CH 03

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SOLUTION (3.1)
Known: Definitions of the terms stress, strength, yield strength, ultimate strength,
elastic limit, proportional limit, modulus of elasticity, and yield point are given in
Section 3.2.
Find: Write definitions of the above terms -- see Section 3.2.
Analysis:
1. The stress is the load divided by the cross-sectional area.
2. The strength is the maximum value of stress a material will carry before failure.
3. The yield strength, Sy, is the value of stress at which significant plastic yielding
first occurs.
4. The ultimate strength is the maximum value of stress a material will carry before
fracture for nondynamic loading.
5. The elastic limit is the highest stress the material can withstand and still return
exactly to its original length when unloaded.
6. The proportional limit is the stress at which the stress-strain curve first deviates
(ever so slightly) from a straight line. Below the proportional limit, Hooke's law
applies.
7. The modulus of elasticity (Young's modulus) E is the constant of proportionality

between stress and strain (which is the slope of the curve between the origin and
the proportional limit).
8. The yield point of a material is a point for a material where appreciable yielding
occurs suddenly at a clearly defined value of stress; for example, in soft steel. In
other materials the onset of appreciable yielding occurs gradually, and the yield
strength for these materials is determined by using the "offset method." This is
illustrated in Fig. 3.1; it shows a line, offset an arbitrary amount of 0.2 percent of
strain, drawn parallel to the straight-line portion of the original stress-strain
diagram. Point B is the yield point of the material at 0.2 percent offset. If the
load is removed after yielding to point B, the specimen exhibits a 0.2 percent
permanent elongation. Yield strength corresponding to a specified (very small)
offset is a standard laboratory determination, whereas elastic limit and
proportional limit are not.
3-1
SOLUTION (3.2)
Known: The Greek letter σ is employed in this textbook to denote normal stress
caused by tensile, compressive, or bending loads; the Greek letter τ is utilized to
denote shear stress caused by torsional or transverse shear loads; and the letter S
designates strength properties of the material.
Find: Discuss the purpose in this text book of using (1) the Greek letter σ to denote
normal stress, (2) the Greek letter τ to denote shear stress, and (3) the letter S to
designate strength properties of the material.
Analysis: The purpose of using Greek letters to denote stress and the letter S (with
appropriate subscripts) to designate strength properties of the material is because
stress and strength are fundamentally different. Stress is a calculated term dependent
on load and geometry wherein the load results in deformation or strain. Strength is a
property of a material and a limiting value of stress. Strength is the maximum value
of stress a material will carry before failure – yielding, fracture, pitting. For example,
yield strength, Sy, is the value of stress at which significant plastic yielding first
occurs. The ultimate strength, Su, is the maximum value of stress a material will
carry before fracture for nondynamic loading.
An important notation convention is observed throughout the textbook: the Greek

letter σ denotes normal stress, which is a function of the applied loads; S (with
appropriate subscripts) designates strength properties of the material.
Whereas S (with suitable subscripts) is used for all strength values including those for
torsion or shear, the letter σ is used for normal stresses only, that is, stresses caused
by tensile, compressive, or bending loads. Shear stresses, caused by torsional or
transverse shear loads, are designated by the Greek letter τ.
3-2
SOLUTION (3.3)
Known: The website http://www.matweb.com lists properties for various materials.
Find: Search this website for AISI 4340 steel, oil quenched 800°C (1470°F), 540°C
(1000°F) temper, 25mm round and list values for (1) modulus of elasticity, (2) ultimate
tensile strength, (3) elongation at break in %, and (4) yield strength, Sy.
Analysis: The web site http://www.matweb.com provides the following information:
(1) 29700 ksi

(2) 175100 psi
(3) 14.2% elongation at break
(4) 166100 psi
3-3
SOLUTION (3.4)
Known: We are to determine the modulus of elasticity, ultimate tensile strength,
elongation at break, and (4) density for certain carbon and alloy steels.
Find: Search the materials property database at http://www.matweb.com and list values
for the (1) modulus of elasticity, E, (2) ultimate tensile strength, Su, (3) elongation at
break in %, and (4) density in g/cc, for the following: (a) AISI carbon steels: 1010 cold
drawn, 1020 cold rolled, 1040 as rolled, 1050 as rolled, 1080 as rolled, and 1116 cold
drawn; and (b) alloy steels: 4140 annealed, 4340 annealed, and 4620 annealed.
Analysis: (a) From www.matweb.com we find for AISI carbon steels:
AISI 1010, cold drawn

Density 7.87 g/cc
Tensile Strength, Ultimate 365 MPa 52900 psi
Modulus of Elasticity 205 GPa 29700 ksi
Elongation at Break 20 %
AISI 1020 Steel, cold rolled

Density 7.87 g/cc
AISI 1040 Steel, as rolled

Density 7.845 g/cc

Density 7.85 g/cc

Density 7.85 g/cc
3-4
AISI 1116 Steel, cold drawn
Density 7.85 g/cc
(b) From www.matweb.com we find for Alloy steels:
AISI 4140 Steel, annealed at 815°C (1500°F) furnace cooled 11°C (20°F)/hour to
665°C (1230°F), air cooled, 25 mm (1 in.) round
Density 7.85 g/cc
Elongation at Break 25.7 %
AISI 4340 Steel, annealed, 25 mm round

