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BKTK-2010, Failure in Material Constructions

The document discusses various failure modes in material constructions including: 1) Failure can occur due to inadequate design, improper material selection, or improper processing. Failure is difficult to avoid completely. 2) Materials can fail through either brittle or ductile fracture depending on factors like temperature and stress concentration. Brittle fractures propagate faster with little deformation while ductile fractures involve more deformation. 3) Fatigue failure can occur from repeated or fluctuating stresses even below the material's yield strength and is influenced by factors like the stress amplitude, mean stress, surface condition, and environment.

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Sorulay Way-ney
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© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
84 views

BKTK-2010, Failure in Material Constructions

The document discusses various failure modes in material constructions including: 1) Failure can occur due to inadequate design, improper material selection, or improper processing. Failure is difficult to avoid completely. 2) Materials can fail through either brittle or ductile fracture depending on factors like temperature and stress concentration. Brittle fractures propagate faster with little deformation while ductile fractures involve more deformation. 3) Fatigue failure can occur from repeated or fluctuating stresses even below the material's yield strength and is influenced by factors like the stress amplitude, mean stress, surface condition, and environment.

Uploaded by

Sorulay Way-ney
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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FAILURE IN MATERIAL

CONSTRUCTIONS

BKTK-2010, Failure in material constructions


BKTK-2010, Failure in material constructions
The cause of failures
• Inadequate equipment design
• Improper material construction selection
• Improper material construction processing
• Miss-use in equipment operation

Failure in material constructions is very difficult to avoid.

BKTK-2010, Failure in material constructions


Continuous plastic deformation

Æ brittle fracture
Stress, σ

Æ ductile fracture

Strain, ε

BKTK-2010, Failure in material constructions


Crack & Propagation
• Ductile fracture (“patahan bahan liat”)
Æ Stress concentration is followed by crack formation
Æ Crack propagation is relatively slow
Æ Large plastic deformation before fracture

• Brittle fracture (“patahan bahan getas”)


Æ Stress concentration is followed by crack formation
Æ Crack propagation is relatively fast
Æ Small plastic deformation before fracture

BKTK-2010, Failure in material constructions


Ductile vs Brittle Fractures

Highly ductile Highly brittle

Cup and cone ductile fracture

BKTK-2010, Failure in material constructions


Ductile vs Brittle Fractures

Ductile fracture
• Cup and cone fracture Æ effects of shear stress
• Fracture surface has a fibrous appearance

Brittle fracture
• Fracture surface is smooth and shinny Æ amorphous mat’l
• Inter-granular surface (cleavage) Æ crystalline mat’l
Fracture cracks occur at grain boundaries (trans-granular /
trans-crystalline)

BKTK-2010, Failure in material constructions


Ductile Fracture to Brittle Fracture
Fracture characteristic is influenced by temperature

A283 steel

ductile

brittle transition

BKTK-2010, Failure in material constructions


Fatigue
• Failure due to dynamic and fluctuating (repeated) stress
• Plastic deformation causes a ductile material more brittle
• Fracture can occur at loads lower than yield strength
• Most of failures in metallic material constructions

σmax
σa
tension

σr
σm
Stress

time
compression

0
σmin

σa : stress amplitude
σm : mean stress
σr : range of stress

BKTK-2010, Failure in material constructions


Fatigue (2)
Diagram S-N (Wohler)
max stress amplitude ≈ 2/3 tensile strength
Stress amplitude

fatigue limit / endurance limit


Steels Æ 35 – 60% tensile strength

Cycles to failure, N
max stress amplitude ≈ 2/3 tensile strength
Stress amplitude

Fatigue life (Nf) : number of cycles to cause


failure at a specific stress level

Fatigue
strength at
Nonferrous materials have no fatigue limit
N1
N1 cycles
Cycles to failure, N
BKTK-2010, Failure in material constructions
Factors influencing fatigue life
Mean stress

σm3 > σm2 > σm1


Stress amplitude, σa

σm1
σm2
σm3

Cycles to failure, N

BKTK-2010, Failure in material constructions


Factors.... (2)

Surface effect
Fatigue can be proceeded by cracks on surfaces
A rough surface Æ stresses Æ cracks

Thermal stresses
At elevated temperature by fluctuating thermal stress (expansion-
contraction) Æ thermal fatigue

Chemical attack (corrosion)


Corrosion results in small pits that cause surface rough Æ lead to surface
stresses Æ crack Æ fatigue

BKTK-2010, Failure in material constructions


Creeping
Plastic deformation at elevated temperature due to a static (constant)
mechanical load Æ time dependent
• Amorphous polymer (rubbers, plastics)
• Metal Æ T = 0.4 Tm

BKTK-2010, Failure in material constructions


Creeping (2)
• Instantaneous deformation Æ elastic
• Primary creep
Æ Transient
Æ creeping rate (dε/dt) decreases
Æ increase in creep resistance or strain hardening

• Secondary creep
Æ Steady state
Æ creeping rate (dε/dt) is constant
Æ strain hardening dan recovery (due to atomic diffusion at elevated
temperature) is in equllibrium

• Tertiary creep
Æ transient
Æ creeping rate (dε/dt) increases
Æ microstructure change; separation of grain boundaries, formation of voids

BKTK-2010, Failure in material constructions


Creeping (3)

T3 > T2 > T1
T3 atau σ3
σ3>σ2>σ1
Steady state creep:
T2 atau σ2
Creep strain

dε
= εs = Kσ n
T1 atau σ1 dt
⎛ − Qc ⎞
′
K = K exp⎜ ⎟
⎝ RT ⎠

T < 0.4Tm

time

BKTK-2010, Failure in material constructions


Creeping (4)

BKTK-2010, Failure in material constructions


Creep modulus
Indicating how a material experiencing creep phenomenon
Constant stress
σ0
Ec (t ) =
ε (t )
Time dependent strain
Time dependent creep modulus
Ec is temperature dependent and the value decreases as temperature
increases
Creep resistant materials have properties:
• High melting point
• High creep modulus
• Large grain size for crystaline materials

BKTK-2010, Failure in material constructions

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