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occurs because
the designers and
tool fabricators
never use the
product common in large
corporations.
Material
characteristics that
relates to the
structure of
materials, its
formation from the
elements, and its
reactivity with
chemicals, other
materials, and
environment.
The
characteristics of
a material that
are displayed
when a force is
applied to the
material.
Characteristics
of materials that
relate to the
interaction of
these materials
with various
forms of energy
and with human
senses.
The properties
of a material
change with
temperature,
usually for worst.
Start to creep or
oxide/degrade.
METALS
Composition
Microstructure
Phases
Grain Size
Corrosion Resistance
Inclusions
POLYMERS
Composition
Fillers, Crystallinity
Molecular weight
Flammability
Spatial configuration
Chemical resistance
CERAMICS
Composition
Porosity
Grain size
Crystal Structure
Corrosion Resistance
COMPOSITES
CHEMICAL
Composition
Matrix/reinforcement bond;
Volume fraction of
reinforcement;
Reinforcement nature
PHYSICAL
Specific heat
Coefficient of
Thermal
Expansion
Thermal
conductivity
Heat
distortion
temp
Glass
transition
temp
Magnetic
Electrical
Optical
Acoustic
Gravimetric
Color
MECHANICAL
Tensile/compressive
Toughness
Ductility
Fatigue
Hardness
Creep resistance
Shear strength
Procurement/
Manufacturing
considerations
Available Shapes,
Sizes, Surface
Texture
Manufacturing
Tolerances
Tensile/compressive
Heat distortion
Pressure-velocity limit
Toughness, Stress
Rupture, Creep
Manufacturing tolerances,
Stability, Available Sizes,
mold ability, surface
texture
Tensile/compressive
Fracture toughness
Transverse rupture
Hardness
Available Shapes,
Sizes, Surface Texture
Manufacturing
Tolerances, Stability
Tensile/compression
Fracture toughness
Creep resistance
Reinforcement orientation
Properties
INTRINSIC
ATTRIBUTIVE
The tensile test is the most common test for determining such
mechanical properties of materials as strength, ductility,
toughness, elastic modulus, and strain-hardening capability.
P
Ao
P
Engineerin g Stress,
Ao
(l lo )
Engineerin g Strain, e
lo
with a
Youngs modulus
Modulus of elasticity, E
Hookes law
Poissons ratio
Poissons
ratio may be
calculated from
the stress
strain test by
measuring the
ratio of
transverse
strain to axial
strain.
300 106 Pa
E
70GPa
0.0043
(b) YS: The 0.2% offset construction
gives YS = 410 MPa
(c) TS: The maximum for the curve
gives: T.S = 480 MPa
Quiz #2
Elongation
(l f lo )
lo
x100
Reduction of area
A0
Af
( Ao Af )
Ao
Quiz #3
d=
=
HB =
2P
D D
D 2 d 2
(2)(1000 kg)
()(10
mm) 10 mm
= 200.5
2P
D 2 D
(HB)
D
(10 mm) 2 10 mm
2
(2)(500 kg)
= 1.45 mm
(300)()(10 mm)
Figure 419
Specification of
hardness
numbers for
metals
(ASTM E 10,
E 384, and E
18).
See ASTM E
140 for scale
conversions.
Toughness
Charpy
Izod
E.g: Sinking of Titanic: Titanic was made up of steel which has ductile brittle
transition temperature 32oC. On the day of sinking, sea temperature was 2oC
which made the structure highly brittle and susceptible to more damage.
3FL
Flexural strength , FS
2wh 2
F: fracture load
L: distance between support points
w: width of the specimen
h: height of the specimen
FL3
Flexural Modulus
Ebend
3
4 wh
Quiz #4
Quiz #5
Kc is useful selection in
designing for prevention of
mechanical failure.
Measured by using tensile
m/c-ASTM E399 with known
size crack:
K1C
K1C
Kc
B a
K1 Y a
K1 = Stress intensity factor
= Applied stress
a = edge crack length
Y = geometric constant
K1c Y f a
K1c
m
m
KIc
KIc
Quiz #6
m
K1c
K1 Y c K1c
tmaterial
Classification:
Fracture
behavior:
Very
Ductile
Moderately
Ductile
Brittle
%AR or %EL
Large
Moderate
Small
Ductile fracture is
usually more desirable
than brittle fracture!