Density 7.85 g/cc
AISI 4620 Steel, annealed, 25 mm round

Density 7.85 g/cc
Elongation at Break 31.3 %
Comment: Matweb is an award winning web site.
3-5
SOLUTION (3.5)
Known: We are to determine the modulus of elasticity, ultimate tensile strength,
elongation at break, and (4) density for certain carbon and alloy steels.
Find: Search the materials property database at http://www.matweb.com and list the (1)
modulus of elasticity, E, (2) ultimate tensile strength, Su, (3) elongation at break in %,
and (4) density in g/cc, for the following: (a) Cast iron: ASTM class 20 and class 35;
(b) Aluminum alloys: 3003-H12, 3003-H18, 5052-H32, 5052-H38, 5052-O, 6061-T4,
6061-T91, and 7075-O.
Analysis: (a) From www.matweb.com we find for Cast iron:
Standard gray iron test bars, as cast, ASTM class 20

Density 7.15 g/cc
Modulus of Elasticity 66 - 97 GPa 9570 - 14100 ksi
Standard gray iron test bars, as cast, ASTM class 35

Density 7.15 g/cc
Modulus of Elasticity 100 - 119 GPa 14500 - 17300 ksi
(b) From www.matweb.com we find for Aluminum alloys:
Aluminum 3003-H12
Density 2.73 g/cc
Ultimate Tensile Strength 131 MPa 19000 psi
Elongation at Break 10 % AA; Typical; 1/16 in. (1.6 mm) Thickness
Elongation at Break 20 % AA; Typical; 1/2 in. (12.7 mm) Diameter
Modulus of Elasticity 68.9 GPa 10000 ksi
Aluminum 3003-H18
Density 2.73 g/cc
Modulus of Elasticity 68.9 GPa
Aluminum 5052-H32
Density 2.68 g/cc
3-6
Aluminum 5052-H38
Density 2.68 g/cc
Aluminum 5052-O
Density 2.68 g/cc
Aluminum 6061-T4; 6061-T451

Density 2.7 g/cc
Aluminum 6061-T91
Density 2.7 g/cc
Modulus of Elasticity 69 GPa
Aluminum 7075-O
Density 2.81 g/cc
3-7
SOLUTION (3.6)
Known: The materials to be selected have E greater than 207 GPa and Su greater than
200 psi (1378 MPa).
Find: Identify five materials with (a) modulus of elasticity greater than steel, and (b)
ultimate strength greater than 200 ksi.
Analysis:
(a) From Appendix C-1, we attempt to select the following materials with higher E
values than steel, but inspection of the materials listed in the appendix of the
textbook, reveals no materials with E values higher than that of steel. ■
(b) From the textbook appendices, we select the following non-steel materials with Su
values greater than 1378 MPa. ■
Material Su (MPa)
Steel 1378 MPa
Leaded beryllium copper 1379 MPa (max)
C17300
(Appendix C-13)
Duranickel 301 1448 MPa (max)
CD aged bar
(Appendix C-15)
Rene 95 1620 MPa
Superalloy
Comment: Inspection of the materials listed in the appendix of the textbook reveals
that steel is a relatively strong and stiff material.
3-8
SOLUTION (3.6D) -- alternate
Known: The materials to be selected have E greater than 207 GPa and Su greater than
1378 MPa.
Find: Identify five materials with (a) modulus of elasticity greater than steel, and (b)
ultimate strength greater than 200 ksi.
Analysis:
(a) From www.matweb.com we select the following materials with higher E values
than steel:
Modulus of Elasticity, ksi, greater than 30 x 106 psi ■
Material E (ksi)
Steel 30000 ksi
Beryllium, Be 40020 ksi
Chromium, Cr 35960 ksi
Recrystallized
Iridium, Ir 75980 ksi
Annealed
Molybdenum, Mo 47850 ksi
Annealed
Osmium, Os 81200 ksi
Annealed
Rhenium, Re 68005 ksi
Annealed
Rhodium, Rh 52055 ksi
Annealed
Ruthenium, Ru 60030 ksi
Annealed
Technetium, Tc 46690 ksi
Annealed
Tungsten, W 58000 ksi
(b) We select the following non-steel materials with ultimate tensile strength Su
greater than 1378 MPa (200,000 psi):
Tensile Strength, Ultimate, psi, greater than 200 ksi ■
Material Su (psi)
AISI Grade 18Ni (300) Maraging 293625 psi
Steel
3-9
Aged, round bar
Tested longitudinal, 75 mm
Carpenter AerMet®-for-Tooling 300005 psi
Tool Steel
Double Aged 468ºC
BioDur™ 316LS Stainless Medical 223445 psi
Implant Alloy
90% Cold Worked
VascoMax® C-300 Specialty Steel 285070 psi
Heat Treatment: 927°C (1700°F) +
Age
W-25 Re Tungsten Rhenium Alloy 580000 psi
Deformed
AISI A6, Type Tool Steel 345100 psi
Austenitized 830-870ºC (1525-
1600°F)
AISI A9, Type Tool Steel 319000 psi
Tempered at 500ºC
Titanium Ti-15Mo-5Zr 246500 psi
ST 730ºC, Aged 400ºC
AISI Type W2 Tool Steel 261000 psi
Water quenched at 775ºC
(1425ºF), and tempered
AISI Type S5 Tool Steel 323350 psi
Austenitized 855-870ºC (1575-
1600ºF)
Oil quenched to 55 HRC
Mo-47.5 Re Molybdenum 464000 psi
Rhenium Alloy
Deformed
Iridium, Ir 290000 psi
Cold-Drawn
Rhenium, Re 304500 psi
Deformed
Rhodium, Rh 299860 psi
Hardened
Technetium, Tc 218950 psi
As-Rolled
Pt-20% Ni Alloy 250125 psi
Hard
79Pt-15Rh-6Ru 300150 psi
Alloy 851
3-10
Pt-8% W Alloy 300150 psi
Hard
3-11
SOLUTION (3.7D)
Known: The website http://www.matweb.com lists properties for various materials.
Find: Search this website for a steel materials of your choice and list values for (1)
modulus of elasticity, (2) ultimate tensile strength, (3) elongation at break in %, and (4)
density in g/cc.
Analysis: The web site http://www.matweb.com provides the following information for
ASI Grade 18Ni (200) Maraging Steel, Annealed.
(1) 26500 ksi

