Mat E 202 Assigned: Jan.

19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
Department of Chemical and Materials Engineering

1. The tensile engineering stress-strain curve for a plain carbon steel is shown below. The tensile
specimen was made with a diameter of 12.5 mm and 25.4 mm gage length. Assume ν = 0.28. Pay
attention to units!

a) Showing your work, determine the following:

i) Young’s modulus of elasticity (GPa)
ii) Strain to fracture (% EL)
iii) Ultimate Tensile Strength (MPa)
iv) 0.2% Offset Stress (Yield Strength) (MPa)
Answer:
i) Young’s modulus of elasticity is calculated to be around 200 GPa.
ii) Strain to fracture (% elongation) is around 14%.
iii) Ultimate Tensile Strength is around 575 MPa
iv) 0.2% Offset
Scanned Stress (aka: Engineering Yield Strength) is around 520 MPa.
by CamScanner

b) After the test is started it is stopped at a strain of 0.004 (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?
Answer:
i) The stress corresponding to 0.004 strain is around 510 MPa. The force required to
maintain the stress is around 510 (MPa) x (pi) x (12.5 ^2) / 4 = 62585 N.
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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
ii) The length of the specimen is estimated as l = 0.004lo + lo =25.50 mm
iii) Since the stress is just below the yield strength, we assume elastic deformation. The
transverse strain is calculated based on Poisson’s ratio:

The diameter of the specimen can be obtained based on the definition of the strain:

iv) The specimen is longer but narrower due to the Poisson’s effect during elastic
loading.

c) Imagine that a test is stopped at a total strain of 0.01 and then unloaded to zero stress.
i) What is the length of the specimen following the unloading (mm)?
ii) What is the diameter of the specimen following the unloading (mm)?
iii) What would the new yield strength be if the tensile test was restarted (MPa)?
Answer:
i) The plastic strain that remains in the specimen is around 0.05 following unloading (the
elastic strain is recovered). From definition of strain
l − lo
ε=
lo
the length of the specimen following unloading is
l = lo (1+ ε ) = 25.4(1+ 0.05) = 26.67mm

ii) The diameter after unloading from 0.01 total strain can be calculated assuming that
volume of the material remains the same after plastic deformation (the assumption is not
correct if the deformation is purely elastic).
From volume conservation condition
d d
π ( )2 l = π ( o )2 lo
2 2
the diameter of the specimen upon unloading is
l 25.4
d = do o = 12.5× = 12.199 mm
l 26.67

iii) The specimen has been work hardened. If reloaded, the new Yield Strength would be
around 570 MPa.

d) What is the maximum load (N) that can be supported by this specimen before necking begins?
Answer:
d) Assuming the necking starts near the peak of the stress-strain curve, the stress level
would be the tensile strength (about 575 MPa). Using the definition of the engineering
stress, the maximum load before necking begins is estimated to be:
575(MPa) × π ×12.52 / 4 = 70560N

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

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
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 maximum and minimum impact shelf energies.
c. Determine the ductile-to-brittle transition temperatures as the temperature at which the
absorbed energy is 25J.
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?
Answer:

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

a. upper shelf energy (J) lower shelf energy (J)

C1-C 275 3
C1-D 275 24
C2-C 200 5
C2-D 287 5
C3-C 148 0
C3-D 190 25
C4-C 175 0
C4-D 165 0

b. DBTT (°C)
C1-C (-48 + (-120))/2 = -84
C1-D (-60 + (-137))/2 = -98
C2-C (-38 + (-120))/2 = -79
C2-D (-40 + (-130))/2 = -85
C3-C (0 + (-100))/2 = -50
C3-D (-48 + (-65))/2 = -56
C4-C (3 + (-103))/2 = -50
C4-D (2 + (-118))/2 = -58

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
c. DBTT (°C) for 25 J
C1-C -130
C1-D -140
C2-C -120
C2-D -140
C3-C -100
C3-D -200
C4-C -120
C4-D -120

d.
DBTT (°C) YS/UTS %EL
C1-C -84 624/801=0.779 21
C1-D -98 604/757=0.798 22.5
C2-C -79 690/897=0.769 19.8
C2-D -85 631/797=0.792 23.5
C3-C -50 699/961=0.727 19.3
C3-D -56 679/867=0.783 19.8
C4-C -50 844/1059=0.797 17.3
C4-D -58 700/955=0.733 18.3
C3-C seems to be the only alloy that satisfies all requirements.

