Mechanical Metallurgy

Lecturer
Dr. Tapany Udomphol
Assessment
Assignment
(homework, quiz, attendance)

20

Midterm exam

40

Final exam

40

Total
Suranaree University of Technology

100
Tapany Udomphol

May-Aug 2007

Mechanical Metallurgy
Subject of interests
Part I Mechanical fundamentals
Introduction to mechanical metallurgy
Stress and strain relationships of elastic behaviour
Elements of the theory of elasticity
Part II Metallurgical fundamentals
Plastic deformation of single crystals
Dislocation theory
Strengthening mechanisms
Fracture

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Mechanical Metallurgy I
Subject of interests
Part III Applications to materials testing
Tension test
Hardness test
Torsion test
Fracture mechanics
Brittle fracture and impact testing
Fatigue of materials
Creep and stress rupture

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Objectives
Interaction of stress and strain on materials in elastic and
plastic manners will be understood.
Deformation behaviour of metals due to dislocation
interaction as well as strengthening mechanisms of metals
will be addressed.
Different methods of mechanical testing will be highlighted
along with the interpretation of sensible information from the
obtained data such that mechanical assessments are
appropriately selected for the required applications.
Metallurgical aspects which affect mechanical properties of
materials will be discussed.
Finally cause of material failure will be studied and suggested
possible solutions will be discussed.
Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Main references
Dieter, G.E., Mechanical metallurgy, 1988, SI metric edition,
McGraw-Hill, ISBN 0-07-100406-8.
Hibbeler, R.C. Mechanics of materials, 2005, SI second
edition, Person Prentice Hall, ISBN 0-13-186-638-9.
Sanford, R.J., Principles of fracture mechanics, 2003,
Prentice Hall, New Jersey, ISBN 0-13-092992-1.
Rolfe, S.T., Barsom, J.M., Fracture and fatigue control in
structures: Applications of fracture mechanics, 1977,
Prentice Hall, New jersey, ISBN 0-13-329953-8.
Edwards, H.L., Wanhill, R.J.H., Fracture mechanics, 1986,
Arnold, Australia, ISBN 0-7131-3515-8.
Smallman, R.E., Bishop, R.J., Modern physical metallurgy &
materials engineering: Science, process, applications, 6th
edition, 1999, Butterworth-Heinemann, ISBN 0-7506-4564-4.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Main references
Brick, R.M., Pense, A.W., Gordon, R. B., Materials science
and engineering series, 1977, 4th edition, McGraw-Hill, ISBN
0-07-007721-5.
Hull, D. Fractography: Observing, measureing,
interpreting, fracture surface topography, 1999, Cambridge,
ISBN 0-521-64684-7.
Dowling, N.E., Mechanical behaviour of materials:
E,ngineering methods for deformation, fracture, and
fatigue, 2nd edition, 1999, Prentice Hall, New Jersey, ISBN 013-010989-4.
Suresh, S., Fatigue of materials, 1998, 2nd edition,
Cambridge university press, ISBN 0-521-57847-7.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Why failure in materials?

Seven of the Liberty ships built

during the world war II has
broken completely in two as a
result of brittle fractures.
Over 1000 of approximately
5000 merchant ships built
during World War II had
developed cracks of
considerable size by 1946.
Failure of Liberty Ships during services in
World War II.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Why failure in materials?

The bridge building industry did

not pay particular attention to the
possibility of brittle failure until the
failure of Point Pleasant bridge in
1967.
The bridge collapsed without
warning, costing 46 lives.

Collapse of Point Pleasant suspension

bridge, West Virginia, on December 15, 1967.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Why failure in materials?

The aircraft was used for interisland transportation for 19 years

before failed.
Failure has been attributed to
multiple-site-damage.

