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Met-2023 (PDF) - SQ
Met-2023 (PDF) - SQ
Q-2.Design a heat treatment that will provide 1000 times more vacancies in copper than are
normally present at room temperature. About 20,000 cal/mol are required to produce a
vacancy in copper.The lattice parameter of FCC copper is 0.36151 nm.
Q-3.Determine the number of vacancies needed for a BCC iron lattice to have a
density of 7.87 g/cm . The lattice parameter of the iron is 2.866 x 10-8 cm.
(at. Wt. for Fe- 55.847 g/mol )
Q-4.(a) The planar density of the ( 1 1 2 ) plane in BCC iron is 9.94 x 10 1 4 atoms/cm 2 .
Calculate (i) the planar density of the ( 1 1 0 ) plane and (ii) the interplanar spacings
for both the (112) and (110) planes. On which plane would s l i p normally occur?
(b) Calculate the length of the Burgers vector in the following materials:
(i) BCC niobium ( a0 – 3.294 Aº )
(ii) FCC silver ( a0 – 4.0862 Aº )
(iii) FCC copper ( a0 – 3.6151 Aº )
Q-6.(a) Calculate the number of vacancies per cm3 expected in copper at 1085°C (just
below the melting temperature). The energy for vacancy formation is 20,000 cal/mol.
( a0 –for Cu - 3.6151 Aº )
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(b) The fraction of lattice points occupied by vacancies in solid aluminum at 660c C is
10-3. What is the energy required to create vacancies in aluminum ?
Q-7. The density of a sample of FCC palladium is 11.98 g/cm3 and its lattice parameter
is 3.8902 A . Atomic mass of Pd is 106.4 g/mol. Calculate
(a) the fraction of the lattice points that contain vacancies and
(b) the total number of vacancies in a cubic centimeter of Pd.
treatment that will produce these optimum properties. Assume that the temperature is high enough
(at least 900°C) so that the iron has the FCC structure.
Q-13.A 0.001 in. BCC iron foil is used to separate a high hydrogen gas from a low
hydrogen gas at 650°C. 5 x 108 H atoms/ cm3 are in equilibrium with the hot side of the
foil, and 2 x 103 H atoms/cm3 are in equilibrium with the cold side. Determine
(a) the concentration gradient of hydrogen and
(b) the flux of hydrogen through the foil.
Q-17.A 1.2% C tool steel held at 1150°C is exposed to oxygen for 48 h. The carbon
content at the steel surface is zero. To what depth will the steel be decarburized to
less than 0.20% C?
Q-18.A BCC steel containing 0.001% N is nitrided at 550°C for 5 h. If the nitrogen content
at the steel surface is 0.08%, determine the nitrogen content at 0.25 mm from the surface.
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Q-20.(a) Define Engineering Stress, True stress and Engineering Strain, True Strain.
(b) A force of 100,000 N is applied to a 10 mm x 20 mm iron bar having a yield
strength of 400 MPa and a tensile strength of 480 MPa. Determine
(i) whether the bar will plastically deform and
(ii) whether the bar will experience necking.
Q-21.An aluminum alloy that has a plane strain fracture toughness of 25,000 psi-√in .fails
when a stress of 42,000 psi is applied. Observation of the fracture surface indicates that
fracture began at the surface of the part. Estimate the size of the flaw that initiated
fracture. Assume that f = 1 . 1 .
Q-23.A 0.4-in. diameter, 12-in. long titanium bar has a yield strength of 50,000 psi,
a modulus of elasticity of 16 x 106 psi, and Poisson's ratio of 0.30. Determine the length
and diameter of the bar when a 500-Ib load is applied.
Q-25.Which factors does depend on the ability of a material to resist the growth of a
crack?
Q-27.A ceramic part for a jet engine has a yield strength of 75,000 psi and a plane strain
fracture toughness of 5,000 psi - √in. . To be sure that the part does not fail, we plan to
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assure that the maximum applied stress is only one-third the yield strength. We use a
nondestructive test that will detect any internal flaws greater than 0.05 in. long.
