Mechanical Metallurgy

Lecturer Dr. Tapany Udomphol Assessment Assignment (homework, quiz, attendance) Midterm exam Final exam Total
Suranaree University of Technology
Tapany Udomphol

20

40 40 100
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

Macro-microhardness (Vickers) instrument

Suranaree University of Technology

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
A

TS y
E

Tensile testing configuration

Ture stress-strain curve of a ductile metal under uniaxial tensile loading.

Suranaree University of Technology

Plate specimens
Tapany Udomphol

Round specimens
May-Aug 2007

Torsion test
Applying twisting moment to the specimen and measure the torque. has not been standardized.
Torsion testing machine

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

Typical creep curve

Suranaree University of Technology

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
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

Clip gauge

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. S-N fatigue test and fatigue crack growth resistance. Parameters: Fracture life (fatigue strength) Fatigue crack growth resistance Paris exponent (m) Fatigue threshold (Kth)

max

min
_ cycles

Stresses in fatigue loading

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