Ductile:
Warning before
fracture
Brittle: No
warning
65
cup-and-cone fracture
brittle fracture
66
Irregular &
fibrous
appearance
Evolution to failure:
Resulting
304 S. Steel
(metal)
316 S. Steel
(metal)
160 mm
4 mm
Polypropylene
(polymer)
Al Oxide
(ceramic)
3 mm
1 mm
71
a
m 2 o Kt o
t
1/ 2
2 E s
c
1/ 2
where
E = Modulus Elasticity
1 2
a
t
m
o
1 2
a
m
Kt
2
o
t
A measure of the
degree to which
external stress is
amplified at the tip
of a cracks
73
max
r,
fillet
radius
2.5
h
increasing w/h
2.0
1.5
1.0
0.5
1.0
sharper fillet radius
r/h
74
75
tip
tip
K
2 x
increasing K
Very
expensive!
(need more
samples)
Fatigue fractured
surface of keyed
shaft
Final rupture
Mean stress = m
max min
Stress amplitude = a
max min
min
Stress ratio = R
max
Quiz #7
K
Fatigue crack propagation at Stage II
is a function of not only a stress level
and crack size but also material
variables mathematically this rate
may be expressed in term of Stress
Intensity Factor, K, as:
da
Log( AK m )
Log
dN
m.Log( K ) Log( A)
*Straight line with slope m under
the (da/dN) vs K diagram
Limiting value of K below which there is
no measurable crack growth is called
stress intensity factor range threshold Kth
Region 1
Non
propagati
ng
fatigue
crack
Region 2
Linear relationship
between Log K and
Log da/dN
Region 3
Unstable
crack
growth
a
a
da
f ( , a)
dN
da
dN
N da
dN
da
AK m
dN
a is small, da/dN
da/dN
da
Fatigue Crack Growth Rate
dN
(increase in crack length per loading cycle)
K Y a Y max min a
da
AK m
dN
But
K Y a
Therefore
m
2
K m Y m m a
m
m
2
af
m
2
m m
da
A
Y
a
a0
Therefore da A(Y m m 2 a 2 )
af
dN
Nf
Integrating and solving for Nf
a0
af
Nf
AY
m
m
2 a0
m
)
2
da
Nf
af
m Nf
2
dN
0
da
m
2
AY m m a
m
) 1
2
a0
m
2
m
2
m
) 1
2
m
AY ( 1)
2
m
*
*
K IC Y ac
ac
Nf
AY
m
m
2 a0
da
AK m
dN
m
)
2 da
m=3.0 and
A= 1.0 x 10 -12
Ce
Q / RT
R
T
Rupture Test
Example
UTS
N
Allow
N)
The need for a factor of safety is most evident when knowledge
is sketchy about:
1. Possible unexpected high load on a structure.
2.The degree of residual stresses within a material due to
manufacturing processes.
3. Homogeneity of the internal structure of a material
throughout its entirety.
Design
Design
UTS
4
YS
2
ductility.
Inadequate Stiffness
(E too low)
Inadequate
Fracture &
Toughness
(K1c too low)
Inadequate
Strength (y low)
Inadequate
Density
( too high)
High
Maximum
Service
Temp, Tmax
Low
Maximum
Service
Temp,
Tmax
creep
High Expansion
Coefficient,
Low Expansion
Coefficient,
High Conductivity,
High Thermal
Diffusivity, a, (ice
cream melts)
Low Conductivity,
3. Some materials-metals-feel cold; others-wood-feel warm. This feel has to do with two
thermal properties of materials: Thermal Conductivity, and Heat Capacity. -measures the
rate at which heat flows through the material when one side is hot and the other cold:
High is needed in conducting heat from one place to another (cooking pans, radiators,
heat exchangers). Low is useful in insulate homes, reduce energy consumptions of
refrigerators and freezers and enable space vehicles to re-enter the earths atmosphere.
When time is limited, Heat Capacity, Cp is matter. It measures the amount of heat that it
takes to make the temp. of material rise by a given amount.
High Maximum
Service Temp, Tmax
High Expansion
Coefficient,
High Conductivity,
High Thermal
Diffusivity, a, (ice
cream melts)
Low Maximum
Service Temp, Tmax
Low Expansion
Coefficient,
Low Conductivity,