Assuming that f = 1.4, does our nondestructive test have the required sensitivity?
Explain.
Q-28.A large steel plate used in a nuclear reactor has a plane strain fracture toughness of 80,000
psi- √in and is exposed to a stress of 45,000 psi during service. Design a testing or
inspection procedure capable of detecting a crack at the surface of the plate before the crack
is likely to grow at a catastrophic rate.
Q-29.A 850-lb force is applied to a 0.15-in. diameter nickel wire having a yield strength of
45,000 psi and a tensile strength of 55,000 psi. Determine
(a) whether the wire will plastically deform and
(b) whether the wire will experience necking.
Q-30.A solid shaft for a cement kiln produced from the tool steel must be 96 inches long and
must survive continuous operation for one year with an applied load of 12,500 lb. The shaft
makes one revolution per minute during operation. Design a shaft that will satisfy these
requirements.
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Q-2. Design a heat treatment that will provide 1000 times more vacancies in copper than are
normally present at room temperature. About 20,000 cal/mol are required to produce a
vacancy in copper. The lattice parameter of FCC copper is 0.36151 nm.
Solution
The lattice parameter of FCC copper is 0.36151 nm.
The number of copper atoms, per cm3 is
4 atoms / cell
= 8.47 x1022 copper atoms/cm3
( 3.6151 x 10−8 cm)3
At room temperature, T = 25 + 273 = 298 K:
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By heating the copper slightly above 100°C, then rapidly cooling the copper back to
room temperature, the number of vacancies in the structure may be one thousand times
greater than the equilibrium number of vacancies.
Q-3. Determine the number of vacancies needed for a BCC iron lattice to have a
density of 7.87 g/cm . The lattice parameter of the iron is 2.866 x 10-8 cm.
(at. wt. for Fe = 55.847 g/mol )
Solution
Theoretical density of iron can be calculated from the lattice parameter and the atomic
mass.
Since the iron is BCC, two iron atoms are present in each unit cell.
theoretical density of iron ;
2 atoms / unit cell x 55.847 g / mole
density = -8 3 23
= 7.8814 g / cm3
(2.866x10 cm ) x (6.02x10 atoms/ mol)
Let's calculate the number of iron atoms and vacancies that would be present in
each unit cell for the required density of 7.87 g/cm3.
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(a)
(b) Calculate the length of the Burgers vector in the following materials:
(i) BCC niobium ( a0 – 3.294 Aº )
(ii) FCC silver ( a0 – 4.0862 Aº )
(iii) FCC copper ( a0 – 3.6151 Aº )
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The repeat distance is along the [l l 0 ] directions and is equal to one-half of the face
diagonal, since lattice points are located at corners and center of the face.
Face diagonal distance = 2 a = 2 x (0.40862 nm ) = 0.5778 nm
The length of the Burgers vector, or the repeat distance, is:
1
b= x ( 0.5778 nm ) = 0.2889 nm
2
Schmid's law
The relationship between shear stress, the applied stress, and the orientation
of the slip system and the resolved shear stress ι in the slip direction is
F
τ= Cosφ Cosλ , τ = σ Cosφ Cosλ
A
where , τ = the resolved shear stress in the slip direction
σ = the applied stress
φ = the angle between the direction of the force and the normal to the slip plane,
λ = the angle between the direction of force and the slip direction.
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Q-5.(b) An aluminum crystal slips on the (111) plane and in the [110] direction with a 3.5
MPa stress applied in the [ 1 1 1 ] direction. What is the critical resolved shear stress?
Solution
Aluminum crystal
slips plane - (111) plane
slip direction - [110] direction
stress applied σ - 3.5 MPa
applied stress direction - [ 1 1 1 ] direction.
the critical resolved shear stress ι = ?
τ = σ Cosφ Cosλ
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the applied stress direction and the direction of the normal to the slip plane are
the same,
the angle φ = 0 , Cos 0 = 1
2a 2
Cos λ = = = 0.8165
3a 3
2
τ = 3.5 x 1 x = 2.875 MPa
3
the critical resolved shear stress, τ = 2.875 MPa
Q-6.(a) Calculate the number of vacancies per cm3 expected in copper at 1085°C (just
below the melting temperature). The energy for vacancy formation is 20,000 cal/mol.
