4B2 TEST 2

Please answer these 10 questions by typing directly on to this document. Then

upload the document to Blackboard. You have 30mins in total. You may
consult your notes and other sources but you may not communicate with
anyone else.

This time there is only one correct answer in the multiple choice questions.

Q1. Brittle failure can happen if the material has:

a) Low Young’s modulus

b) Low yield strength
c) Low toughness
d) Low hardness

Q2. Which of the following pictures shows brittle fracture:

(a) (b)

(c) (d)
Q3. Write down the equation for the stress intensity K for a component containing a crack
of length a and loaded with a stress s.

K = Fs√pa

Q4) If the F factor in this equation is 1.0, the crack length is 3mm and the applied stress is
500MPa, what is the value of K? Choose the nearest answer:

a) 0.5 MPa√m
b) 5 MPa√m
c) 50 MPa√m
d) 500 MPa√m

Q5) In the pressure vessel in Case Study 2 there were four different regions: Steel Plate,
Steel Forging, Weld Metal and Heat Affected Zones. Which of these four regions is most
likely to be a source of brittle fracture?

The Heat Affected Zone

Q6) Give one reason for your answer to Q5.

Brittle material (martensite) due to rapid cooling. (You could also say residual stress,
or because it contains defects)

Q7) Briefly describe how Finite Element Analysis can be used to estimate the K value for a
component in which a crack has been found.

Make an FE model, including the crack in the model. Apply forces to the model to
simulate the use of the component. Look at the stress in the material at a short distance
ahead of the crack. There’s an equation that relates this stress to the K value. (Alternatively
you could say look at the opening of the faces of the crack, or find how the energy changes
when the crack gets slightly longer).

Q8) Proof testing involves overloading a component. For pressure vessels a typical overload
factor is:

a) 1.4
b) 2
c) 10
d) 100

Q9) Give one reason why proof tests are carried out.
 To allow for the fact that the operating stresses may be higher than predicted. (You
could also say to allow for errors in the stress analysis, or to allow for fatigue crack growth).

Q10) The maximum possible value for residual stress in a material is:

a) The yield strength

b) The ultimate tensile strength
c) The Young’s modulus
d) The failure stress

THE END