Cairo University MDPN464

Faculty of Engineering Analysis of Mechanical Failures

Senior 2- MDE. Program Assignment 1

Problem 1
The creep rupture data for a type of super-alloy is obtained in two tests as:

Temperature (oC) Stress (MPa) Rupture time tr (hr)

600 300 180

800 100 1.10

a) Use the above data to get the relation between the stress and Larson-Miller parameter PLM ;
where PLM = T(20 + log t r)
b) A pressure vessel of 250 mm diameter and 2 mm thickness is made from the above alloy and
used in a chemical process. What pressure would cause rupture in 100,000 h at 450 oC.
c) Calculate the vessel life for an allowable creep diameteral strain of 0.1% under internal
pressure of 3 MPa.
The test in the cylinder material indicate that N = 4.2 while the secondary creep strain rate is 
= 7.9  10-12 at stress 25 MPa at 450 oC.

Problem 2

A copper cylindrical vessel with hemispherical caps has a nominal diameter of 200 mm, length
1.2 m and wall thickness of 2 mm. The cylinder is filled with a gas under pressure of 2 atm. and
fixed inside a pressurized pipe with diameter 500 mm and thickness 5mm as shown in Fig. 1. If
the pipe is made of steel and has two thick flange closures as its ends which allow for gas flow
with a pressure 4 atm. and temperature 450 oC.

a) Calculate the maximum stress developed in the pipe

b) Show that the assembly can withstand the above pressure such that both the pipe and the
vessel do not fail by instability.
Take: For the steel pipe E = 180 GPa,  = 0.3,  = 650 0.2 MPa, and maximum allowable
shear stress is 50 MPa. For the vessel E= 100 GPa and  = 0.28
Problem 3

The cylindrical pressure vessel shown in the figure has a 750 mm

diameter and 9 mm thickness. It is fabricated from two parts
which are tightened securely by 48 bolts, each of 25 mm
diameter. If the vessel operates at 450oC and at service pressure
of 1.5 MPa, then;

a) Determine the creep life for diameteral deformation of

0.1%. (neglect the effect of the flange on the stress
distribution)
b) Determine the period after which the leakage may occur; assuming an initial bolt's
tightening of 0.01 % strain.
The vessel and the bolts are made of stainless steel of elastic modulus E = 190 GPa and Y =
250 MPa. For creep behavior at 450o C, the vessel material has N = 8 and B = 1.45  10-22,
while the bolt material has N = 9 and B = 2.3  10-22 in the creep law  = B N.

Problem 4

A solid shaft of 1000 mm length and 50 mm diameter is subjected to temp of 450 o C during
service. If the shaft is designed to limited twisting angle of 2o and for service life is 100,000 hrs
under steady creep conditions, then determine:
a) The maximum shear stress at service
b) The allowable applied torque.
Take N = 7, B=1.47 × 10-20 and E= 170 GPa at temperature 450oC.

Problem 5

The pressure vessel shown in the

Figure is used in chemical processing.
It has 200 mm diameter, 5 mm
thickness and it operates at 3 MPa
internal pressure and temperature of
550oC. The vessel is welded to rigid
flange at the end which is fixed to the
cover with 12 bolts. The material of the cylinder is stainless steel and it is designed to operate
10000 hrs before checking according to the periodical maintenance plane. Determine the margin
of safety against the following failure conditions and comment on the results:

a. Yielding in the pipe wall (away from the ends)

b. Failure at welding.
c. Bursting (away from the ends)
d. Creep failure considering a limit of 0.05% diameteral deformation.
 e. Leakage at the flanged connection if the bolts of 12 mm diameter each are initially
tightened with strain 0.05%.
f. If the pipe operates under vacuum, determine its highest allowable value? (neglect the
effect of the flange and assuming an infinitely long pipe)

Material data for pipe and bolts at 550o C:

The material is stainless steel of yield strength = 220 MPa, UTS = 450 MPa, Young's modulus
E = 170 GPa, Poisson's ratio = 0.3,   K 0.3 . Creep relation for the vessel material
  45  1016 3.5 (the units are in MPa and hr). ,