( a0 = for Cu - 3.6151 Aº )
Solution
(a) copper metal, FCC structure, 4 atoms/ unit cell ,
a0 = 3.6151 A°, = 3.6151 x 10−8 cm, Q = 20, 000 cal / mol , R = 1.987 cal / mol.D K
−Q
nv = n x exp
RT
no.of atom per unit cell
n=
volume of unit cell
−Q − 20, 000
nv = n x exp ( ) = 1.106 x1024 x exp ( )
RT 1.987 x1358
= 5.12 x 1019 vacancies / cm3
nv −Q
= exp
n RT
−Q
10−3 = exp ( )
1.987 x 933
Q = 12800 cal / mol
Q-7. The density of a sample of FCC palladium is 11.98 g/cm3 and its lattice parameter
is 3.8902 A . Atomic mass of Pd is 106.4 g/mol. Calculate
(a) the fraction of the lattice points that contain vacancies and
(b) the total number of vacancies in a cubic centimeter of Pd.
Solution
FCC Pd – density = 11.98 g/cm3 , 4 atoms/ unit cell
At. wt. of Pd - 106.4 g/mol
a0 = 3.8902 A = 3.8902 x 10−8 cm
nv n
(a ) = ?, (b) v 3 = ?
n cm
mass of unit cell
theoretical density =
volume of unit cell
4 atoms per unit cell x 106.4 g / mol
ρ= −8 3 23
= 12.0085 g / cm3
(3.8902 x10 cm) x (6.02 x10 atom / mol )
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The rate at which atoms diffuse in a material can be measured by the flux J, which is
defined as the number of atoms passing through a plane of unit area per unit time.
Fick's first law explains the net flux of atoms:
+c
J = − D.
+x
where, J is the flux (atoms/cm2.s),
D is the diffusivity or diffusion coefficient (cm2/s), and
Δc/Δx is the concentration gradient (atoms/cm3.cm).
Q-8.(b) Atoms are found to move from one lattice position to another at the rate of
5 x 1 0 5 jumps per second at 400 c C when the activation energy for their movement is
30,000 cal/mol. Calculate the jump rate at 750°C.
Solution
the rate of diffusion = 5 x 1 0 5 jumps per second at 400 c C
the activation energy Q = 30,000 cal/mol.
the jump rate at 750°C = ?
T1 = 4000D C + 273 = 673 D K
−Q
By the equation , Rate of diffusion = c0 .exp ( )
RT
−Q
5 x 105 = c0 exp ( ) ----- eq. (1)
RT1
−Q
x = c0 exp ( ) ----- eq. (2)
RT2
eq. (2) ÷ eq.(1)
−Q −Q
x = c0 exp ( ) / 5 x 105 = c0 exp ( )
RT2 RT1
−30, 000 −30, 000
x = c0 exp ( ) / 5 x 105 = c0 exp ( )
1.987 x 673 1.987 x 1023
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Q-9.(b) Consider a diffusion couple set up between pure tungsten and a tungsten-1 at %
thorium alloy. After several minutes of exposure at 2000° C, a transition zone of 0.01 cm
thickness is established. What is the flux of thorium atoms at this time if diffusion is
due to (a) volume diffusion, (b) grain boundary diffusion, and (c) surface diffusion?
The lattice parameter of BCC tungsten is 3.165A°.
Diffusion Coefficient for Thorium in Tungsten
Solution
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-15
Q-10.(b) The diffusion coefficient for Cr in Cr2 O 3 is 6 x 10 cm2 /s at 727°C and is
1x10– 9 cm2 /s at 1400°C. Calculate (i) the activation energy and ( ii ) the constant Do.
