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Engineering Materials
Materials
Ferrous metals: carbon-, alloy-, stainless-, tool-and-die steels
Non-ferrous metals: aluminum, magnesium, copper, nickel,
titanium, superalloys, refractory metals,
beryllium, zirconium, low-melting alloys,
gold, silver, platinum,
Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,)
thermosets (epoxies, Polymides, Phenolics, )
elastomers (rubbers, silicones, polyurethanes, )
Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride
Composites: reinforced plastics, metal-, ceramic matrix composites
Nanomaterials, shape-memory alloys, superconductors,
Properties of materials
Properties of materials
Physical properties
Density, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties
Chemical properties
Oxidation, Corrosion, Flammability, Toxicity,
Physical properties
colour light wave length
specific heat the heat required to raise the temperature of one
gram of a substance by one degree centigrade (J/kg K)
density mass per unit volume expressed in such units as kg/cm 3
thermal conductivity rate at which heat flows through a given
material (W/m K)
melting point a temperature at which a solid begins to liquify
electrical conductivity a measure of how strongly a material
opposes the flow of electric current (m)
7800
Concrete
Rubber
2300
1100
Biological materials
Bone
2000
Cartilage
1100
Tendon
1300
Locust cuticle
1200
Physical properties
permeability is the measure of the ability of a material to support the
formation of a magnetic field within itself. Magnetic permeability is
typically represented by the Greek letter
In SI units, permeability is measured
in henries per meter (Hm1),
or Newton per ampere squared (NA2).
The permeability constant (0), also
known as the magnetic constant or the
permeability of free space, 0 =
Simplified comparison of
7
1
410 Hm
permeabilities
ferromagnets (f),paramagnets(p),
free space(0) anddiamagnets (d)
coefficient of thermal expansion degree of expansion divided
by the change in temperature (m/C)
Chemical properties
corrosion resistance - is the property of a metal, or in general a
material, to resist to corrosion attack in a particular environment at
defined operating conditions, pressure, temperature and fluid
velocity. Usually the resistance to corrosion is expressed in terms
of Corrosion rate, mm/y or mils per year (mpy). 1 mpy = 0.0254
mm/y = 25.4 microm/y
To calculate the corrosion rate from metal loss:
mm /y = 87.6 x (W / DAT)
where:
W = weight loss in milligrams, D = metal density in g /cm3
A = area of sample in cm2, T = time of exposure of the metal
sample in hours
Mechanical properties
tensile strength measures the force required to pull something
such as rope,wire or a structural beam to the point where it breaks
ductility a measure of how much strain a material can take
before rupturing
malleability the property of a material that can be worked or
hammered or shaped without breaking
brittleness breaking or shattering of a material when subjected
to stress (when force is applied to it)
Mechanical properties
elasticity the property of a material that returns to its original
shape after stress (e.g. external forces) that made it deform or
distort is removed
plasticity - the deformation of a material undergoing nonreversible changes of shape in response to applied forces
toughness the ability of a material to absorb energy and
plastically deform without fracturing
hardness the property of being rigid and resistant to pressure;
not easily scratched
machinability the property of a material that can be shaped by
hammering, pressing, rolling
types of stresses
Tension
Compression
Shear
Torsion
13
Tensile Test
14
Stress-Strain Test
specimen
machine
15
Terminology
Load - The force applied to a material during testing.
Strain gage or Extensometer - A device used for
measuring change in length (strain).
Engineering stress - The applied load, or force,
divided by the original cross-sectional area of the
material.
Engineering strain - The amount that a material
deforms per unit length in a tensile test.
Elastic Deformation
1. Initial
2. Small load
3. Unload
bonds
stretch
return to
initial
F
Elastic means reversible.
Linearelastic
Non-Linearelastic
18
2. Small load
3. Unload
bonds
stretch
& planes
shear
planes
still
sheared
elastic + plastic
plastic
F
F
Plastic means permanent.
linear
elastic
linear
elastic
plastic
19
Typical stress-strain
behavior for a metal
showing elastic and
plastic deformations,
the proportional limit P
and the yield strength
y, as determined
using the 0.002 strain
offset method (where there
is noticeable plastic deformation).
