MATERIALS ENGINEERING
SEM2SESSION2011/2012
DrTutyAsmaAbuBakar O:075534707 Email:[email protected] C23422
SME3623
Whystudy?
Anengineer~willbeexposedtoadesignprobleminvolving materials proper*esrequired deteriora*onduringservice cost Knowledgeneeded materialscharacteris*cs Structurepropertyrela*onship Processingtechniques
Ableto: 1) explain,analyseanddierenSatethefailure mechanisms(fracture,creep,faSgue,corrosion)of materials 2) Applythetheoryoffracturemechanicsinfailure analysis 3) Relatestructure,properSesandprocessingofnon metallicmaterials(polymer,ceramic,composite)
Bytheendofthiscourse:
References:
CallisterW.D.,MaterialsScienceandEngineering AnintroducCon,7thediCon,Wiley,2007. SmithW.F.,FoundaConofMaterialsScienceand Engineering,4thediCon,McGrawHill,2006. FontanaM.G.,CorrosionEngineering,3rdediCon, McGrawHill,1991. DieterG.E.,MechanicalMetallurgy,3rdediCon, 1991.
Assessment
2xTest=40% Assignment=20% FinalExam=40% ATendance:80%
Topic/content
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. IntroducCon Metalfracture Metalcreep MetalfaCgue Metalwear Corrosion Polymer Ceramic Composite MaterialsselecConandcasestudies
Stressandstrain:Thesearesizeindependent measuresofloadanddisplacement,respecSvely. ElasScbehavior:Thisreversiblebehavioro[en showsalinearrelaSonbetweenstressandstrain. TominimizedeformaSon,selectamaterialwitha largeelasScmodulus(EorG). PlasScbehavior:ThispermanentdeformaSon behavioroccurswhenthetensile(orcompressive) uniaxialstressreachesy. DucSlity:TheplasScstrainatfailure.
Strength:abilitytosupportloadtension, compression,shear Hardness:ResistancetopenetraCon/ scratches Toughness:Abilitytoresistimpactforce.
Typeofloading
CommonStatesofStress
Simpletension:cable
F
Ao=crosssecSonal area(whenunloaded)
F
=
Ao
Skili[(photocourtesy P.M.Anderson)
Torsion(aformofshear):drivesha_
Ac M
2R
F s
Ao
F s
=
Ao
Note:=M/AcRhere.
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Simplecompression:
OTHERCOMMONSTRESSSTATES(1)
Ao
CanyonBridge,LosAlamos,NM
(photocourtesyP.M.Anderson)
BalancedRock,Arches NaSonalPark
(photocourtesyP.M.Anderson)
F
=
Ao
Note:compressive structuremember (<0here).
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StressStrainTesSng
Typicaltensiletest machine Typicaltensile specimen
extensometer
specimen
Adaptedfrom Fig.6.2, Callister7e.
gauge length
AdaptedfromFig.6.3,Callister7e.(Fig.6.3istakenfromH.W.Hayden, W.G.Moaf,andJ.Wul,TheStructureandProper*esofMaterials,Vol. III,MechanicalBehavior,p.2,JohnWileyandSons,NewYork,1965.)
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LinearElasScProperSes
ModulusofElasCcity,E: (alsoknownasYoung'smodulus) Hooke'sLaw:
=E
E
Linear
elasSc
simple tension test
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YoungsModuli:Comparison
Metals Alloys
1200 1000 8 00 6 00 4 00
Graphite Composites Ceramics Polymers /bers Semicond
Diamond
E(GPa)
2 00 100 8 0 6 0 4 0
109Pa
2 0 10 8 6 4 2 1 0.8 0.6 0.4 0.2
Sicarbide Tungsten Aloxide Molybdenum Sinitride Steel,Ni <111> Tantalum Sicrystal PlaSnum <100> Cualloys Zinc,Ti Silver,Gold Glass soda Aluminum Magnesium, Tin Concrete
G raphite
CFRE(||bers)* A ramidbersonly A FRE(||bers)* Glassbersonly G FRE(||bers)*
Carbon bersonly
GFRE*
Polyester PET PS PC
PP HDP E
PTF E LDPE
CFRE(bers) * AFRE(bers) *
CFRE * G FRE(bers)*
Epoxyonly
BasedondatainTableB2, Callister7e. Compositedatabasedon reinforcedepoxywith60vol% ofaligned carbon(CFRE), aramid(AFRE),or glass(GFRE) bers.
