1021 材料機械性質 Homework 8

Solution Set

Problem sets of Chapters 16, 17, and 18 from the (old) Hosford’s textbook.

Chapters 16 and 17 (Creep and Fatigue)

1. A wing panel of a supersonic aircraft is made from a titanium alloy that has a
yield strength 1035 MPa and toughness of KIc = 55 MPa√m. It is 3.0 mm thick,
2.40 m long and 2.40 m wide. In service it is subjected to a cyclic stress of ± 700
MPa which is not enough to cause yielding but does cause gradual crack growth
of a pre-existing crack normal to the loading direction at the edge of the panel.
Assume that the crack is initially 0.5 mm long and grows at a rate of da/dN = 120
nm/cycle. Calculate the number of cycles to catastrophic failure if the shape
factor is 1.15.

Solution:
f = KIC/(f√(πa), a = (KIC/f)2/(πf2). Substituting f = 700 MPa, KIC = 55
MPa√m, and f = 1.15, a = (55/700)2/(π1.152) = 1.486x10-3 m = 1.486 mm.

The crack must grow by 1.486 – 0.5 = 0.986 mm = 0.986 x 106 nm.
If da/dN = 120 nm per cycle, N = a/120nm = 0.986x106 nm/120nm = 8,200 cycles.
2. A thin-wall pressure vessel is made from Ti-6Al-4V with KIC = 57 MPa√m and
yield strength yield = 900 MPa. The internal pressure produces a circumferential
hoop stress of 360 MPa. Consider now a semi-elliptical surface crack exists in
the vessel and the crack orients with the major plane of the crack perpendicular to
the uniform tensile hoop stress. (a) Calculate the size of the critical crack which
will cause rupture of the pressure vessel. For this type of loading and geometry,
the shape factor in the stress intensity factor can be approximated as 0.7. (b) If
the thickness of the vessel wall is 12 mm. Will the vessel break through the
vessel before fluid could leak or will the fluid leak before rupture fracture occur?

Solution:

3. The deformation-mechanism maps have been proved as a useful tool for

predicting the plasticity and creep behavior of metals and ceramics. Please visit
the website of Prof. H. J. Frost at the Dartmouth College (U.S.A.), read his web
 content created specifically for the deformation-mechanism maps, download a
map of a metal or ceramics according to your student ID number.
Website of Prof. Frost: http://engineering.dartmouth.edu/defmech
Rules:
a) Read the website information.
b) Download a map from a chapter based upon your NCHU student ID number.
For example: If the last two digits of your student ID number are 08, i.e.,
xxxxxxxx08, please download a map (or maps) from Chapter 8 which contains a
selection of pure iron, 1% Cr-Mo-V steel, or 316 and 304 stainless steel. Note
that if the last two digits of your ID are greater than 19, please deduct 19 from
your number, e.g, xxxxxxxx22 is then 22 – 19 = 03. Go to Chapter 3, please.
Similarly, if the last two digits of your ID are greater than 38, deduct 38 from your
number then.
c) Describe the general feature of the map that you’ve downloaded.

Chapters 18
4. Consider a piece of polycrystalline iron that has been plastically deformed in
tension under a stress of 220 MPa and then unloaded. Because of the orientation
dependence of the Taylor factor, it is reasonable to assume that the stress before
unloading was 20 % higher in grains oriented with <111> parallel to the tensile
axis than in the average stress. Young's modulus for polycrystalline iron is listed
as 208 GPa but for crystals oriented in a <111> direction, it is 283 MPa.
Determine the level of residual stress in the <111>-oriented grains.

Solution:
The stress under load in the [111] grains was 1.2x220 = 264 GPa. On unloading
the change of strain was -220MPa/208GPa = -1.06x10-3. The change of stress in
the [111] grains was -283 GPa(1.06x10-3) = -267 MPa. The final stress in the
[111] grains was 264 – 267 = -3 MPa

5. Thermal annealing is a process often used in practice to relieve residual stress in

metals and ceramics. Based upon the discovery of the deformation-mechanism
map, we know that an annealing temperature high enough may “trigger” creep to
occur in the annealed materials. In this regard, do you think we can obtain a
complete stress relief by thermal annealing? Explain.

Solution:
To remove residual stresses in a material (metals or ceramics), elastic strains must
be converted to plastic strains. Therefore, creep is desired since the elastic
strains can be converted to plastic strains during a stress-relief anneal. Higher
temperatures accelerate the conversion process. But, as the magnitude of the
residual stresses diminishes, the driving force for additional creep also decreases
so the process of stress relief slows. For this reason, a complete stress relief is
almost impossible during the conventional stress-relief anneals.