4. 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 copper-beryllium alloy (C17300 TH04)
with σ ys = 1100 MPa and 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 3 against yield, and a safety factor of 4 against static
fracture (overload - 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?
Answer:
a.

For the actual design stress, choose the smaller value to ensure that both safety factors
are satisfied.

b. The cross-section of the bar is a 2:1 rectangle:

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

Using :

Thus, the bar dimensions should be: 8.2 mm thick by 16.2 mm wide.

5. The fatigue data for a steel was determined:

Stress Amplitude Cycles to Failure

(MPa)
470 1.0 x 104
440 3.0 x 104
390 1.0 x 105
350 3.0 x 105
310 1.0 x 106
290 3.0 x 106
290 1.0 x 107
290 1.0 x 108

a) Construct a S-N curve (stress amplitude versus logarithm cycles to failure) using these data.
b) Determine the fatigue strengths at 2 x 104 and 6 x 105 cycles.
c) Determine the fatigue life for 410 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 σm in the test is increased.

Answer:

a) The S-N plot:

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
b) 450 MPa and 330 MPa
c) 6.0X104 cycles
d) Yes, it exhibits a fatigue limit, because the as the stress is lowered, there is an infinite
number of cycles to failure.
e) The S-N curve would be shifting to the lower left direction if the mean stress 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. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

Answer:

a)

b) σ = 100 MPa, T = 538°C

To determine an exact value on a log scale (e.g. rupture lifetime), we need to find the
value of the exponent at the point of interest from the Stress vs. Rupture time (h) plots.

Therefore, our point of interest is at:

b) Time = 7500 hours, Temperature = 538°C

→
Note: at the start of secondary creep, the sample has an initial length of:

Again, we need to find the exponent at the point of interest from the Stress vs. Steady-
state creep rate (h-1) plots. Measuring “A” and “B” we find that:
A = 20 mm, B = 35 mm
(Note: again, you can use any method of measurement here [e.g. ruler]; only the relative
values of A and B are important.)

Therefore, our point of interest is at:

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
If we assume that the change in the material’s diameter is negligible (or using the
definition of the engineering stress):

c) Given: K2 = 5.5 and T = 649°C = 922 K

In order to determine the activation energy, we need to use:

Now, we need to choose any two points (i.e. any two sets of corresponding values of stress
and steady state creep rate) on the T = 649°C line – for example:

Point 1: σ1 = 10 MPa; h-1

Point 2: σ2 = 16.05 MPa; h-1
For Point 1:

Likewise, for Point 2:

Subtracting the equation for Point 2 from that for Point 1:

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

7. Below is an example of a real materials failure! (photos © John A. Nychka) The photos depict an
adapter from a socket wrench set that failed when John was changing a tire on his car. The tool was at
least 20 years old when it failed. The photos on the next page depict matching failure surfaces from
different perspectives in order to get a better understanding of the shapes of the failed surfaces. The
red arrows point to the same corner of the failed tip of the adapter (socket end) in each photograph.

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
7 continues…
a. What were the “normal” service conditions for the adapter? (e.g., what was the stress state –
dynamic or static, did temperature, moisture, corrosive solutions, pressure, or any other
variables play a role?).
b. Describe the failure surface. Note any discolorations, brightness and textural differences, and
location and degree of permanent deformation. Are there visible beach marks/rough
surface/smooth surfaces? Are the surfaces shiny or dull? Are there visible flaws (including
pores or cracks).
c. What was the likely failure mechanism? (Creep, corrosion, wear, brittle or ductile fracture,
fatigue)
i. Classify the nature of the final fracture (brittle or ductile)
ii. Could there have been more than one type of failure mechanism operating?
iii. Was the failure catastrophic? Why or why not?
d. Was the design flawed, was an improper material chosen, was the material processed poorly,
was it misused or was there a combination of factors involved? Explain your answer.
e. How would you improve the design? (Consider materials selection, geometry (shape), service
conditions, surface finish, and any other relevant variables).
f. Based on your analysis of the failed adapter, did it fail while tightening or loosening the wheel
nut? Provide an explanation for your choice (i.e., what evidence is there?).