P is the gradual
elastic to plastic
transition.
20
22
(c)2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Permanent Deformation
Permanent deformation for metals is
accomplished by means of a process called slip,
which involves the motion of dislocations.
Most structures are designed to ensure that only
elastic deformation results when stress is
applied.
A structure that has plastically deformed, or
experienced a permanent change in shape, may
not be capable of functioning as intended.
24
Yield Strength, y
Elastic+Plastic
at larger stress
tensile stress,
Elastic
initially
tensile stress,
permanent (plastic)
after load is removed
engineering strain,
plastic strain
engineering strain,
p = 0.002
25
Stress-Strain Diagram
ultimate
tensile
strength
3
Slope=
E
UTS
yield
strength
Strain
Hardening
Stress (F/A)
Plastic
Region
Elastic
Region
1
E
necking
y
2 1
Fracture
5
Elastic region
slope =Youngs (elastic) modulus
yield strength
Plastic region
ultimate tensile strength
strain hardening
fracture
Strain ( ) (L/Lo)
or
: Stress(psi)
E : Elastic modulus (Youngs Modulus) (psi)
: Strain (in/in)
(c)2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Stress-strain
behavior found
for some steels
with yield
point
phenomenon.
31
T
E
N
S
I
L
E
P
R
O
P
E
R
T
I
E
S
32
300
200
Al (6061)ag
Steel (1020)hr
Ti (pure)a
Ta (pure)
Cu (71500)hr
100
70
60
50
40
Al (6061)a
30
20
10
Tin (pure)
dry
PC
Nylon 6,6
PET
humid
PVC
PP
HDPE
LDPE
Hard to measure,
700
600
500
400
Ti (5Al-2.5Sn)a
W (pure)
Cu (71500)cw
Mo (pure)
Steel (4140)a
Steel (1020)cd
1000
Composites/
fibers
Steel (4140)qt
Hard to measure,
since in tension, fracture usually occurs before yield.
2000
Graphite/
Ceramics/ Polymers
Semicond
Room T values
a
hr
ag
cd
cw
qt
= annealed
= hot rolled
= aged
= cold drawn
= cold worked
= quenched & tempered
33
Tensile Strength, TS
After yielding, the stress necessary to
continue plastic deformation in metals
increases to a maximum point (M) and then
decreases to the eventual fracture point (F).
All deformation up to the maximum stress
is uniform throughout the tensile sample.
However, at max stress, a small
constriction or neck begins to form.
Subsequent deformation will be confined
to this neck area.
Fracture strength corresponds to the stress
at fracture.
34
In an undeformed
thermoplastic polymer
tensile sample,
(a)the polymer chains are
randomly oriented.
(b)When a stress is
applied, a neck develops
as chains become aligned
locally. The neck
continues to grow until the
chains in the entire gage
length have aligned.
(c)The strength of the
polymer is increased
35
5000
3000
2000
1000
300
200
100
40
30
20
Graphite/
Ceramics/ Polymers
Semicond
Composites/
fibers
C fibers
Aramid fib
E-glass fib
Steel (4140)qt
Diamond
W (pure)
a
Ti (5Al-2.5Sn)
a
Steel (4140)
Si nitride
Cu (71500)cw
Cu (71500)hr Al oxide
Steel (1020)
Al (6061)ag
Ti (pure)a
Ta (pure)
Al (6061)a
Si crystal
<100>
Glass-soda
Concrete
Graphite
Room T values
Nylon 6,6
PC PET
PVC
PP
HDPE
wood(|| fiber)
GFRE( fiber)
CFRE ( fiber)
AFRE( fiber)
LDPE
10
wood(
fiber)
a = annealed
hr = hot rolled
ag = aged
cd = cold drawn
cw = cold worked
qt = quenched & tempered
AFRE, GFRE, & CFRE =
aramid, glass, & carbon
fiber-reinforced epoxy
composites, with 60 vol%
fibers.
36
Ductility, %EL
Ductility is a measure of the
plastic deformation that has
been sustained at fracture:
Engineering
tensile
stress,
A material that
suffers very
little plastic
deformation is
brittle.
