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MAT E 202 Assigned: Jan.

22, 2018
Winter 2018 Assignment #2 Due: Feb. 2, 2018
Department of Chemical and Materials Engineering

1. The tensile engineering stress-strain curve for a polycrystalline aluminum alloy rod AA6061-T6
is shown below. Pay attention to units! A tensile specimen was made with a diameter of 12.5 mm
and 25.4 mm gage length. Assume  = 0.28.

a) After the test is started, it is stopped at a strain of 0.4% (and remains under stress):
i) What would be the force required to maintain the stress? (N)
ii) What is the length of the specimen (mm)?
iii) What is the diameter of the specimen (mm)?
iv) Why is the specimen longer/shorter, or wider/narrower?

b) Imagine that a test is stopped at a total strain of 0.08 and then unloaded to zero stress.
i) What is the length of the specimen (mm)?
ii) What is the diameter of the specimen (mm)?
iii) What would the new yield strength be if the tensile test was restarted (MPa)?

c) What is the maximum load (N) that can be supported by this specimen before necking begins?

d) Search for published AA6061 Aluminum mechanical properties data. State the typical yield
strength %El, UTS and Brinell hardness for both the 0 temper and a T6 temper in both PSI and
MPa. How do these values compare with the values for AA6061-T6 that you calculated from
the graph above?

2. Define the following and provide the appropriate formulae and units (where applicable) for each:
a. Poisson’s ratio c. Tensile toughness
b. Fracture toughness d. DBTT

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MAT E 202 Assigned: Jan. 22, 2018
Winter 2018 Assignment #2 Due: Feb. 2, 2018
3. The following tensile and Charpy Impact data was collected from four types of low carbon steel
(C < 0.1 wt%) designated as C1, C2, C3, and C4. The designations *-C or *-D indicate that the
specific steel (e.g. C1-C or C1-D) was processed differently and as a result possess different
microstructures. Using this information answer the following questions.

a. Determine the upper and lower shelf energies for each steel designation (e.g C1-C, C1-D etc.)
b. Determine the ductile-to-brittle transition temperatures as the temperature corresponding to
the average of the upper and lower shelf energies.
c. Determine the ductile-to-brittle transition temperatures as the temperature at which the
absorbed energy is 20J.

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MAT E 202 Assigned: Jan. 22, 2018
Winter 2018 Assignment #2 Due: Feb. 2, 2018
d. A design calls for a steel that has YS/UTS ratio < 0.75, a DBTT <-50°C and a %El >19.0%.
What steel would you chose?

4. Copper-beryllium (Cu-Be) alloys are often used in non-sparking tools in the oilpatch; the alloys
are very formable, expensive, and Be is toxic in powder form! Consider a Cu-Be alloy (C17300
TH04) with ys = 1100 MPa; UTS = 1500 MPa. Consider the fabrication of a clamp, which will
be required to sustain a uniaxial tensile load of 5000kg. The rectangular cross section of the part
is twice as wide as it is thick. A safety factor of 2 against yield (ys), and a safety factor of 3
against static fracture (UTS) are to be used.
a. What is the design stress that you will use for the application? Why?
b. What are the appropriate bar dimensions for use?

5. The fatigue data for brass was determined


:

Stress Amplitude Cycles to Failure


(MPa)
170 3.7 x 104
148 1.0 x 104
130 3.0 x 105
114 1.0 x 106
92 1.0 x 107
80 1.0 x 108
74 1.0 x 109

a) Construct a S-N plot (stress amplitude versus logarithm cycles to failure) using this data.
b) Determine the fatigue strength at 4 x 106 cycles.
c) Determine the fatigue life for 120 MPa.
d) Does the alloy exhibit a fatigue limit? Why or why not?
e) Sketch on your S-N diagram the curve for this material if the m in the test is increased.

6. A cylindrical low carbon-nickel alloy was creep tested. The original diameter was 19 mm and the
length was 635 mm. Assume the sum of the instantaneous and primary creep elongations is 1.8
mm. A stress versus steady-state creep rate plot for the alloy and a rupture lifetime plot are shown
in the figures on the next page.
a. This alloy melts at 1475°C. What is the temperature at which creep begins for this alloy (°C)?
b. If the component were exposed to a stress of 100 MPa at 538°C, estimate the rupture lifetime.
c. What tensile load is necessary to produce a total elongation (i.e., sum of elongations from
instantaneous, primary, and secondary creep) of 6.4 after 7500 hours at 538°C?
d. Determine the activation energy for creep in this alloy. (Hint: choose 649°C as the
temperature). Assume that K2 = 5.5.

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MAT E 202 Assigned: Jan. 22, 2018
Winter 2018 Assignment #2 Due: Feb. 2, 2018

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MAT E 202 Assigned: Jan. 22, 2018
Winter 2018 Assignment #2 Due: Feb. 2, 2018

INTENDED LEARNING GOALS FOR THIS ASSIGNMENT


Declarative knowledge
Definitions of mechanical properties

Procedural knowledge
Tensile test curve interpretation
Calculation of properties from tensile curves
Calculation of dimensional changes under different magnitudes of simple tension
Determination of yield stress post deformation

Proper use of units, nomenclature, and vocabulary; Effect of mean stress and determining fatigue
lifetime; construction of S-N curves
Calculations of creep elongations, relationships between stress and steady-state creep rate,
determination of critical temperatures for creep, calculation of activation energy for creep
Identification of features on failure surfaces

Conditional knowledge
Selection of a steel type based on the mechanical properties.
Analysis steps in an engineering failure.

Reflective knowledge
Difference in deformation response in different materials, under different loading: static, dynamic,
and high temperature