Solution:

a) Normal Service Conditions:

Stress state was dynamic and consisted of rotating and bending stress (shear). During use,
stress levels would undergo cycles of sharp increase followed by a plateau (think about how
you repeatedly push/pull on the wrench when changing a tire – you need to use some extra
force to get the wrench going each time).
Operating temperature was likely around room temperature.
The tool was probably very rarely in contact with moisture during usage and/or storage. /2
b) Failure Surface:
One side is flat and shiny
(brittle fracture zone),
while the other is dull and
rippled (ductile fracture
zone). The fracture likely
initiated up at the top of
the brittle zone and then
propagated towards the
ductile zone. The final
failure surface is up by the
ball bearing. /2
**Note that the visible lines in the ductile zone are not
fatigue beachmarks or striations. The ridges in the
ductile zone are evidence of ductile tearing – they are
not in the brittle zone, and they are not perpendicular to
the direction of crack growth as with beachmarks.
Striations are only visible in a microscope.

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
c) Failure Mechanism: Overload – even though the adapter would have operated in dynamic
stress cycling, the final failure was in static fracture – in the application of a load too high for
the tool to support. A high a stress combined with a likely surface flaw led to brittle fracture
(above right). The ductile zone (above left) is present because the stress that was induced on
the wrench sharply declined once brittle fracture occurred, and the remaining cross section
was in high levels of shear which induced severe plastic deformation (large changes in shape
are seen in the ductile side).
i. Final fracture: DUCTILE. A transition from brittle to ductile fracture occurred during
the failure because the stress state changed ahead of the crack tip (the crack blunted).
This frequently occurs with fractures and is not related to a ductile to brittle transition
due to temperature.
ii. It is possible that the initial flaw that led to overload was created by fatigue loading.
However, if there is a fatigue failure zone (i.e. beachmarks/striations) in the vicinity of
where the crack initiated, it is not visible in the given photos – microscopy would be
required to take a closer look.
iii. YES, the failure was catastrophic – since the adapter broke into two pieces, it is no
longer useful. /2
d) Design/Materials Assessment:
The design was somewhat flawed, as the cavity for the bearing-spring assembly (used to keep
the socket attached to the adapter) reduces the cross-sectional area of the adapter and creates a
stress concentration in the exact location that the failure occurred. In addition, there are deep
machining grooves in the walls of the cavity that would have further concentrated stress – it is
highly likely that the failure (whether by fatigue or not) initiated at one of these grooves.

Grooves!

The material choice appears to be reasonable, as there is no evidence of corrosion and the tool
operated for >20 years before failing.
/2
There is no visible evidence of manufacturing defects – we cannot see any pores/voids/large
inclusions on the fracture surface.
e) Potential Design Improvements:
Geometry: find an alternate way of keeping the socket attached to the adapter– e.g. magnets
(although it could be argued that due to the mechanical shocks experienced by the adapter,
magnets might become demagnetized faster than the 20 years that this design lasted).
Material: although the steel used here performed well for a long time, a stronger grade of steel
could be used (although this would likely increase costs).
/2
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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015
Surface Finish: polish/harden the surface (especially inside the cavity!) to minimize stress
concentrations and potential for crack initiation.

f) Fail on Tightening or Loosening?

The adapter appears to have failed while tightening the wheel nut. The final fracture surface
(see above) appears to have deformed in a clockwise direction, suggesting that the wrench
was moving clockwise relative to the broken (socket) end of the adapter when failure
occurred. Assuming right hand threads, clockwise rotation is used for tightening. /2

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Mat E 202 Assigned: Jan. 19, 2015
Winter 2015 Assignment #2 Due: Feb. 2, 2015

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

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