Failed fuselage of the Aloha 737 aircraft in 1988.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Material property assessments

Hardness
Strength
Ductility (elongation, area
of reduction)
Creep (elevatedtemperature strength)
Torsion
Toughness (resistance
to failure)
Fatigue
Suranaree University of Technology

Micro/Macro hardness tests

Tension tests

Creep tests
Torsion tests
Impact tests
Fracture toughness tests
S-N fatigue tests
Fatigue crack growth tests
Tapany Udomphol

May-Aug 2007

Hardness tests
Hardness is a property
which is a measure of a
resistance to permanent or
plastic deformation.
Using difference
indenters, i.e., ball,
diamond.

Parameters:
Brinell hardness (BHN)
Meyer hardness
Vickers hardness (VHN)
Rockwell hardness

Suranaree University of Technology

Macro-microhardness (Vickers) instrument

Tapany Udomphol

May-Aug 2007

Tensile tests

Provide basic design

information on the strength
of materials.
Acceptance test for the
specification of the
materials.

Parameters:
Tensile strength
Yield stress
Youngs Modulus of
elasticity
%Elongation
Area of reduction

Suranaree University of Technology

TS
y

Tensile testing
configuration

Ture stress-strain curve of a ductile

metal under uniaxial tensile loading.

Plate specimens
Tapany Udomphol

Round specimens
May-Aug 2007

Torsion test
Applying twisting moment
to the specimen and measure
the torque.

Torsion testing
machine

has not been standardized.

Parameters:
Shear Modulus
Torsional yield strength
Modulus of rupture

Ultimate torsion test results

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Creep test
Creep is high temperature
progressive deformation of a
material at constant stress.
A tensile specimen is loaded
at a constant (elevated)
temperature. Strain is
measured with time.
Parameters:
Creep strength
Creep rate

Suranaree University of Technology

Typical creep curve

Tapany Udomphol

May-Aug 2007

Impact tests
Measure toughness of materials in terms of
energy absorption.
Specimen is impacted by a hammer and the
energy absorbed during fracture is measured
in Joul.
Easy and practical.
Establish Ductile to Brittle Transition
Temperature (DBTT).
Not a standard material parameter, should
be used in conjunction with other material
properties such as strength and fracture
toughness for materials determination.
Parameters:
Impact energy
Ductile to brittle transition temperature
Suranaree University of Technology

Tapany Udomphol

www.twi.co.uk

Charpy impact testing

May-Aug 2007

Fracture mechanics

Clip gauge

Resistance of materials to crack

propagation (to failure).
Crack propagation can be
predicted before failure.
Material will fail when the
stress intensity factor K
reaches the critical value KIC.
Parameters:
Fracture toughness
Crack tip opening
displacement
J-integral

Fracture toughness testing

KIC
CTOD
J
Failed fracture toughness
specimens.

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

Fatigue tests

Material is subjected to a
repetitive or fluctuating stress
(cyclic loading) and will fail at
a stress level much lower than
that causes failure in statistic
loading.

max

min
_

cycles

Stresses in fatigue loading

S-N fatigue test and fatigue

crack growth resistance.
Parameters:
Fracture life (fatigue strength)
Fatigue crack growth resistance
Paris exponent (m)
Fatigue threshold (Kth)
Fatigue striations on fatigue
fracture surface
Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

To improve properties of metals

Materials assessment

Improvement of materials properties

WE NEED TO

Understand mechanical aspects

Stress and strain relationships of elastic behaviour
Elements of the theory of plasticity.

Understand Metallurgical aspects

Plastic deformation
Dislocation theory
Strengthening mechanisms
Fracture
Suranaree University of Technology

Tapany Udomphol

May-Aug 2007

References
www.ndsu.nodak.edu
www.kockums.se
www.indentec.com
www.enduratec.com
www.bactechnologies.com
www.twi.co.uk
www.jaeri.go.jp
www.hghouston.com
www.minton.co.uk
www2.umist.ac.uk
www.materialsengineer.com

Suranaree University of Technology

Tapany Udomphol

May-Aug 2007