(2) 140000 psi
(3) 17% elongation at break
(4) 8 g/cc
SOLUTION (3.8)
Known: Appendix C-1 provides representative values for physical properties of
common metals.
Find: List common materials in Appendix C-1 that have a lower density and a higher
thermal conductivity than steel.
Analysis:
1. According to Appendix C-1, aluminum alloy, gray cast iron, magnesium alloy,
titanium alloy, and zinc alloy have lower densities that steel.
2. According to Appendix, C-1, aluminum alloy, copper Beryl, brass, bronze, copper,
gray cast iron, magnesium alloy, and zinc alloy have a higher thermal conductivity
than steel.
3. Aluminum alloy, gray cast iron, magnesium alloy, and zinc alloy all have lower
densities and have higher thermal conductivities than steel. ■
Comment: Titanium alloy has both a lower density and a lower thermal conductivity
than steel.
3-12
SOLUTION (3.9)
Known: The critical location of a part made from known steel is cold worked during
fabrication.
Find: Estimate Su, Sy and the ductility.
Schematic and Given Data:
S u = 66 ksi
Stress
C
D
Sy F
B
Se Hot Rolled 1020 Steel
A
G H
Strain
Assumption: After cold working the stress-strain curve for the critical location starts at
point G.
Analysis:
1. At point G in Fig. 3.2, the part has been permanently stretched to 1.1 times its
initial length. Hence, its area is 1/1.1 times its original area Ao.
2. On the basis of the new area, the yield strength is Sy = 62(1.1) = 68.2 ksi. ■
3. The ultimate strength is Su = 66(1.1) = 72.6 ksi. ■
4. At fracture, R increases to 2.5 on the graph.
5. R = 2.5/1.1 = 2.27
6. Using Eq. (3.3) and Eq. (3.2)
Ar = 1 - 1 = 1 - 1 = 0. 56
R 2. 27 ■
ε = R - 1 = 2.27 - 1 = 1.27 or 127% ■
3-13
SOLUTION (3.10)
Known: The critical location of a part made from known steel is cold worked during
fabrication.
Find: Estimate Su, Sy and the ductility.
S u = 66 ksi
I
D
Stress
C F
B Sy
A
G J H
Strain
Assumption: After cold working the stress-strain curve for the critical location starts at
point J.
Analysis:
1. The area ratio at J is R = Ao/Af = 1.2. The initial area is thus 1/1.2.
2. The yield strength is Sy = 65(1.2) = 78 ksi. ■
3. The ultimate strength is Su = 66(1.2) = 79.2 ksi.
4. At fracture, R increases to 2.5 on the graph.
5. R = 2.5/1.2 = 2.08
6. Using Eq. (3.3) and Eq. (3.2)
Ar = 1 - 1 = 1 - 1 = 0. 519 ε = R - 1 = 2.08 - 1 = 1.08 or 108% ■

R 2. 08
3-14
SOLUTION (3.11)
Known: A tensile specimen of a known material is loaded to the ultimate stress, then
unloaded and reloaded to the ultimate stress point.
Find: Estimate the values of σ, ε, σT, εT for the first loading and the reloading.
S u = 66 ksi
C
D
Stress
Sy
B
A
G H
Strain
Assumption: After unloading the stress-strain curve starts at point H for the new
specimen.
Analysis:
1. For the initial sample, σ = 66 ksi, ε = 30%. ■
2. For Figure 3.2, R = 1.3 at point H.
3. From Eq. (3.4), σT = σR = (66)(1.3) = 85.8 ksi. ■
4. From Eq. (3.5), εT = ln(1 + ε) = ln 1.30 = 0.26 = 26%. ■
5. For the new specimen; σ = 66(1.3) = 85.8 ksi. ■
6. The new specimen behaves elastically, so ε = σ/E = 85.8/30,000 = .00286. ■
7. Within the elastic range, σT ≈ σ and εT ≈ ε. Therefore σT = 85.8 ksi and
εT = 0.29%. ■
Comment: Note also that εT = ln(1 + ε) = ln(1.0029) = 0.29%.
3-15
SOLUTION (3.12)
Known: A tensile specimen of a known material is loaded to a known stress, then
unloaded and reloaded to the same stress point.
S u = 66 ksi
C
D
Stress
B Sy
A
G H
Strain
Assumption: After unloading, the stress-strain curve starts at point G for the new
specimen.
Analysis:
2. For Figure 3.2, R = 1.1 at point G.
3. From Eq. (3.4), σT = σR = (62)(1.1) = 68.2 ksi. ■
4. From Eq. (3.5), εT = ln(1 + ε) = ln 1.10 = 0.095 = 9.5%. ■
5. For the new specimen; σ = 62(1.1) = 68.2 ksi. ■
6. The new specimen behaves elastically, so ε = σ/E = 68.2/30,000 = .00227. ■
7. Within the elastic range, σT ≈ σ and εT ≈ ε. Therefore σT = 68.2 ksi and
εT = 0.23%. ■
3-16
SOLUTION (3.13)
Known: A tensile specimen of a known material is loaded to a known stress, then
unloaded and reloaded to the same stress point.
S u = 66 ksi
I
D
Stress
C F
B Sy
A
G J H
Strain
Assumption: After unloading the stress-strain curve starts at point J for the new
specimen.
Analysis:
2. For Figure 3.2, R = 1.2 at point J.
3. From Eq. (3.4), σT = σR = (65)(1.2) = 78.0 ksi. ■
4. From Eq. (3.5), εT = ln(1 + ε) = ln 1.20 = 0.18 = 18%. ■
5. For the new specimen; σ = 65(1.2) = 78 ksi. ■
6. The new specimen behaves elastically, so ε = σ/E = 78/30,000 = .0026. ■
7. Within the elastic range, σT ≈ σ and εT ≈ ε. Therefore σT = 78 ksi and
εT = 0.26%. ■
3-17
SOLUTION (3.14)
Known: An AISI 1030 steel part is annealed to 126 Bhn.
Find: Estimate values of Su and Sy for the part.
AISI
1030
Steel
126 Bhn
Su = ? Sy = ?
Assumptions:
1. The experimentally determined relationship of ultimate strength to hardness is
sufficiently accurate.
2. The experimentally developed relationship of yield strength to ultimate strength is
sufficiently accurate for our purposes.
Analysis:
1. Using Eq. (3.11), we can estimate Su.
Su = KBHB
where KB ≈ 500 for most steels.
For the part, Su = 500(126) = 63,000 psi. ■
2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi.

