (@) The material that failed was a welded low alloy steel. Briefly explain why low alloy steels, require special attention to welding procedures. (b) To improve weld quality it is common to specify the use of low hydrogen welding, electrodes. What are low hydrogen electrodes and how do they contribute to improving the integrity of welds?EQUATION SHEET E ae pet oyma=/EG Av = 6, -«, Saux ~ TO Lange av G aoa E o = Ce™ &,5 = Bo"exp(-Q/RT) D = D,exp(-Qcy/RT) D= D,exp| -(K,* yr,/7| eg kT ” s ° =a& DGb (3) 3 5 5. - 7920 500D,,b S kTd? Td - AD,b s)* L-M = T(C+logT) NG ee L a) -43)| v2y| Byers, g ALA