% EL
l f lo
lo
x100
smaller %EL
(brittle if %EL<5%)
larger %EL
(ductile if
%EL>5%)
Lo
Ao
% AR
Af
Ao A f
Ao
Lf
x100
37
Toughness is
the ability to
absorb
energy up to
fracture (energy
Toughness
Lower toughness: ceramics
Higher toughness: metals
A tough
material has
strength and
ductility.
Approximated
by the area
under the
stress-strain
curve.
38
Toughness
Energy to break a unit volume of material
Approximate by the area under the stress-strain
curve.
Engineering
tensile
stress,
Hooke's Law:
Poisson's ratio: xy
metals:
~ 0.33
ceramics: ~0.25
polymers: ~0.40
simple
tension
test
E
1
Linearelastic
Units:
E: [GPa] or [psi]
: dimensionless
Modulus of Elasticity, E:
(Young's modulus)
40
E(GPa)
200
100
80
60
40
109 Pa
Graphite
Composites
Ceramics Polymers
/fibers
Semicond
Diamond
Si carbide
Tungsten
Al oxide
Molybdenum Si nitride
Steel, Ni
<111>
Tantalum
Si crystal
Platinum
<100>
Cu alloys
Zinc, Ti
Silver, Gold Glass-soda
Aluminum
CFRE(|| fibers)*
Aramid fibers only
AFRE(|| fibers)*
Glass fibers only
Magnesium,
Tin
GFRE(|| fibers)*
Concrete
GFRE*
20
10
8
6
4
2
1
0.8
0.6
0.4
0.2
E ceramics
>E metals
>>Epolymers
CFRE *
GFRE( fibers)*
Graphite
Polyester
PET
PS
PC
CFRE( fibers)*
AFRE( fibers)*
Epoxy only
PP
HDPE
PTFE
LDPE
Wood(
grain)
41
Material Specification
Chemical composition
Mechanical properties Strength, hardness
(under various conditions: temperature,
humidity, pressure)
Physical properties density, optical,
electrical, magnetic
Environmental green, recycling
Metals
Ferrous Metals
Cast irons
Steels
Super alloys
Iron-based
Nickel-based
Cobalt-based
Non-ferrous metals
Stainless steels
Characterized by their corrosion resistance,
high strength and ductility, and high
chromium content.
Stainless as a film of chromium oxide protects
the metal from corrosion.
Stainless steels
Five types of stainless steels:
1. Austenitic steels
2. Ferritic steels
3. Martensitic steels
4. Precipitation-hardening (PH) steels
5. Duplex-structure steels
Aircraftforgings,
tubing,fittings
Automobilebodies
Axles
Ballbearingsandraces
Bolts
Camshafts
Chains(transmission)
Coilsprings
Connectingrods
Crankshafts(forged)
Steel
4140,8740
1010
1040,4140
52100
1035,4042,4815
1020,1040
3135,3140
4063
1040,3141,4340
1045,1145,3135,3140
Product
Differentialgears
Gears(carandtruck)
Landinggear
Lockwashers
Nuts
Railroadrailsandwheels
Springs(coil)
Springs(leaf)
Tubing
Wire
Wire(music)
Steel
4023
4027,4032
4140,4340,8740
1060
3130
1080
1095,4063,6150
1085,4063,9260,6150
1040
1045,1055
1085
Condition
1020
Asrolled
Normalized
Annealed
Asrolled
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed
1080
3140
4340
8620
Ultimate
tensile
strength
(MPa)
448
441
393
1010
965
615
891
689
1279
744
632
536
Yield
Strength
(MPa)
Elongationin
50mm(%)
Reductionof
area(%)
Hardness
(HB)
346
330
294
586
524
375
599
422
861
472
385
357
36
35
36
12
11
24
19
24
12
22
26
31
59
67
66
17
20
45
57
50
36
49
59
62
143
131
111
293
293
174
262
197
363
217
183
149
565620
240290
6055
316
(S31600)
550590
210290
6055
410
(S41000)
480520
240310
3525
416
(S41600)
480520
275
3020
Resistance to
cracking
Medium
High
Medium
Highest
Highest
Highest
Approximate
hardness
(HRC)
6065
6065
6065
3855
5762
3556
Machinability
Medium
Medium
Medium
Medium to high
Medium
Medium
Toughness
Low
Low
Low
Very high
Medium
High
Resistance to
softening
Very high
Very high
Highest
High
High
High
D2
Medium
Highest
5461
Low
Low
High
D3
H21
Medium
Medium
High
High
5461
3654
Low
Medium
Low
High
High
High
H26
P20
Medium
High
High
High
4358
2837
Medium
Medium to high
Medium
High
Very high
Low
P21
W1, W2
High
Highest
Highest
Medium
3040
5064
Medium
Highest
Medium
High
Medium
Low
AISI
designation
M2
T1
T5
H11, 12, 13
A2
A9
Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.