For the part, Sy = 1.05(63,000) - 30,000 = 36,150 psi. ■
Comments:
1. Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved
(not cold-worked) steels.
2. Experimental data would be helpful to refine the above equations for specific
steels.
3-18
SOLUTION (3.15)
Known: An AISI 1040 steel part is annealed to 149 Bhn.
Find: Estimate values of Su and Sy for the part.
AISI
1040
Steel
149 Bhn
Su = ? Sy = ?
Assumptions:
Analysis:
Su = KBHB
For the part, Su = 500(149) = 74,500 psi. ■
2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi.

For the part, Sy = 1.05(74,500) - 30,000 = 48,225 psi. ■
Comments:
steels.
3-19
SOLUTION (3.16)
Known: An AISI 4340 steel part is heat treated to 217 Bhn. A second AISI 4340 steel
part is heat treated to 363 Bhn.
Find: Estimate values of Su and Sy for both parts.
AISI
4340
Steel
Part 1, 217 Bhn Part 2, 363 Bhn

Su = ? Sy = ? Su = ? Sy = ?
Assumptions:
Analysis:
Su = KBHB
For Part 1, Su = 500(217) = 108,500 psi; for Part 2, Su = 500(363)
= 181,500 psi ■
2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi. For Part 1, Sy
= 1.05(108,500) - 30,000 = 83,925 psi. For Part 2, Sy = 1.05(181,500) - 30,000 =
160,575 psi. ■
Comments:
steels.
3-20
SOLUTION (3.17D)
Known: A steel is to be selected from Appendix C-4a.
Find: Estimate Su and Sy from the given value of Brinell hardness for the steel selected.
AISI
Steel
Su = ? Sy = ?
Decision: Select ANSI 1020 annealed.
Assumptions:
Analysis:
1. Appendix C-4a shows that ANSI 1020 annealed steel has Su = 57.3, Sy = 42.8, and
Bhn =111.
2. Using Eq. (3.11), we can estimate Su from the Brinell hardness using:
Su = KBHB
Su = 500(111) = 55,500 psi ■
3. Sy can be estimated by using Eq. (3.12).
Sy = 1.05 Su - 30,000 psi = 1.05(55,500) - 30,000 = 28,275 psi. ■
Comments:
(not cold-worked) steels. Note that the estimated value of Su from the Brinell
hardness of 55.5 ksi is close to the value given in Appendix C-4a of Su ≈ 57.3 ksi.
steels.
3-21
SOLUTION (3.18D)
Find: Estimate Su and Sy from the given values of Brinell hardness for the selected
steel.
AISI
1040
Steel
annealed
Su = ? Sy = ?
Decision: Select ANSI 1040 annealed steel.
Assumptions:
Analysis:
1. Appendix C-4a shows that ANSI 1040 annealed steel has Su = 75.3 ksi, Sy = 51.3
ksi, and Bhn = 149.
2. Using Eq. (3.11), we can estimate Su from the Brinell hardness value using:
Su = KBHB
SuB = 500(149) = 74,500 psi ■
SyB = 1.05 Su - 30,000 psi = 1.05(74,500) - 30,000 = 48,225 psi. ■
4. Ratio of strength (Appendix C-4a values to Brinell hardness based values):
S u 75. 3
= = 1. 011
S u B 74. 5
S y 51. 3
= = 1. 064
S y B 48. 2
Comments:
3-22
2. The Brinell hardness based strength values are slightly less than the Appendix C-
4a strength values.
3-23
SOLUTION (3.19D)
Find: Estimate Su and Sy from the given values of Brinell hardness for the selected
steel.
AISI
1030
Steel
as-rolled
normalized
annealed
Su = ? Sy = ?
Decision: Select ANSI 1030 steel.
Assumptions:
Analysis:
1. Appendix C-4a shows that for ANSI 1030 the strengths are as follows: (1) as-
rolled Su = 80.0 psi, Sy = 50.0 psi, Bhn = 179; (2) normalized Su = 75.5 psi, Sy =
32.0 psi, Bhn = 149; (3) annealed Su = 67.3 psi, Sy = 31.2 psi, Bhn = 126.
Su = KBHB
4. In as-rolled condition:
Su = 500(179) = 89,500 psi ■
Sy = 1.05 Su - 30,000 psi = 1.05(89,500) - 30,000 = 63,975 psi. ■
5. In normalized condition:
Su = 500(149) = 74,500 psi. ■
Sy = 1.05Su - 30,000 psi = 48,225 psi. ■
6. In annealed condition:
Su = 500(126) = 63,000 psi. ■
Sy = 1.05Su - 30,000 psi = 36,150 psi. ■
3-24
7. Ratio of strength (Appendix C-4a values to Brinell hardness based values):
as-rolled:
S u 80. 0 Sy
= = .894 = 50. 0 = .781
S u B 89. 5 S y B 63. 98
normalized:
S u 75. 5 S y 32. 0
= = 1. 01 = = .664
S u B 74. 5 S y B 48. 2
annealed:
S u 67. 3 S y 31. 2
= = 1. 068 = = .862
S u B 63. 0 S y B 36. 2
■
Comments:
2. Experimental data would be necessary to refine the above equations.
3-25
SOLUTION (3.20)
Known: An AISI 3140 steel part is heat treated to 210 Bhn.
Find: Estimate Su and Sy.
AISI
3140
Steel
Heat
Treated
to
Su = ? Sy = ? 210 Bhn
Assumptions:
Analysis:
Su = KBHB
Su = 500(210) = 105,000 psi ■
Sy = 1.05 Su - 30,000 psi = 1.05(105,000) - 30,000 = 80,250 psi. ■
Comments:
steels.
3-26
SOLUTION (3.21)
Known: An AISI 1020 steel part is heat treated to 111 Bhn.
Find: Estimate Su and Sy.
AISI
1020
Steel
Heat
Treated
to
Su = ? Sy = ? 111 Bhn
Assumptions:
Analysis:
Su = KBHB
Su = 500(111) = 55,500 psi ■
Sy = 1.05 Su - 30,000 psi = 1.05(55,500) - 30,000 = 28,275 psi. ■
Comments:
steels.
3-27
SOLUTION (3.22)
Known: The hardness versus distance curve for a Jominy end-quench test of AISI 4340
steel is given.
Find: Search the materials property database at http://www.matweb.com and list the
properties of nylon 6 with 30% glass fibers. Compare the 30% glass filled nylon
properties with those of unreinforced nylon 6.
4340 Low Alloy Plain Carbon