Solution
The diffusion coefficient for Cr in Cr2 O 3
-15
D = 6 x 10 cm2 /s at T1 = 727°C + 273 K = 1000 K
D = 1 x10– 9 cm2 /s at T2 = 1400°C + 273 K = 1673 K
(i) the activation energy Q = ? ( ii ) the constant Do. = ?
−Q
D = D0 exp ( )
RT
−Q
6 x 10−15 = D0 exp ( ) ----- eq. (1)
RT1
−Q
1 x 10−9 = D0 exp ( ) ----- eq. (2)
RT2
eq. (1) ÷ eq.(2)
−Q −Q
6 x 10−15 = D0 exp ( ) /1 x 10−9 = D0 exp ( )
RT1 RT2
−Q −Q
6 x 10−15 = D0 exp ( ) / 1 x 10−9 = D0 exp ( )
1.987 x 1000 1.987 x 1673
Q = 59230 cal / mol
−Q
(ii) 1 x 10−9 = D0 exp ( )
RT2
−59230
1 x 10−9 = D0 exp ( )
1.987 x 1673
D0 = 0.055 cm 2 / sec
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Solution
Cs = 1.2 % C , Cx = 0.45% C , C0 = 0.1% C , x = 0.2 cm
Given:
t = ? ,T = ?
By Fick's second law ,
Cs − C x x
= erf [ ]
C s − C0 2 Dt
1.2 − 0.45 0.2
= 0.68 = erf [ ]
1.2 − 0.1 2 Dt
From Table 2-3 , we find that,
0.2 0.1
= 0.71 or = 0.71
2 Dt Dt
0.1 2
D.t = ( ) = 0.0198
0.71
Any combination of D and t whose product is 0.0198 will work.
For carbon diffusing in FCC iron, the diffusion coefficient is related to temperature by:
−Q
D = D0 exp ( )
RT
From the table 2-1, D0 = 0.23 , Q = 32,900 cal/mol
− 32900
D = 0.23 exp ( )
1.987 T
Therefore, the temperature and time of the heat treatment are related by:
0.0198
t=
D
0.0198
t=
0.23exp ( −16558 / T )
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Fick's second law describes the dynamic or non-steady state diffusion of atoms
by the differential equation dc/dt = D (d c/dx2), whose solution depends on the
boundary conditions for a particular situation. One solution is
Cs − C x x
= erf [ ]
C s − C0 2 Dt
where,
Cs - concentration of the diffusing atoms at the surface of the material
Cx - the concentration of the diffusing atom at location x below the surface after time t.
C0 - the initial uniform concentration of the diffusing atoms in the material
t - the diffusion time in (s)
x – the depth from the surface of the material ( cm )
D - the diffusion coefficient
Q-12.(b) We find that 10 h are required to successfully carburize a batch of 500 steel gears at
900°C, where the iron has the FCC structure. We find that it costs $ 1000 per hour to operate
the carburizing furnace at 900°C and $ 1500 per hour to operate the furnace at 1000° C. Is it
economical to increase the carburizing temperature to 1000°C ?
Solution
T = 900°C + 273 K = 1 173 K , t1173 = 10 hour
T = 1000°C = 273 K = 1273 K. , t 1273 = ?
For carbon diffusing in FCC iron, from Table,
the activation energy Q = 32,900 cal/mol. for the same carburizing treatment at
1000°C as at 900°C:
D1273 .t 1273 = D1173 .t1173
.t 1273 = D1173 .t1173 / D1273
(10h) exp(−32,900) /(1.987).(1173)
t1273 =
exp(−32,900) /(1.987).(1273)
t1273 = 3.299 hour
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Q-13. A 0.001 in. BCC iron foil is used to separate a high hydrogen gas from a low
hydrogen gas at 650°C. 5 x 108 H atoms/ cm3 are in equilibrium with the hot side of the
foil, and 2 x 103 H atoms/cm3 are in equilibrium with the cold side. Determine
(i)the concentration gradient of hydrogen and
(ii)the flux of hydrogen through the foil.