Resistance to
wear
Very high
Very high
Very high
Medium
High
Medium to
high
High to very
high
Very high
Medium to
high
High
Low to
medium
Medium
Low to
medium
Superalloys
Superalloys are high-temperature alloys use
in jet engines, gas turbines and reciprocating
engines.
Refractory metals
Refractory metals have a high melting point
and retain their strength at elevated
temperatures.
Applications are electronics, nuclear power
and chemical industries.
Molybdenum, columbium, tungsten, and
tantalum are referred to as refractory metal.
Ship-cyclic loading
from waves.
Adapted from chapter-opening photograph,
Chapter 8, Callister 7e. (by Neil Boenzi, The
New York Times.)
Computer chip-cyclic
thermal loading.
Adapted from Fig. 22.30(b), Callister 7e. (Fig.
22.30(b) is courtesy of National
Semiconductor Corporation.)
Hip implant-cyclic
loading from walking.
Adapted from Fig. 22.26(b),
Callister 7e.
Fracture mechanisms
Ductile fracture
Occurs with plastic deformation
Brittle fracture
Occurs with Little or no plastic deformation
Thus they are Catastrophic meaning they
occur without warning!
Very
Ductile
Moderately
Ductile
Brittle
Large
Moderate
Small
Ductile fracture is
nearly always desirable!
%Ra or %El
Ductile:
warning before
fracture
Brittle:
No
warning
Brittle failure:
--many pieces
--small deformation
Figures from V.J. Colangelo and F.A. Heiser,
Analysis of Metallurgical Failures (2nd ed.),
Fig. 4.1(a) and (b), p. 66 John Wiley and
Sons, Inc., 1987. Used with permission.
Resulting
fracture
surfaces
fracture
50
50mm
mm
(steel)
Inclusion
From V.J. Colangelo and F.A. Heiser,
Analysis of Metallurgical Failures (2nd ed.),
particles
Fig. 11.28, p. 294, John Wiley and Sons,
Inc., 1987. (Orig. source: P. Thornton, J.
serve as void Mater. Sci., Vol. 6, 1971, pp. 347-56.)
Nucleation sites.
100 mm
Fracture surface of tire cord wire loaded
in tension. Courtesy of F. Roehrig, CC
Technologies, Dublin, OH. Used with
permission.
cup-and-cone fracture
Adapted from Fig. 8.3, Callister 7e.
brittle fracture
Brittle Failure
Arrows indicate point at which failure originated
Intergranular
(between grains)
4 mm
304 S. Steel
(metal)
(within grains)
316 S. Steel
(metal)
Polypropyle
ne
(polymer)
160 mm
Al Oxide
(ceramic)
Reprinted w/ permission
from "Failure Analysis of
Reprinted w/ permission
Brittle Materials", p. 78.
from R.W. Hertzberg,
Copyright 1990, The
"Deformation and Fracture American Ceramic Society,
Westerville, OH.
Mechanics of Engineering
Materials", (4th ed.) Fig. (Micrograph by R.M. Gruver
and H. Kirchner.)
7.35(d), p. 303, John
1 mm
Wiley and Sons, Inc.,
(Orig. source: K. Friedrick, Fracture 1977, Vol.
1996.
3, ICF4, Waterloo, CA, 1977, p. 1119.)
3 mm
(Charpy Specimen)
final height
initial height
a
m 2o
t
t
1/ 2
K t o
where
t = radius of curvature of
crack tip
o = applied stress
m = stress at crack tip
Adapted from Fig. 8.8(a), Callister 7e.
