Bachelor of Engineering in Mechanical Engineering

(Hons)
335MAE Reliability and Durability

Coursework Title:
Evaluation of Fracture Toughness of an Aluminium Alloy

Name:
Student ID:

Lecturer
Dr. Lim Geok Hian

Date: 29 January 2024

Abstract

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1. Introduction

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2. Experimental Procedure
The steps taken for the procedure is summarised as follows.
1. Two samples of the 6061-T6 series aluminium alloy, using SE(B) specimens,
were used for this experiment. The first sample had a thickness of 3 mm, and
the second sample had a thickness of 5 mm. The aluminium alloy had a
modulus of elasticity of 69 GPa, ultimate tensile stress of 300 MPa and a yield
stress of 240 MPa.

2. A crack of 1 mm depth was sawn into the centre edge of both samples by a
saw as shown in Figure . Figure shows a picture of one of the samples after
the crack was sawn.

3. The tensile machine was used to apply force with a three-point bending. The
applied force and the crack-mouth opening displacement are recorded
digitally and stored by the machine. Figure shows the sample before force is
applied on it, Figure shows the crack becoming larger at the beginning of the
process and Figure shows the crack when it had fully propagated through the
sample.

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 Figure : Crack before being applied with the force

Figure : Crack being applied by the force at the beginning

Figure : Crack had fully propagated through the sample

4. From the graph of Force versus the Displacement, a tangent to the initial
straight portion of the graph is drawn to find its gradient and point O where the
tangent meets the Displacement axis.

5. A new line with a gradient that is 95% of the tangent was drawn from point O
to meet the curve. The value of P Q was found as shown in the Type 1 curve in
Figure (ASTM 2018). The graph showing the Force versus Displacement
curve for the 3 mm thickness sample, the tangent to the initial straight portion
of the curve and the additional line with 95% gradient of the tangent line is
shown in Figure . The corresponding graph for the 5 mm thickness sample is
shown in Figure .

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Figure : Principal Types of Force-Displacement (CMOD) Records (ASTM
2018)

Figure : Force versus Displacement Graph (3 mm thickness sample)

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Figure : Force versus Displacement Graph (5 mm thickness sample)

6. Bend specimen KQ was calculated using the following equations which appear
as (A3.1) and (A3.2) in ASTM 2018.

where

In these equations,
PQ = force in N,
B = specimen thickness in m,
BN = B in m, for plane-sided specimens,
S = span in m as shown in Figure ,
W = specimen width (depth) in m and
a = crack size in m.

7. From Figure , the value of PQ was read as 3.6 kN. When the data from the
tensile machine is sorted by Force in descending order, the value of the
P max 3.993
maximum force, Pmax was found to be 3.993 kN. The ratio = =1.11.
PQ 3.6

8. From Figure , the value of PQ was read as 12 kN. When the data from the
tensile machine is sorted by Force in descending order, the value of the
maximum force, Pmax was found to be 13.6849 kN. The ratio
P max 13.6849
= ≈ 1.14 .
PQ 12

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Figure : Loading Fixture for Standard SE(B) Bend Specimens (ASTM 2018)

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1. Experimental Results

3 mm sample
Using similar figures to find the value of a at the point of the largest applied force,
a = 1.7068/5.36*14.5/1000 = 0.004617
a/W = 4617/19120
0.644
22.6 MPa

5 mm sample
Using similar figures to find the value of a at the point of the largest applied force,
a = 2.6203/6.52*18/1000=0.007234
a/W = 3617/11300
1.602
74.2 MPa

The results of the experiment are tabulated in Table .

Table : Results of Measurements and Calculations
Measurements
3 mm sample 5 mm sample
and Calculations
PQ (N) 3,600 12,000
B (m) 0.00272 0.00534
S (m) 0.07 0.07
W (m) 0.01912 0.02260
a (m) 0.004617 0.007234
W −a (m) 0.01450 0.01537
f ( )
W
a
0.644 1.602
K Q (MPa) 22.6 ×10
6
74.2 ×10
6

2.5 ( )
KQ 2
σ YS
0.235 0.773

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2. Discussion

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3. Conclusion

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References
American Society for Testing and Materials (2018) Standard Test Method for Linear-
Elastic Plane-Strain Fracture Toughness KIc of Metallic Materials. ASTM
E399-12e3. Pennsylvania: ASTM International

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