QUESTION 1:

Following is tabulated data that were gathered from a series of Charpy impact tests on a ductile cast iron.

Temperature (degC) Impact Energy (J)

-25 124
-50 123
-75 115
-85 100
-100 73
-110 52
-125 26
-150 9
-175 6

(a) Plot the data as impact energy versus temperature.

(b) Determine a ductile-to-brittle transition temperature as that temperature corresponding to the average of the maximum and
minimum impact energies.
(c) Determine a ductile-to-brittle transition temperature as that temperature at which the impact energy is 80 J.

Answers:
(a) The plot of impact energy versus temperature is shown below.

(b) The average of the maximum and minimum impact energies from the data is
124 J +6 J
Average = = 65 J
2
As indicated on the plot by the one red dashed line, the ductile-to-brittle transition temperature according to this criterion is
about –105°C.
(c) Also, as noted on the plot by the green dashed line, the ductile-to-brittle transition temperature for an impact energy of 80 J is
about –95°C.
QUESTION 2:
A polystyrene component must not fail when a tensile stress of 1.25 MPa (180 psi) is applied. Determine the maximum allowable
surface crack length if the surface energy of polystyrene is 0.50 J/m2 (2.86 10-3 in.-lbf/in.2). Assume a modulus of elasticity of 3.0 GPa
(0.435 106 psi).
Answer:
The maximum allowable surface crack for polystyrene may be determined by the equation defined below taking 3.0 GPa as the
modulus of elasticity, and solving for a leads to:

3 x 109 N N
(2)( )(0.50 )
2EУ s m
2
m
a= 2 = = 6.1 x 10-4m = 0.61mm
( )
2
π σc 6 N
π 1.25 x 10 2
m
QUESTION 3:
A specimen of a 4340 steel alloy having a plane strain fracture toughness of 45 MPa m 1/2 (41ksi in1/2) is exposed to a stress of 1000
MPa (145,000 psi). Will this specimen experience fracture if it is known that the largest surface crack is 0.75 mm (0.03 in.) long? Why
or why not? Assume that the parameter Y has a value of 1.0. Note: Y is a dimensionless parameter or function that depends on both
crack and specimen sizes and geometries as well as the manner of load application.
Answer:
This problem asks us to determine whether or not the 4340 steel alloy specimen will fracture when exposed to a stress of 1000 MPa,
given the values of KIC, Y, and the largest value of a in the material. This requires that we solve for σc.

K IC 45 MPa √ m
σc = = = 927 MPa
Y √ πa ( 1.0 ) √ π (0.75 x 10−3 m)
Therefore, fracture will most likely occur because this specimen will tolerate a stress of 927 MPa before fracture, which is less than the
applied stress of 1000MPa.
QUESTION 4:
Each student is to obtain an object/structure/component that has failed. It may come from your home, an automobile repair shop, a
machine shop, and so on. Conduct an investigation to determine the cause and type of failure (i.e., simple fracture, fatigue, creep). In
addition, propose measures that can be taken to prevent future incidents of this type of failure. Finally, submit a report that addresses
these issues.
Answer:

