NANYANG TECHNOLOGICAL UNIVERSITY M6102 Advanced Materials Engineering LECTURE NOTES (Modules 1 & 2) 2005-06 (I) Sunil C. Joshi mscjoshi@ntu.edu.sg; #6790 5954Teaching Plan “Week | Lecture Topic 1 “| 0M | Generai/ Mechanical Fundamentals (3hrs) [2 Metallurgical Fundamentals 2 3 Alloy Steels (3 hrs) [4 ‘Superalloys & Composites 3 5 Corrosion & Wear Failures i (3hrs) [6 Fatigue, High Temperature & Other Failures 4 7 Material Selection in Design _| (3hrs) [8 Design Constraints & Implications 5 9 ‘Case Studies & Revision (Material (hrs) Selection) _ 10 |Case Studies & Revision (Failure Analysis) 2005-06 (#) Sunil C. Joshi mscjoshi@ntu.edu.sg; #6790 5954ees e102 Adraneo Maes Engine MECHANICAL FUNDAMENTALS, {In strength of materials approach: I is always sured thatthe body, which i being analyzed it continuous, bomogensous, ard isotropic. A continous Bod fs one, which does fot contain voide or empty spaces of any kind ‘A body is homogeneous if it has identieal properties at all points. A body is considered to be Isotropic with respect to some property when that propery does not vary with dcecion or ‘orientation. Stes in the materia is assumed tobe proportional to sain. Also itis assumed that the member being salyzed isin equilibrium. The equations of static equilibrium are applied to the forces acting on some part of the body in order to obian relationship between the externa forces acting onthe member and the inven forces resisting he action ofthe extemal loa fn realty: Engineering materials such as steel, cat icon, std slarinum may appear to meet the above ‘conditions when viewed on a gross scale. However, ii ealy apparent when they are viewed though a microscope th they are anything but Fomogenoous and izovopic. Most engineering metals ae made up of mare than one phase, with diferent mechenical properties, such that on Iniro seale they are heterogeneous. Fuster, even a single-phase metal will usually exhibit chemical segregation, and therefore she properties will not be ideaticel ftom point fo poi Motats tre made up of an aggregate of erstl gains having different properties in diferent ‘eojtallographic directions. The reason why the equations of strength of materials describe the behavior of eal metas i tha, in general, the crystal grins ace so small that, fora specimen of any macroscopic volume, the materials are sttisieally homogeneous and isotropic. However, ‘When mills are severely deformed in a particular dtection, as in rolling o forging, the rmechacieal properties may be anisotropic on a macro seale Other examples of anisotropic properties are Sber-reinforeed composite materials and single crystals. Lack of eonfinalty msy be presen in porous eastings or powder metallurgy pars and, on an atom level at defects such as vacances and dislocations Elastic and plastic bebavior of materials ‘All solid matenal ean be deformed when subjected to extemal losd. Upto cera limiting loads 2 solid will recover is original dimensions when he load is removed, The recovery of the ‘original dimensions of a deformed body when the lod is removed is know as elastic behavior. "The linitng lad beyond which the material no longer Eehaves elastically isthe elastic fit. the elastic limt is exoeoded, the body will experience e perranent set or deformation when the load is removed, A body which iz permanently deformed ig said to have undergone plastic deformation, Once plastic deformation begin, only a small increase in sees usualy causes & relatively large addtional deformation, This process of relatvely easy deformation is called 005.0681) Sut © at Fundamental: |Noss M6102 Adsened Motels Egesing yielding, and the value of stress where ths Behavior begins tobe important for s given material is Called the yeld strength For most materials, 2s long as the load does nat exceed the elastic Limit, the deformation is proportional to the load expressed ss Hooke's law (erase is proportional to strait). Elastic. Aeformaions in metals are quite small and require very seosive instruments for th ‘measurement, For rnst meals thece is only a rather narow rsoge of loads over whick Hooke’ law src applies. This is, however, primarily of acaderce imporance, Hook's lw remains & ite valid elatonskip for engineering design, However it dots not necessarily follow that all” materials which behave elastically will have a linear suess strain relationship. Rubber isan example of s material with a conlnear stresz-stain relationship that stil falisfies the definition ‘of =n elastic rater Large plastic deformations ae often harmful ang virusly always constitute falco For example, collapse of a stect ‘ridge or building during un earthquake ‘ould cccar due te plastic deformation, However, plastic deformation can be relavely “small but sill enue realfinction of a component. For ‘example, in a rating sha, slight ‘permanent bend results in unbalanced retain, which in wm may cause vibration and perhaps carly failure ofthe bearings supporting he sha. ce ‘uette tanner, abd those that fracture without very tne plsticGelormaion bekave ina brite ‘manner. Ductile behavior occurs for many metal, such at low-stength sels, copper, end etd, snd for some plastic. Britle behavior occur for pass, store, asl pase, end yome meal, Sch asthe high-svength steel used to make a file. ‘Tension tess are often employed to seuss the stength and ductility of materiel. The ultimate senile sength 0, whichis the highest ses reached before frsture, is obtained tlong with the ‘fl stengia ard the suain at fsctuve, ¢,. The later isa measure of uetlty and is ustlly expressed 26a percentage, being called the percent elongation. Masrials having high value of| 1, and é, are sad tobe tough, and (ough materials ere generally desirable for we in desig. 72005-0681) Swe nt Fundam: 2Notes M6102 Advanced Mars Engi A completely brite material would facture tlmostat the elastic Kini, while a brie meta, such as white cast iro, shows slight plasticity Defore flactue, Adequate ductility is an Inmporeantcoasideration, bocaus i alles the material (9 redietrbule localized stesses. ‘When localized stresses al notches snd other tecidenal sees concentrations do not hve (9 ‘be considered iis possible to design fr state situations on the basis average sresses. However, with brite materials, localized streses conic fo build up when there Is mo Toeal yielding. Finally, a crack forms atone ot sore points of sess concentration, and it spreads rapidly over te section. 7am Wis important to note that brtlenes isnot sn solute property of a metel, Metal such es tungsten, which is brite at room temperature, i ‘uctile st an elevated temperatuce. A. meal, whichis Britle in tension, may be ductile under ‘compression. Furtetmore, a metal which is duet in tension a¢ room temperature can become brite in the presence of notches, low temperature high rues of leading, or embrdling agens such as hydeogen, stress concent ‘Nominal sires ie the average stess (5. j4= Pvt for axial loading and Sa Mel Mow! 2y ne 12)=6Mfw't in lastis ‘bending. However, if yielding occurs, the actual stress sistibation becomes sonlincss, and the sist (oat the edge of the member is no longer egual to 8. For notched members, Sis conventionally esleleed from the net area remicing aller removal of cha notch (The term notch is used to indies any sess raise, including hoes, grooves, fillets, ec.) ‘At some region ner the discontinuity the sires will be higher than the sverage stress. Due to the stress raiser cffect, S needs to be mukipied by an elastic siress concentration factor, k to obtain the peak sess (10 ylding) atthe notch. in edition to producing a stress notch alo creates a localizes condition of biaxial or wiaxal sess. “The elfest of a stress taser is much more pronounced in a brite muterial than in a ductile tateial. Ina ductile materia, plastic deformation occurs when the yield sess is exceeded atthe point of maximum sess. Farber inzoate in Toad produces a local increase in evain at the 2005.05 ;St ‘Sunile Jos Fudamerta: 3