58 Rc 58 Rc 58 Rc
70 4340
Hardness (Rockwell C)
60
50
Low Alloy
40
30
20 Plain Carbon
10
0
0 10 20 30 40 50
Distance From Quenched End (mm)
Assumption: We assume that the hardness for the non heat treated end of the Jominy
test specimen properties is similar to 4340 steel.
Analysis: From Appendix C-4a, for 1040 Normalized, HB = 170 and for 4340
Normalized, HB = 363. We would expect at the end of the Jominy bar that the hardness
of the 1040 would be approximately 50% of the 4340 hardness.
Comment: The Jominy curves show the effectiveness of the alloying elements in
imparting hardenability to steel.
3-28
SOLUTION (3.23D)
Known: Four given applications require steel.
Find: Choose between (a) 0.1% C and 0.4% C, and between (b) plain carbon and alloy
steel.
(a) Machine Frame
(b) Round Rod
(c) Irregular Shaped Part (d) Rail Car Wheel
Assumption: Material is of usual quality.
Analysis:
(a) Machine frame. All steel materials provide approximately the same rigidity
(30 ✕ 106 psi). In this application, since stresses are low and we also want the cost
to be low, we would select plain carbon because of low price and 0.1% C because
of low strength.
(b) Small round rod. For high bending and torsional stresses we select 0.4% C and to
keep cost down we select plain carbon steel.
(c) Large irregular shaped part. For high stress we select 0.4% C and for ease in heat
treating we select alloy steel.
(d) Rail car wheel. For low cost we select carbon steel and for low interior strength
we choose 0.1% C. If we carburized the 0.1% C steel we can obtain a high
strength wear surface.
3-29
Comment: In summary, (1) alloy steel is more expensive but it is more easily heat
treated than plain carbon steel, and (2) 0.4% C steel has greater strength than 0.1% C
steel.
3-30
SOLUTION (3.24D)
Known: The site http://www.matweb.com provides the properties of aluminum 7075-
0.
Find: Compare the material properties for aluminum 7075-0 from the web to those
given in Appendix C-10 of the textbook.
Analysis:
1. From www.matweb.com we obtain for aluminum 7075-O:
Key Words: Aluminum 7075-O; UNS A97075; ISO AlZn5.5MgCu(A); Aluminum