Solution
In BCC iron foil, the flux of hydrogen through the foil, from hot side to cold side.
at 650°C., T = 650 + 273 = 923 K
Cinitial = 5 x 108 H atoms/ cm3
Cfinal = 2 x 103 H atoms/cm3
thickness - Δx = 0.001 in. = 0.001 in x 2.54 cm
(i) the concentration gradient (Δc/Δx) = ?
(ii) the flux of hydrogen through the foil = ?
2 x103 − 5 x108
(i) the concentration gradient (Δc/Δx) =
(0.001) x(2.54)
= - 1969x10 8 H atoms/ cm3
(ii) the flux of hydrogen through the foil , J = - D.Δc/Δx
−Q
D = D0 exp ( )
RT
From Table 2-1, H in BCC iron, D 0= 0.0012 , Q = 3600
D = 0.0012 exp( −36,00 / 1.987.923) =
J = - D.Δc/Δx
= - 0.0012 exp( −36,00 / 1.987.923) x (- 1969x108 )
= 0.33 x108 H atoms/ cm2.s
Q-14. What temperature is required to obtain 0.50% C at a distance of 0.5 mm beneath the
surface of a 0.20% C steel in 2 h, when 1.10% C is present at the surface? Assume
that the iron is FCC.
Solution
Cs = 1.1% C , Cx = 0.5% C , C0 = 0.2 % C , x = 0.5 mm = 0.05 cm
Given:
t = 2 hr x 3600 = 7200sec , T = ?
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Q-17. A 1.2% C tool steel held at 1150°C is exposed to oxygen for 48 h. The carbon
content at the steel surface is zero. To what depth will the steel be decarburized to
less than 0.20% C ?
Solution
Cs = 0.% C , Cx = 0.2 % C , C0 = 1.2 % C , x( cm) = ?
Given;
T =1150 DC + 273 = 1423 D K , time(t ) = 4 hr = 4 x3600sec = 4400sec
By Fick's second law
Cs − C x x
= erf [ ]
C s − C0 2 Dt
0 − 0. 2 x
= 0.1667 = erf [ ]
0 − 1 .2 2 Dt
x
erf [ ] = 0.1667 , From Table 2-3 , we find that,
2 Dt
x
= 0.149 ,
2 Dt
−Q
D = D0 exp ( )
RT
From the table 2-1, C in FCC iron, D0 = 0.23 , Q = 32,900 cal/mol
D = 0.23 exp( −32,900 / 1.987.1423) = 2.034 x 10-6 cm2 /s
Q-18. A BCC steel containing 0.001% N is nitrided at 550°C for 5 h. If the nitrogen content
at the steel surface is 0.08%, determine the nitrogen content at 0.25 mm from the surface.
Solution
Cs = 0.08 N % , Cx = ? N % , C0 = 0.001N % , x = 0.25 mm = 0.25 cm
Given;
T = 550 DC + 273 = 823 D K , time(t ) = 5 hr = 5 x3600sec = 8000sec
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0.08 − C x x
= erf [ ]
0.08 − 0.001 2 Dt
−Q
D = D0 exp ( )
RT
From the table 2-1, N in BCC iron, D0 = 0.0047 , Q = 18,300 cal/mol
D = 0.0047 exp( −18,300 / 1.987.x.823) = 6.488 x 10-8 cm2 /s
D .t = 6.488.x.10−8.x.5.x.3600 = 0.0342 ,
x 0.025
erf [ ] = erf [ ]
2 Dt 2 x0.0342
x x
= 0.3655 , erf [ ] = 0.394
2 Dt 2 Dt
0.08 − C x x
= erf [ ] = 0.394
0.08 − 0.001 2 Dt
Cx = 0.049 N%
(i) % Elongation - The total percentage increases in the length of a specimen during
a tensile test.
l f − l0
% Elongation = x 100 %
l0
where l f – final length of the specimen
l0 – initial length of the specimen
(ii) Endurance limit - The stress below which a material w i l l not fail in a fatigue test.
(iii) Endurance Ratio - The endurance l i m i t divided by the tensile strength of the
material. The ratio is about 0.5 for many ferrous metals.
