Effect of Stress

Risers on Tensile
Tests
Eileen OByrne-Hudson
Mario Trinchero
Jessica Enos
Shawna Enos
SRJC Engineering 45
December 9, 2009
 Great Failures From
Poor Design

Failure around an escape hatch DH.106 in flight

The de Havilland Comet:

Problems with explosive cabin decompression due to poor
window design
Punch riveting around the windows and escape hatches
caused stress risers that induced failure
 Great Failures From
Poor Design
Liberty Ships
Ships had a tendency to
break in half when in
cold waters and
overloaded
Stress risers occurred
where sharp corners on The S.S. Schenectady, A T2 tanker
Liberty Ship
hatches met weld
seams, and the welded
design allowed cracks
to propagate easily
through the entire
vessel

S.S. John W. Brown

 1045 Steel
1045 is a medium carbon steel is used when
greater strength and hardness is desired
than in the "as rolled" condition. Extreme
dimensional accuracy, straightness and
concentricity combine to minimize wear in
high speed applications. Turned, ground
and polished bars can be machined
asymmetrically with minimal distortion.
 Properties of Steel
Chemical Composition: C=0.45%, Mn=0.75%, P=0.04% max, S=0.05% max
Density : 7.872* 10 kg/m
Modulus of elasticity : 201 GPa
Thermal expansion (20 C) : 11.7*10-6 C
Specific heat capacity : 486 J/(kg*K)
Thermal conductivity : 50.9 W/(m*K)
Electric resistivity: 1.62*10-7 Ohm*m
Tensile strength (hot rolled) : 565 MPa
Yield strength (hot rolled) : 310 MPa
Elongation (hot rolled) : 16%
Hardness (hot rolled) : 84 RB
Testing of Steel with
Fractures
This is an image of the
stress at the tip of a
fracture
Stress at the crack tip
can be approximated
by the formula
A very small crack
radius will result in a
tip stress many
times that of the
applied stress
 Sample Preparation
Each sample started as a standard 1045 tensile
specimen, with a length of 2 and a diameter of
0.5.
A crack was machined around the circumference
of each sample.
All cracks have a depth of 0.005.
The three crack diameters are 0.002, 1/64
(0.0156), and 1/32 (0.0313). These diameters
are at the very tip of the crack. The diameter of
the smallest crack is a best estimation, as there
were no tools available to measure the actual
diameter.
 Setup
We used a standard
tensile testing setup
for our tests.
Top Left: Tester with
loaded sample; Bottom
Left: Strain gauge on
sample
 Results
Stress-Strain Plot For 1045 Steel With Cracks

140000

120000

100000
Stress (psi)

1/64"
80000
.002"
1/32"
60000
Standard 1045

40000

20000

0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Strain (in/in)
 Fracture Surfaces

0.002 fracture surface 1/64 fracture surface

Standard
1/32 fracture surface
1045 fracture
surface
 o vs. m
The following graphs are of the maximum
stress at the crack tip compared to the
value of the applied stress.
 1/32
Stress-Strain Plot of Nnormal Stress and Stress at Crack Tip for
1/32" Crack

250000

200000
Stress (psi)

150000
Normal
At Stress Riser
100000

50000

0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Strain (in/in)
 1/64
Stress-Strain Plot of Normal Stress and Stress at Crack Tip for 1/64"
Crack

250000

200000
Stress (psi)

150000
Normal
At Stress Riser
100000

50000

0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Strain (in/in)
 0.002
Stress-Strain Plot of Normal Stress and Stress at Crack Tip for
0.002" Crack

500000
450000
400000
350000
Stress (psi)

300000
Normal
250000
At Stress Riser
200000
150000
100000
50000
0
0 0.01 0.02 0.03 0.04 0.05 0.06
Strain (in/in)
 Interpretation of
Results:
None of the samples exhibited the necking
of the standard sample
Cracks induced a brittle failure instead of
ductile
0.002 crack radius failed much earlier
Sharper stress risers effectively make
material more brittle, indicating why rounded
joints and seams are favored in many designs.
 Work Cited
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<http://www.metalsuppliersonline.com/Research/Property/metals/845.asp>.
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Steel Manufacturing, on the Internet at <http://www.bls.gov/oco/cg/cgs014.htm> (visited December
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<http://chl.erdc.usace.army.mil/library/publications/chetn/pdf/chetn-ix-16.pdf>.
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<http://en.wikipedia.org/wiki/De_Havilland_Comet>.
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Print.