7075-O; AA7075-O;
PHYSICAL PROPERTIES
Density, g/cc 2.81
Hardness, Brinell 60 500 kg load with 10 mm ball
Hardness, Knoop 80 Converted from Brinell Hardness Value
Hardness, Vickers 68 Converted from Brinell Hardness Value
MECHANICAL PROPERTIES
Tensile Strength, Ultimate, MPa 220, 31,900 psi
Tensile Strength, Yield, MPa 95, 13,775 psi
Elongation %; break 17, In 5 cm; Sample 1.6 mm thick 17 %
Modulus of Elasticity, GPa 72, Average of Tension and Compression. In
Aluminum alloys, the compressive modulus is typically 2% greater than the tensile
modulus, 10,440 ksi
Poisson’s Ratio 0.33
Shear Modulus, GPa 26.9, 3,901 ksi
Shear Strength, MPa 150, 21,750 psi
THERMAL PROPERTIES
CTE, linear 20ºC, µm/m-°C, 23.6, 20-100ºC, 13 µin/in-°F
CTE, linear 250ºC, µm/m-°C, 25.2, Average over the range 20-300ºC, 14 µin/in-°F
Heat Capacity, J/g-°C, 0.96, 0.23 BTU/lb-°F
Thermal Conductivity, W/m-K, 173, 1,201 BTU-in/hr-ft2-°F
Melting Point, °C, 477, Solidus, 891 °F
Solidus, °C, 477, 891 °F
Liquidus, °C, 635, 1,175 °F
ELECTRICAL PROPERTIES
Electrical Resistivity, Ohm-cm 0.0000038 ■
2. From Appendix C-10 of the textbook for 7075-0 aluminum we find:
3-31
Aluminum 7075-0
Brinell Hardness 60
Tensile Strength, Ultimate, 38 ksi, MPa 230
Tensile Strength, Yield, 15 ksi, MPa 105
Elongation in 2 in %; 16 ■
Comments:
1. The web wins again, providing a vast amount of information.
2. The tensile strength and the yield strength values from Appendix C-10 are higher
than those from www.matweb.com.
3-32
SOLUTION (3.25D)
T4.
Find: Compare the material properties for aluminum 2024-T4 from the web to those
Analysis:
1. From www.matweb.com we obtain for aluminum 2024-T4 (UNS number:
A92024):
2024-T4 aluminum
Tensile Yield Strength 290 MPa 42000 psi
Elongation at Break 19 % ■
2. From Appendix C-10 of the textbook for 2024-T4 aluminum we find:
2024-T4 aluminum
Ultimate Tensile Strength 470 MPa 68 ksi
Tensile Yield Strength 325 MPa 47 ksi
Elongation in 2 in. 19 % ■
Comments:
2. The tensile strength and the yield strength values from Appendix C-10 are higher
than those from www.matweb.com.
3-33
SOLUTION (3.26D)
T6.
Find: Compare the material properties for aluminum 6061-T6 from the web to those
Analysis:
1. From www.matweb.com we obtain for aluminum 6061-T6 (UNS number A96061):
6061-T6 aluminum
Hardness, Brinell 95
Tensile Yield Strength 276 MPa 40000 psi
■
2. From Appendix C-10 of the textbook for 6061-T6 aluminum we find:
6061-T6 aluminum
Hardness, Brinell 95
Ultimate Tensile Strength 310 MPa 45 ksi
Tensile Yield Strength 275 MPa 40 ksi
Elongation in 2 in. 17 %
■
Comments:
2. The tensile strength and the yield strength values from Appendix C-10 are
essentially identical to those from www.matweb.com.
3-34
SOLUTION (3.27D)
Known: Reference [16] MIL-HDBK-17-2F, Vol 2 is a reference for chapter 3.
Find: Review the given reference and provide the purpose of the volume.
Analysis: From the handbook:
A primary focus of this Handbook is guidance on the selection and use of composite
materials. The data collected within this volume are presented to allow initial assessments of
material adequacy for a particular application. It provides a common database that will
allow significant reductions in the amount of validation data necessary to use the data for
design purposes. This handbook cannot be cited as a DoD contractor requirement.
This handbook volume provides a standard source of statistically based mechanical property
data for current and emerging polymeric matrix composite materials. Physical, chemical,
and mechanical values of the composite constituents - the fibers, matrix material, and
prepreg - are reported where applicable. Subsequent chapters include data summaries for
the various composite systems. Individual chapters focus on particular type of reinforcement
fiber. Strength and strain-to-failure properties are reported in terms of mean and A-values
and/or B-values. The A and B statistical allowable values are determined by the procedures
of Volume 1. Only mean values are reported for stiffnesses. Maximum and minimum data
points, and coefficients of variation are reported for all data items.
SOLUTION (3.28D)
Known: Reference [17] MIL-HDBK-17-3F, Vol 3 is a reference for chapter 3.
Find: Review the given reference and provide the purpose of the volume.
Volume 3 of MIL-HDBK-17 provides methodologies and lessons learned for the design,
analysis, manufacture, and field support of fiber-reinforced, polymeric-matrix composite
structures. It also provides guidance on material and process specifications and procedures
for utilization of the material data presented in Volume 2. The information provided is
consistent with the guidance provided in Volume 1 and intended to be an extensive
compilation of the current "best knowledge and practices" of composite materials and
structures engineers and scientists from industry, government, and academia. This volume
will be continually updated as the "state-of-the-art" of composites technology advances.
3-35
SOLUTION (3.29)
Known: Reference [15], MIL-HDBK-17-1F, Vol 1 is a reference for textbook
Chapter 3.
Find: Review Table 2.3.4.1.4 in reference [15] and list examples of key material or
structural performance parameters.

PHYSICAL
TACK
RESIN CONTENT
AREAL WEIGHT
FLOW
GLASS TRANSITION
TEMPERATURE
FORM
OUT TIME
SHELF LIFE
STORAGE
REQUIREMENTS
MOISTURE
ABSORPTION
SOLVENT RESISTANCE
PROCESSING
CURED PLY THICKNESS
CURE CYCLE
SENSITIVITY
FIBER VOLUME
THERMAL
CYCLING
DENSITY
EXOTHERM
TOXICITY
MECHANICAL
LAMINA PROPERTIES
ENVIRONMENTAL EFFECTS
DAMAGE TOLERANCE
INTERLAMINAR SHEAR
FLATWISE TENSION
FLAW GROWTH
EFFECT OF DEFECTS
PRESSURE BOTTLE
TESTS
MANUFACTURING
DRILLING
TOOLING
NONDESTRUCTIVE
INSPECTION
COST
3-36
LEAD TIME
AVAILABILITY
REPEATABILITY
MACHINABILITY
UNIFORMITY
HARDWARE SCALE-UP
STATICSTRENGTH
FATIGUE
STRENGTH
STIFFNESS
FAILURE MODES
QUALITY
BEARING
CRIPPLING
OPEN HOLE
TENSION
OPEN HOLE
COMPRESSION
PANEL TESTS
FATIGUE TESTS
3-37
SOLUTION (3.30)
Known: Reference [16], MIL-HDBK-17-2F, Vol 2 is a reference for textbook Chapter
3 and uses material system codes consisting of a fiber system code and a matrix
material code separated by a virgule (i.e., a slash, /).
Find: Present several examples of material systems codes for polymer matrix
composites.
B/EP : Boron fiber in epoxy matrix