Endurance lim it
Endurance ratio = ≅ 0.5
trnsile strength
The endurance ratio allows us to estimate fatigue properties from the tensile test.
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(iv) Fatigue life - The number of cycles permitted at a particular stress before a material
fails by fatigue. Fatigue life tells us how long a component survives at a particular stress.
(v) Elastic deformation - Deformation of the material that is recovered when the applied
load is removed.
Q-20. (a) Define Engineering Stress, True stress and Engineering Strain, True Strain.
(b) A force of 100,000 N is applied to a 10 mm x 20 mm iron bar having a yield
strength of 400 MPa and a tensile strength of 480 MPa. Determine
(i) whether the bar will plastically deform and
(ii) whether the bar will experience necking.
Solution
(a) Engineering Stress - The applied load, or force, divided by the original cross
sectional area of the material.
force F
Engineering stress = =σ =
initial.cross sec tional.area A0
True stress - The load divided by the actual cross-sectional area of the
specimen at that load.
F1 F2
True stress = σ 1 = , σ2=
A1 A2
Engineering Strain - The amount that a material deforms per unit length in a tensile test.
l − l0
Engineering strain = ε =
l0
where l – final length of the specimen
l0 – initial length of the specimen
True Strain - The strain, given by ε t = ln (l/l0), produced in a material.
⎡l ⎤
True Strain ε t = ln ⎢ ⎥
⎣ l0 ⎦
where l – final length of the specimen
l0 – initial length of the specimen
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Solution
Q-20.(b) Applied force = 100,000 N
(i) area of iron bar = 10 mm x 20 mm = 200 mm2
yield strength - 400 MPa
tensile strength - 480 MPa.
force F
Engineering stress = =σ =
initial.cross sec tional.area A0
σ = 100,000 N / 200 mm2 = 500 N/mm2
1 MPa = 1 N/mm2 , 500 MPa
applied stress σ is greater than yield strength ( 500 MPa > 400 MPa ),therefore,
the iron bar will plastically deform.
(ii) applied stress σ is greater than tensile strength ( 500 MPa > 480 MPa ),therefore,
the bar will occur necking.
Q-21. An aluminum alloy that has a plane strain fracture toughness of 25,000 psi-√in .fails
when a stress of 42,000 psi is applied. Observation of the fracture surface indicates that
fracture began at the surface of the part. Estimate the size of the flaw that initiated
fracture. Assume that f = 1 . 1 .
Solution
plane strain fracture toughness Kc = 25,000 psi-√in .
stress σ = 42,000 psi is applied.
the fracture began at the surface of the part.
the size of the flaw = ?. Assume that f = 1 . 1 .
K IC = f .σ. π .a
25,000 = 1.1 x 42,000 x π .a
a = 0.093 in
the initial flaw size on the surface – 0.093 in
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Poisson's ratio
The ratio between the lateral and longitudinal strains in the elastic
region. Poisson's ratio, μ, relates the longitudinal elastic deformation produced by a
simple tensile or compressive stress to the lateral deformation that occurs simultaneously:
− ε (lateral )
μ= , ( μ is about 0.3)
ε (longitudional
Q-23. A 0.4-in. diameter,12-in. long titanium bar has a yield strength of 50,000 psi,
a modulus of elasticity of 16 x 106 psi, and Poisson's ratio of 0.30. Determine the length
and diameter of the bar when a 500-Ib load is applied.
Solution
a titanium bar ,
diameter = 0.4-in., length = 12-in.
yield strength = 50,000 psi,
modulus of elasticity E = 16 x 106 psi,
Poisson's ratio μ = 0.30.
the length = ? and the diameter of the bar = ? when a 500-Ib load is applied.
F = 500 lb
the stress σ = F/A = 500 lb / (π/4 )(0.4 in.)2 = 3979 psi
σ
By Hook's Law, E =
ε
σ
the strain ε= = 3979 psi / 16 x 106 psi = 0.00024868 in/in
E
l f − l0 l f − 12
Engineering strain = ε = == = 0.00024868
l0 12
l f = 12.00298 in
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−ε (lateral )
Poisson's ratio: μ = = − 0.3
ε (longitudional
ε(lateral) = - (μ )x ε(longitudinal) = - (0.3 ) (0.00024868) = -0.0000746 in/in
D f − D0 D f − 0.4
= = - 0.0000746 in / in
D0 0.4
D f = 0.39997 in
Q-25.Which factors does depend on the ability of a material to resist the growth of a crack?