Object: Drive Bushing

Material: Bronze
Function: The drive bushing is one of the parts of a 36” Double Disc Through Conduit (DDTC) Gate Valve. It serves as the movement
guide of the valve stem as it moves up and down with the aid of its actuator or its manual handwheel. The drive bushing is made of
bronze while the valve stem is made of stainless steel.
Failure: Ductile Failure in the form of Wearing (Worn-out threads of the drive bushing)
Problem: The difference of material between the drive bushing and the valve stem is intentionally designed in order for the drive
bushing, which is the cheaper one, to serve as the sacrificial part in the valve system. However, the problem or issue in this provided
sample situation is the premature failure of the object which consequently results to inoperability of the equipment. It is considered as a
premature failure because it occurred much earlier than the expected years of service that the object is designed to. Because of that
failure, the equipment cannot be properly operated which calls for a shutdown of the mother equipment that it is serving which is the
Cracking Heater, and thus leading to a big loss in production – a major concern of the Management.
Analysis: In the narrated problem, it can be said that the drive bushing had a ductile failure, particularly, a wearing of the object. Hence,
an investigation was made and its results identified the causes of the problem which are enumerated in the following:
- Deviation in the Operational Procedures
There is a deviation because it is stated in the procedure that the steam purging for the valve should be always maintained,
even if the Cracking Heater is shutdown or under preventive maintenance, because the steam keeps the valve hot or in high
temperature which is necessary in order for the flowing medium, which is the Naphtha, not to solidify. The solidification of
Naphtha will make the valve discs hard to be operated which leads to the application of excessive torque either in the actuator
or in the manual handwheel. The applied excessive torque forces the valve stem to rotate in the drive bushing thereby
resulting damage to the threads of the bushing.
- Absence of Preventive Maintenance
There is somehow a negligence because there is no preventive maintenance (PM) established for the mechanical parts of the
valve. The supposed PM should include lubrication or application of grease in the valve stem in order for the bushing and the
stem not to have a metal-to-metal contact, however, this was missed during its years of service which resulted to that severe
damage and premature failure.
Proposed Measures: In order to prevent the occurrence of similar problem in the future, the following actions are hereby recommended:
- Emphasize or highlight in the Work Instruction Procedure or Operating Procedure of the 36” DDTC Gate Valve that the steam
purging should be always maintained even if the Cracking Heater is shutdown or under preventive maintenance. Hence, the
steam purging should be supplied within the right parameters such as the recommended temperature and pressure in order
for it to serve its purpose.
- Establish a Preventive Maintenance (PM) for the mechanical parts of the 36” DDTC Gate Valve and upload it in the SAP
(which is the company’s computerized maintenance management system) in order for it not to be missed and it will
continuously provide a notification whenever the PM is due for implementation. The said PM should include the lubrication
activity which is the application of grease and should define as well the specific type of grease that is recommended by the
vendor.
Related Report: Please see attached presentation/report made to train maintenance and operations personnel in addressing the issues
encountered regarding the 36” DDTC Gate Valve.
QUESTION 5:
An engineering product is designed and manufactured to perform specific functions and serve certain needs over a predetermined
period of time, named service life. Cutting tools have been developed and used in all industrial applications. The cutting performance
usually depends on tool design, selected material, manufacturing conditions, heat treatments, material to be processed, operating
conditions and maintenance. These factors determine the tool lifetime, which in turn affects its final price. When a tool stops operating
prior to its expected service life, it is considered to have failed.
As a Material Engineer, conduct failure analysis: identify the causes of failure, and the possible prevention control in terms of:
1. Design
2. Materials of construction
3. Application and operating conditions
4. Maintenance
5. Material to be processed
Justify your claims through supporting literature.
Answers:
1. Design
The following are the failures that can be associated in terms of the design process:
o forming/dimensioning failures
o wrong working hardness
Causes of Failure:
o One common failure in terms of the design of cutting tools are the sharp-edged radii, which is a sample of forming
failure / dimensioning. The sharp-edged radii in tools cause a pronounced notch effect when it is operated under load
and may cause it to break if its tensile strength is exceeded. Hence, cracking can occur due to the high notch stress
along the sharp-edged radius which can lead to the object’s breakage.
Possible Prevention Control:
o The said failure can be resolved by providing a maximum radius in all load bearing areas. Another effective reduction
of the radius notch effect can be achieved by polishing the radius surfaces. If these measures should still not give an
adequate fracture resistance, a tougher material must be used.