SGl/PSU : S-Glass fiber in Polysulfone matrix
Gr/PAl : Graphite fiber in Polyamide-imide matrix
Ti/TPES : Titanium fiber in Thermoplastic polyester
Comment: The above fiber and matrix compositions are only to demonstrate the
system codes and there is no guarantee that the composite is practical, useful or that the
fiber-matrix is compatible.
3-38
SOLUTION (3.31D)
Known: A designers favorite materials are 1020 steel, 1040 steel, 4340 steel, 2024-T4
aluminum, nylon 6/6, and acetal.
Find: Compare the specific material properties for each material.
Assumptions: The material properties presented in Appendix C are sufficient for

comparison purposes.
Decision: The material properties compared will be tensile strength, yield strength,
elongation, and hardness.
Analysis:
1. From Appendix C-4a, we obtain properties for normalized steel in 1 inch round
sections.
2. From Appendix C-10, we obtain properties for wrought aluminum alloy for 1/2
inch sizes.
3. From Appendix C-18a, we obtain mechanical properties of plastics.
MATERIAL Tensile Strength Yield Strength Elongation (%) Brinell

(MPa) (MPa) Hardness
1020 steel 441.3 346.5 35.8 131
normalized
1040 steel 589.5 374.0 28.0 170
normalized
4340 steel 1279.0 861.8 12.2 363
normalized
2024-T4 470 325 19 120
aluminum
Nylon 6/6 83 ---- 60 ----
Acetal 60.7 ---- ---- ----
4. Inspection of the table provides a comparison of the properties of the six materials.
Comments: The site http://www.matweb.com will provide additional material

property information.
3-39
SOLUTION (3.32D)
Known: A jump rope is made from two hollow hard plastic handles that are attached to
each end of a highly elastic cord. Two boys, instead of using the rope for jumping, decide to
use it for a “tug-of-war”. Each boy pulls on an end of the rope. One boy lets go of his handle;
the other boy holds his end and is almost immediately struck by the released handle. In
contrast, an old fashion jump rope has wooden handles and a cotton rope. The cotton rope
when tensioned, stores only a small amount of energy so that if one of the wooden handles
were released (as in the “tug-of-war” example), the released handle would fall harmlessly to
the ground.
Find: Determine the properties of a cotton rope of the type used in an old fashion jump
rope, especially the strength and the “elasticity”. Also, select a more modern material (like
an elastomer) that could be used as a safe replacement for a cotton rope. Provide the name
of the material and list its properties.
Analysis: The potential energy stored in the rope when one handle is released can be
calculated as
PE = ½ Fδ = ½ kδ2 (a)
where F is the force after the rope has stretch a distance δ, and k is the spring constant of the
rope. The rope is assumed to be linearly elastic.
Once the rope is released the PE will be converted to kinetic energy, and this energy can be
calculated as
KE = ½ mV2 (b)
If we equate PE = KE, we can solving for V, the velocity of the rope (free handle), as
V = [Fδ/m] 1/2 = [kδ2/m]1/2 (c)
Comments:
1. In order to compare the elastic cord versus the nonelastic cord consider stretching a
rubber band versus stretching a computer mouse cord.
2. The weight of the handle is important as a heavier handle will “fall faster” than a
light handle for the same cord length and elasticity.
3. The modern material replacement for the cotton cord would have a relatively high
spring constant and a cord that would not stretch much and most importantly would
store little energy in normal usage; i.e., the quantity U/δ would be low, where U is
the total energy stored for a total displacement δ. ■
3-40
SOLUTION (3.33D)
Known: A full-page open letter with more than 700 signatures was recently released in
a university campus newspaper. The letter according to www.texasenvironment.org
protested the sale of the single-use, disposable plastic water bottles “shaped” like a
university “symbol”. The bottles are marketed to students and in local grocery stores
and according to the article this does not align with the school's own “Sustainability
Program”. The article reveals that with a global movement to ban plastic water bottles
from college campuses, the universities decision has left students at the back of the
environmental movement.
Find: Discuss the advantages and disadvantages of plastic bottles. What steps or
procedures could be taken to minimize environmental impact of “single” use bottles?
How would an engineer deal differently than a businessperson with the sale of
disposable plastic water bottles?
Comments:
1. The headline for the article stated: “Over 700 Concerned Citizens Tell the
University of Texas, "Don't Trash the Tower!"”
2. Reportedly, “a full-page open letter with more than 700 signatures was released in
UT's campus newspaper, The Daily Texan. The letter protests the sale of the single-use,
disposable plastic water bottles in the shape of the UT Tower -- H2Orange. These
polluting bottles are being marketed to students but they do not align with the school's
own Sustainability Program. With an international movement to ban plastic water
bottles from college campuses, UT's decision has left Longhorns at the back of the
herd.”
3. Reference: http://www.texasenvironment.org/ ■
3-41
SOLUTION (3.34)
Known: We are to determine the material properties of nylon 6 with 30% glass fibers
and those of unreinforced nylon 6 from the materials property database at
http://www.matweb.com.
Find: Search the materials property database at http://www.matweb.com and list the
properties of nylon 6 with 30% glass fibers. Compare the 30% glass filled nylon
properties with those of unreinforced nylon 6.
Comment: This problem is left as an exercise for the student. Comparatively, 30%
glass filled nylon is a stronger and stiffer material than unreinforced nylon 6.
SOLUTION (3.35D)
Known: The shaft of a gear train carries high loads and stops abruptly.
Find: Select a suitable material for the shaft of the gear train.
Analysis: For a shaft that must stop abruptly, a shock-resistant material is required. S1
could be considered and has a hardness of 45 Rockwell C. But 4140 and 4340 steels at
30 Rockwell C hardness have sufficient hardness and have a greater toughness than S1,
and moreover these steels even after hardening are machinable. This would eliminate
the effect of distortion during hardening. Because of added alloys, 4340 it easier to
harden. For this reason, we would chose 4340 steel for shafts over 1.5 inch in diameter,
and use 4140 steel for shafts less than 1.5 inch in diameter.
SOLUTION (3.36D)
Known: The website www.plastics.dupont.com is a source of information for material
properties for plastics.
Find: Select a nylon (polyamide) from the website which has 35% glass reinforcement
and combines good surface appearance, excellent welding and fatigue retention, and
exceptional resistance to hot air and hot engine oil. List the stress at break in MPa and
the strain at break in %. Also list the deflection temperature in °C at 1.80 MPa.
Analysis: From the website DuPont Zytel PLUS (PLS95G35DH1 BK031) fits the
desired characteristics. The stress at break is 210 MPa with a strain at break of 3.5%.
The deflection temperature for 1.80 MPa is 250°C.
3-42
SOLUTION (3.37)
Known: The iPhone (3G and 3GS) by Apple reportedly utilizes a number of
engineering materials: (a) glass, for the front display cover, (b) steel, for the perimeter
edge trim piece, and (c) plastic, for the molded rear back.
Find: Search material property databases and select candidate materials for the (a)
glass, (b) steel, and (c) plastic. List the requirements for each application and list the
desired characteristics of each material.
Analysis:
1. Application
Glass: piece of see through material for the front of the iPhone, non conductive,
Steel: finish with chrome, rectangular trim like piece
Plastic: moldable with accuracy into a finishable part
2. Characteristics
Glass – see through it, scratch resistant, easy to clean, stain resistant, …
Steel – strong, durable, chrome finish, easy to clean, stain resistant, …
Plastic – strong, moldable, inexpensive fabrication, relative to machined aluminum
Comment: The materials selected are reportedly environmentally friendly. ■
3-43