Solution
The ability of a material to resist the growth of a crack depends on a large number
of factors:
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1). the larger the flaws size, the smaller the permitted stress.
2). Increasing the strength of a given metal usually decreases ductility and gives a
lower fracture toughness.
3).Thicker, more rigid materials have lower fracture toughness than thin materials.
4). Increasing the rate of application of the load, such as in an impact test, typically
reduces the fracture toughness of the material.
5). Increasing the temperature normally increases the fracture toughness, just as in the
impact test.
6). A small grain size normally improves fracture toughness, more point defects and
dislocations reduce fracture toughness.
(iii) Ductility
The ability of a material to be permanently deformed without breaking when a force is
applied. Ductility measures the amount of deformation that a material can withstand
without breaking.
Q-27. A ceramic part for a jet engine has a yield strength of 75,000 psi and a plane strain
fracture toughness of 5,000 psi - √in. . To be sure that the part does not fail, we plan to
assure that the maximum applied stress is only one-third the yield strength. We use a
nondestructive test that will detect any internal flaws greater than 0.05 in. long.
Assuming that f = 1.4, does our nondestructive test have the required sensitivity ?
Explain.
Solution
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Q-28. A large steel plate used in a nuclear reactor has a plane strain fracture toughness of 80,000
psi- √in and is exposed to a stress of 45,000 psi during service.Design a testing or
inspection procedure capable of detecting a crack at the surface of the plate before the crack
is likely to grow at a catastrophic rate.
Solution
steel plate used in a nuclear reactor,
applied stress σ = 45,000 psi
plane strain fracture toughness K IC = 80,000 psi - √in.
surface crack = a = ? , f = 1,
Under these condition, to determine the minimum size of crack.
K IC = Kc = f.σ. π .a
80,000 = 1 x 45,000 x π .a
a = 1 in.
This minimum crack size ( 1 in.) on the surface can be observed visually.
If the growth rate of the crack is slow, the inspection is performed by regular
method.
Q-29. A 850-lb force is applied to a 0.15-in. diameter nickel wire having a yield strength of
45,000 psi and a tensile strength of 55,000 psi. Determine
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Q-30. A solid shaft for a cement kiln produced from the tool steel must be 96 inches long and
must survive continuous operation for one year with an applied load of 12,500 lb. The shaft
makes one revolution per minute during operation. Design a shaft that will satisfy these
requirements.
Solution
a tool steel solid shaft for a cement kiln,
length L = 96 in. , applied load ( F ) = 12,500 lb.
continuous operation for one year, and one revolution per minute during operation.
Design a shaft that will satisfy these requirements.
It means that minimum diameter of the shaft (d ) = ?
1 cycle.x.365.days.x 24.hr.x.60.min
Number of cycle / year = N =
1.min .x.1. year.x.1.day.x.1.hr.
N = 5.265 x 105 cycles/year
From Fig. 3-13 , S-N curve for tool steel,
N = 5.265 x 105 ,,, applied stress σ = 72,000 Psi or 72 Ksi.
applied stress σ must be less than 72,000 Psi or 72 Ksi.
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10.18.L.F
By the equation, σ=
d3
10.18.x.96.x.12500
72, 000 =
d3
d = 5.54 in
For these conditions, the diameter of the shaft 5.54 in. will operate for one year.
But, safety is required in the design without failure.
In Fig. endurance limit 60,000 Psi, < 72,000 Psi., this condition is minimum diameter required
to prevent failure.
10.18.x.96.x.12500
60, 000 =
d3
d = 5.88 in
The condition that will operate for more than one year.
without failure, the minimum diameter of the shaft (d ) is 5.88 in
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