Reference Literature: I. Jung et al.”Tool Failures – Causes and Prevention”. 6 th International Tooling Conference
(http://www.isoflama.com.br/assets/pdf/literaturas/1468268343.pdf)

2. Materials of Construction
The following are the failures that can be associated in terms of the materials of construction:
o plastic deformation
o thermal deformation
Causes of Failure:
o Plastic deformation happens due to high temperature, thus, the geometry of the cutting edge (nose radius) is
completely changed.
o Thermal deformation happens due to cyclic heating and cooling of the cutting edge; thus, thermal stresses and
cracks are developed on the cutting edge of the tool.
Possible Prevention Control:
o One reason why plastic deformation occur is because the hardness of the tool is not appropriate which means that
there is a wrong choice of materials. Thus, it can be prevented by means of using carbides and other hard grade
materials for cutting tool.
o One reason why thermal deformation occur is because of the use of poor thermal conductive materials as cutting tool
like tungsten carbide which again means that there is a wrong choice of materials. Thus, it can be prevented by
means of using good thermal conductive materials as tool material, like using a tougher grade of carbides.

Reference Literature: M. Depabriya.“Tool Failure: Definition and Types | Metal Cutting”. Your Article Library
(https://www.yourarticlelibrary.com/metallurgy/tool-failure-definition-and-types-metal-cutting/96098)

3. Application and operating conditions

The following is the failure that can be associated in terms of the application and operating conditions:
o built-up edge formation
Cause of Failure:
o Built-up edge means the adhesion of work material on the rake face of the cutting tool near the cutting edge. It occurs
frequently while machining softer or ductile metals at lower cutting speeds. For example, low carbon steel, aluminum
and copper.
Possible Prevention Control:
o Some reasons why built-up edge formation occur are because of the machining of mostly ductile metals like Al, Cu,
low carbon steel, etc, at low cutting speeds and also having longer contact time available between the tool and the
work material. Thus, these can be prevented by means of increasing cutting speeds, using larger positive rake
angles, using effective lubricant, and increasing feed rates.
 Reference Literature: M. Depabriya.“Tool Failure: Definition and Types | Metal Cutting”. Your Article Library
(https://www.yourarticlelibrary.com/metallurgy/tool-failure-definition-and-types-metal-cutting/96098)

4. Maintenance and Handling

The following are the failures that can be associated in terms of the maintenance and handling:
o breakage of insert
o microchipping of cutting edge
Causes of Failure:
o The breakage of insert includes either the breakage at the corner or a breakage right across.
o Chipping is the breaking away of a small piece from the cutting edge of the tool and this phenomenon is similar to
breaking the tip of a sharp pencil. Chipping results in a sudden loss of material unlike wear, which is gradual process.
Possible Prevention Control:
o Some reasons why breakage of insert occur are because of the lack of support at the corner and the tip is not seated
properly on tool holder. Thus, these can be prevented by means of using shims of smaller nose radius and also use a
square-shaped insert in place of a triangular-shaped insert. Hence, the insert and insert seat should be cleaned and
the tool holder should be replaced if damaged.
o One reason why microchipping of cutting edge occur is because of thermal fatigue (cyclic variations in temperature of
the tool as in interrupted cutting). Thus, it can be prevented by means of using proper coolant and lubricant.

Reference Literature: M. Depabriya.“Tool Failure: Definition and Types | Metal Cutting”. Your Article Library
(https://www.yourarticlelibrary.com/metallurgy/tool-failure-definition-and-types-metal-cutting/96098)

5. Material to be processed
The following is the failure that can be associated in terms of the material to be processed:
o notch wear
Cause of Failure:
o Due to uncontrolled metal chips from the material being processed, they may strike to the cutting edge of the tool and
produce a notch like wear.
Possible Prevention Control:
o Some reasons why notch wear occur are because of the uncontrolled chips going to the tool edge and that the
material to be processed is tougher than that of the tool material. Thus, these can be prevented by means of using a
chip breaker and also using a tougher tool material compared to that of the material to be processed.

Reference Literature: M. Depabriya.“Tool Failure: Definition and Types | Metal Cutting”. Your Article Library
(https://www.yourarticlelibrary.com/metallurgy/tool-failure-definition-and-types-metal-cutting/96098)