CH 03

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Find: Write definitions of the above terms -- see Section 3.2.

7. The modulus of elasticity (Young's modulus) E is the constant of proportionality

An important notation convention is observed throughout the textbook: the Greek

Analysis: The web site http://www.matweb.com provides the following information:

(1) 29700 ksi

Analysis: (a) From www.matweb.com we find for AISI carbon steels:

AISI 1010, cold drawn

AISI 1020 Steel, cold rolled

AISI 1040 Steel, as rolled

AISI 1050 Steel, as rolled

AISI 1080 Steel, as rolled

(b) From www.matweb.com we find for Alloy steels:

AISI 4340 Steel, annealed, 25 mm round

AISI 4620 Steel, annealed, 25 mm round

Comment: Matweb is an award winning web site.

Analysis: (a) From www.matweb.com we find for Cast iron:

Standard gray iron test bars, as cast, ASTM class 20

Standard gray iron test bars, as cast, ASTM class 35

(b) From www.matweb.com we find for Aluminum alloys:

Aluminum 6061-T4; 6061-T451

Comment: Matweb is an award winning web site.

Modulus of Elasticity, ksi, greater than 30 x 106 psi ■

Tensile Strength, Ultimate, psi, greater than 200 ksi ■

Comment: Matweb is an award winning web site.

(1) 26500 ksi

Find: Estimate Su, Sy and the ductility.

Schematic and Given Data:

ε = R - 1 = 2.27 - 1 = 1.27 or 127% ■

Find: Estimate Su, Sy and the ductility.

Schematic and Given Data:

Ar = 1 - 1 = 1 - 1 = 0. 519 ε = R - 1 = 2.08 - 1 = 1.08 or 108% ■

Schematic and Given Data:

Comment: Note also that εT = ln(1 + ε) = ln(1.0029) = 0.29%.

Schematic and Given Data:

Comment: Note also that εT = ln(1 + ε) = ln(1.0023) = 0.23%.

Schematic and Given Data:

Comment: Note also that εT = ln(1 + ε) = ln(1.0026) = 0.26%.

Find: Estimate values of Su and Sy for the part.

Schematic and Given Data:

2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi.

Find: Estimate values of Su and Sy for the part.

Schematic and Given Data:

2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi.

Find: Estimate values of Su and Sy for both parts.

Schematic and Given Data:

Part 1, 217 Bhn Part 2, 363 Bhn

Schematic and Given Data:

Decision: Select ANSI 1020 annealed.

Schematic and Given Data:

Decision: Select ANSI 1040 annealed steel.

Schematic and Given Data:

Decision: Select ANSI 1030 steel.

Find: Estimate Su and Sy.

Schematic and Given Data:

Find: Estimate Su and Sy.

Schematic and Given Data:

Schematic and Given Data:

4340 Low Alloy Plain Carbon

Distance From Quenched End (mm)

Schematic and Given Data:

(a) Machine Frame

(b) Round Rod