Kt = max
o
2.5
2.0
increasing w/h
1.5
1.0
0.5
1.0
sharper fillet radius
r/h
Crack Propagation
Cracks propagate due to sharpness of crack tip
A plastic material deforms at the tip, blunting the
crack.
brittle
Plastic
deformed
region
i.e., m >c
orKt > Kc
2E s
c
1/ 2
where
E = modulus of elasticity
s = specific surface energy
a = one half length of internal crack
Kc = c/ 0
Fatigue behavior:
Fatigue = failure under cyclic stress
specimen compression on top
bearing
bearing
motor
counter
flex coupling
tension on bottom
max
m
min
time
max 5340
min
6.4*10 2
5340
3
6.4*10
5340
3.22 105
5340
165.99 MPa
3.22 10
165.99 MPa
0
2
2
r stress range Max min 331.99 MPa
a stress amplitude S r 2 165.99 MPa
S = stress amplitude
unsafe
Sfat
case for
steel (typ.)
safe
10
10
10
10
N = Cycles to failure
10
6.4*10 2
5340
min 5340
165.99MPa
2
3
3.22 105
6.4*10
0
2
2
r Max min 331.99 MPa
a S r 2 165.99 MPa
Examining Fig (right) at S = 165.99
m
For polymers, we
consider fatigue life to
be (only) 106 cycles to
failure thus fatigue
strength is the stress
that will lead to failure
after 106 cycles
Fatigue Mechanism
Cracks in Material grows incrementally
da
m
K
dN
typ. 1 to 6
~ a
Adapted from
from D.J. Wulpi,
Understanding How
Components Fail,
American Society for
Metals, Materials Park,
OH, 1985.
S = stress amplitude
Adapted from
Fig. 8.24, Callister 7e.
Increasing
--Method
1: shot peening
shot
--Method 2: carburizing
put
surface
into
compression
2. Remove stress
concentrators.
bad
C-rich gas
better
Adapted from
Fig. 8.25, Callister 7e.
bad
better
SUMMARY
Why Failure?
All unanticipated mechanical failures
must have a cause:
Designed incorrectly
Manufactured incorrectly
Mis-maintained
Mis-operated
SUMMARY
Engineering materials don't reach theoretical strength.
Flaws produce stress concentrations that cause
premature failure.
Sharp corners produce large stress concentrations
and premature failure.
Failure type depends on T and stress:
- for noncyclic and T < 0.4Tm, failure stress decreases with:
- increased maximum flaw size,
- decreased T,
- increased rate of loading.
- for cyclic :
Case Study
Conventional
tensile failure
mode that we
are all familiar
with.
Brittle Fracture
Ductile Fracture
Failure in Compression
Failure in Torsion
Failure in Bending
Sneaky failure
Fatigue Failure
CORROSION AND
DEGRADATION
What is Corrosion?
Corrosion is the oxidation of a metal due to an
ELECTROCHEMICAL reaction. The oxidizing agent is
most often O2 (atmospheric corrosion) or H+ (chemical
corrosion) or both.
Why is it a problem?
Financial - $350 Billion Dollar Annual Problem in U.S.
(4.25% of GNP) Department of Defense spends $6 8
Billion
Zinc
H+
H+
Acid
solution
H+
H+
H2(gas)
H+
reduction reaction
O2 4H 4e 2H2O
O2 2H2O 4e 4(OH)
3
H2(gas) 2e
Mn+ H+
ions
H+
Platinum
metal, M
ne-
e-
25C
e-
nemetal, M
e-
Mn+
ions
H+ 2eH+
Platinum
25C
1M Mn+soln 1M H+ soln
o
Vmetal
0 (relative to Pt)
m
o
r
e
a
n
o
d
i
c
m
o
r
e
c
a
t
h
o
d
i
c
EMF series
metal
Au
Cu
Pb
Sn
Ni
Co
Cd
Fe
Cr
Zn
Al
Mg
Na
K
o
Vmetal
+1.420 V
+0.340
- 0.126
- 0.136
- 0.250
o
- 0.277 V =
- 0.403 0.153V
- 0.440
- 0.744
- 0.763
- 1.662
- 2.262
- 2.714
- 2.924
Vmetal corrodes.