Wood(grain)
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TensileStrength,TS Maximumstressonengineeringstressstraincurve.
TS engineering stress
y
AdaptedfromFig.6.11, Callister7e.
Typical response of a metal
F=fractureor ulSmate strength Neckacts asstress concentrator
strain engineeringstrain
Metals:occurswhennoSceableneckingstarts. Polymers:occurswhenpolymerbackbonechainsare
alignedandabouttobreak.
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5000
Metals/ Alloys
Graphite/ Ceramics/ Semicond
Polymers
Composites/ bers
TensileStrength: Comparison
Tensile strength,TS
(MPa)
3000 2000 1000
Cbers Aramid b Eglassb AFRE (||ber) GFRE (||ber) CFRE (||ber)
Steel (4140) qt W (pure) Ti(5Al2.5Sn) aa Steel (4140) Sinitride Cu (71500) cw hr Cu (71500) Aloxide Steel (1020) Al (6061) ag Ti(pure) a Ta(pure) Al (6061) a Sicrystal Glasssoda Concrete Graphite
<100>
Diamond
300 200 100 40 30 20 10
RoomTemp.values
Nylon6,6 PC PET PVC PP H DPE LDPE wood(||ber) GFRE (ber) CFRE (ber) AFRE(ber)
wood (ber)
BasedondatainTableB4, Callister7e. a=annealed hr=hotrolled ag=aged cd=colddrawn cw=coldworked qt=quenched&tempered AFRE,GFRE,&CFRE= aramid,glass,&carbon berreinforcedepoxy composites,with60vol% bers.
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DucSlity
PlasSctensilestrainatfailure:
L
-
L
o
x100
%
EL
=
f
L
o
Engineering tensile stress,
AdaptedfromFig.6.13, Callister7e.
smaller%EL larger%EL
Ao
L o
Af
L f
Engineeringtensilestrain,
AnotherducSlitymeasure:
%RA =
Ao A f x 100 Ao
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Toughness
Energytobreakaunitvolumeofmaterial Approximatebytheareaunderthestressstrain curve.
E
ngineering
tensile
stress,
AdaptedfromFig.6.13, Callister7e.
smalltoughness(ceramics)
largetoughness(metals)
verysmalltoughness
(unreinforcedpolymers)
Engineeringtensilestrain,
Briflefracture:elasScenergy DucSlefracture:elasSc+plasScenergy
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Hardness ResistancetopermanentlyindenSngthesurface.
Largehardnessmeans:
resistancetoplasScdeformaSonorcrackingin compression. beferwearproperSes.
e.g., 10mmsphere applyknownforce measuresize ofindenta[er removingload
D
most plasScs brasses Alalloys
Smallerindents meanlarger hardness.
cuvng tools nitrided steels diamond
easytomachine steels lehard
increasinghardness
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Hardness:Measurement
Table 6.5
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TrueStress&Strain
Note:S.A.(crosssecSonalarea)changeswhensample stretched Truestress T = F Ai T = (1 + ) TrueStrain
T = ln( i o )
T = ln(1 + )
AdaptedfromFig.6.16, Callister7e.
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DesignorSafetyFactors
DesignuncertainSesmeanwedonotpushthelimit. Factorofsafety,N
working =
y N
O[enNis between 1.2and4
Example:Calculateadiameter,d,toensurethatyielddoes
notoccurinthe1045carbonsteelrodbelow.Usea factorofsafetyof5.
working =
220,000N d2 / 4
y N
d L o
5 d=0.067m=6.7cm
1045plain carbonsteel: y
=310MPa TS=565MPa F=220,000N
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