Cd
25C
Ni
1.0 M
1.0 M
Cd 2+ solutionNi 2+solution
CORROSION IN A GRAPEFRUIT
Cathode
Cu +
Anode
H+
H+
Zn2+
2e-
reduction
2H 2e H2(gas)
O2 4H 4e 2H2O
H+
H+
Zn
oxidation
H+
Acid
H+
H+
Cd
25C
Ni
1.0 M
1.0 M
Cd2+ solution Ni2+solution
n = #eper unit
oxid/red
Cd
Ni
T
reaction
(=2 here)
F=
XM
YM
Faraday's
Cd2+ solution Ni2+solution constant
Reduce VNi - VCd by =96,500
C/mol.
--increasing X
--decreasing Y
m
o
r
e
a
n
o
d
i
c
m
o
r
e
c
a
t
h
o
d
i
c
GALVANIC SERIES
(
a
c
t
i
v
e
)
(
i
n
e
r
t
)
FORMS OF CORROSION
Stress corrosion
Selective Leaching
Preferred corrosion of
one element/constituent
(e.g., Zn from brass (Cu-Zn)).
Intergranular
Forms
of
corrosion
Pitting
Downward propagation
of small pits & holes.
Corrosion along
grain boundaries,
Galvanic
often where special Dissimilar metals are Crevice Between two
pieces of the same metal.
phases exist.
physically joined. The
Rivet holes
g.b.
more anodic one
prec.
corrodes.(see Table
17.2) Zn & Mg
attacked
very anodic.
zones
9
DETERIORATIVE
Stress & Saltwater... Heat treatment: slows
crack speed in salt water!
c r a c k s p e e d (m /s )
--causes cracks!
10-8
as-is
held at
160C for 1hr
before testing
10-10
increasing load
--material:
4m
7150-T651 Al
"alloy"
(Zn,Cu,Mg,Zr)
10
Prevention:
Paint
Plate
Sacrificial anode
Galvanic Corrosion
Causes:
Dissimilar metals
Electrolyte
Current Path
Described by Galvanic Series
Solutions:
Choose metals close in galvanic
series
Have large anode/cathode ratios
Insulate dissimilar metals
Use Cathodic protection
Causes:
concentration gradients in
electrolyte cause some areas high in ion
concentrations that accelerate oxidation
Prevention:
Weld dont rivet
Use non-absorbing gaskets
Polish surfaces
Add drains avoid stagnant water
Adjust composition; e.g., add Mo to SS
Intergranular Corrosion
Occurs in specific alloys precipitation of corrosive
specimens along grain boundaries and in particular
environments
e.g. : Chromium carbide forming in SS, leaving adjacent areas depleted in Cr
Solutions:
stronger carbide
Erosion Corrosion
Causes: abrasive fluids impinging on
surfaces
Commonly found in piping, propellers,
turbine blades, valves and pumps
Solutions:
Change design to minimize or eliminate fluid
turbulence and impingement effects.
Use other materials that resist erosion
Remove particulates from fluids
Selective Leaching
Occurs in alloys in which one
element is preferentially removed
e.g., in Brass, Zinc is electrically
active and is removed, leaving
behind porous Copper
Occurs in other metals, such as Al,
Fe, Co, Cr
Solutions:
Use protective coating to protect surfaces
Use alternative materials
Stress Corrosion
Aka: stress corrosion cracking
Cracks grow along grain
boundaries as a result of residual or
applied stress or trapped gas or
solid corrosion products
e.g., brasses are sensitive to
ammonia
Stress levels may be very low
Solutions:
Hydrogen Embrittlement
Metals loose strength when Hydrogen is
absorbed through surface, especially along
grain boundaries and dislocations
Often occurs as a result of decorative
plating
High strength steels particularly susceptible
Can be removed by baking the alloy
CONTROLLING CORROSION
Metal oxide
Metal (e.g., Al,
stainless steel)
Self-protecting metals!
zinc
2e- 2esteel
zinc
e.g., Mg Anode
steel
pipe
e-
Cu wire
Mg Mg2+
anode
Earth
11
Corrosion prevention
Sacrificial Anode
Applied Voltage
SUMMARY