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    Fatigue & Creep in Engineering Fatigue & Creep in Engineering Materials Materials (Chapter 8) (Chapter 8)

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    Prabhat Singh
    This document summarizes key concepts about fatigue, creep, and failure in engineering materials from Chapter 8: 1) Fatigue failure can occur when a material is subjected to cyclic stresses even if the maximum stress is below the yield stress, and it accounts for around 90% of mechanical engineering failures. The number of cycles to failure decreases as the stress amplitude increases. 2) Creep is deformation that occurs in ductile materials subjected to stresses above around 40% of the melting temperature. It follows three stages - primary, secondary, and tertiary creep. The steady-state creep rate increases with increasing temperature and stress. 3) Failure mechanisms depend on temperature and stress levels. Fatigue is more likely under cyclic stresses

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    Fatigue & Creep in Engineering Fatigue & Creep in Engineering Materials Materials (Chapter 8) (Chapter 8)

    Uploaded by

    Prabhat Singh
    35 views27 pages
    This document summarizes key concepts about fatigue, creep, and failure in engineering materials from Chapter 8: 1) Fatigue failure can occur when a material is subjected to cyclic stresses even if the maximum stress is below the yield stress, and it accounts for around 90% of mechanical engineering failures. The number of cycles to failure decreases as the stress amplitude increases. 2) Creep is deformation that occurs in ductile materials subjected to stresses above around 40% of the melting temperature. It follows three stages - primary, secondary, and tertiary creep. The steady-state creep rate increases with increasing temperature and stress. 3) Failure mechanisms depend on temperature and stress levels. Fatigue is more likely under cyclic stresses

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    Lecture opt

    Original Title

    Lecture 14

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    This document summarizes key concepts about fatigue, creep, and failure in engineering materials from Chapter 8: 1) Fatigue failure can occur when a material is subjected to cyclic stresses even if the maximum stress is below the yield stress, and it accounts for around 90% of mechanical engineering failures. The number of cycles to failure decreases as the stress amplitude increases. 2) Creep is deformation that occurs in ductile materials subjected to stresses above around 40% of the melting temperature. It follows three stages - primary, secondary, and tertiary creep. The steady-state creep rate increases with increasing temperature and stress. 3) Failure mechanisms depend on temperature and stress levels. Fatigue is more likely under cyclic stresses

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    © All Rights Reserved
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    Download as pdf or txt
    35 views27 pages

    Fatigue & Creep in Engineering Fatigue & Creep in Engineering Materials Materials (Chapter 8) (Chapter 8)

    Uploaded by

    Prabhat Singh
    This document summarizes key concepts about fatigue, creep, and failure in engineering materials from Chapter 8: 1) Fatigue failure can occur when a material is subjected to cyclic stresses even if the maximum stress is below the yield stress, and it accounts for around 90% of mechanical engineering failures. The number of cycles to failure decreases as the stress amplitude increases. 2) Creep is deformation that occurs in ductile materials subjected to stresses above around 40% of the melting temperature. It follows three stages - primary, secondary, and tertiary creep. The steady-state creep rate increases with increasing temperature and stress. 3) Failure mechanisms depend on temperature and stress levels. Fatigue is more likely under cyclic stresses

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    of 27

    Lecture 14

    Fatigue & Creep in Engineering


    Materials
    (Chapter 8)

    Chapter 8 - 1

    Fatigue
    Fatigue = failure under applied cyclic stress.
    specimen compression on top
    bearing

    bearing

    motor

    counter

    flex coupling
    t
    tension
    i on b
    bottom
    tt

    Stress varies with time.

    -- key parameters are S,


    S m, and
    cycling frequency

    max
    m

    min

    time

    Key points: Fatigue...

    --can cause part failure, even though max < y.


    --responsible
    ibl ffor ~ 90% off mechanical
    h i l engineering
    i
    i ffailures.
    il
    Chapter 8 - 2

    Fatigue: Definitions
    Asymmetric
    Symmetric

    Random
    d

    Chapter 8 - 3

    Fatigue: Definitions

    Chapter 8 - 4

    --no fatigue if S < Sfat

    For some materials,


    there is no fatigue
    limit!

    S = stress aamplitude

    Fatigue limit, Sfat:

    S = stress amplitude

    Types of Fatigue Behavior


    unsafe

    case for
    steel (typ.)

    Sfat
    safe
    10 3

    10 5
    10 7
    10 9
    N = Cycles to failure

    unsafe

    case for
    Al (typ.)

    safe
    10 3

    10 5
    10 7
    10 9
    N = Cycles to failure
    Chapter 8 - 5

    Ex: Fatigue in 7075-T6 Aluminum


    Alloy

    Chapter 8 - 6

    Rate of Fatigue Crack Growth


    Crack grows incrementally

    da
    m
    K
    dN

    typ. 1 to 6

    ~ a

    increase in crack length per loading cycle

    Failed rotating shaft

    crack origin

    -- crack grew even though


    Kmax < Kc
    -- crack grows faster as
    increases
    crack gets longer
    loading freq. increases.

    Chapter 8 - 7

    Fatigue Failure in Ductile Materials


    (Aluminum)

    Chapter 8 - 8

    Fatigue Failure in Brittle Material

    Chapter 8 - 9

    Importance of Mean Stress

    Chapter 8 - 10

    1. Impose compressive
    surface stresses
    (to suppress surface
    cracks from growing)

    S = stress a
    amplitude

    Improving Fatigue Life

    --Method 1: shot peening

    near zero or compressive m


    moderate tensile m
    Larger tensile m
    N = Cycles to failure

    --Method 2: carburizing

    shot

    putt
    surface
    into
    compression

    2. Remove stress
    concentrators.

    Adapted from
    Fig. 8.24, Callister &
    Rethwisch 8e
    8e.

    bad
    bad

    C-rich
    C
    rich gas

    better
    better

    Adapted from
    Fig. 8.25, Callister &
    Rethwisch 8e.
    Chapter 8 - 11

    Effect of Surface Compressive


    Stresses

    Chapter 8 - 12

    Effect of Surface Compressive


    Stresses
    Hardened
    Case depth by
    Carburization (or
    Nitriding)

    In compression

    Micro-indentation
    marks

    Chapter 8 - 13

    Environmental Effects

    Thermal cycle..stress cycle..Thermal fatigue.


    Chapter 8 - 14

    Creep
    Sample deformation at a constant stress () vs. time

    Primary Creep: slope (creep rate)


    decreases with time.
    Secondary Creep: steady-state
    i.e., constant slope /t)
    Tertiary Creep: slope (creep rate)
    increases with time, i.e. acceleration of rate.

    Adapted from
    Fig. 8.28, Callister &
    Rethwisch 8e.
    Chapter 8 - 15

    Creep: Temperature Dependence


    Occurs at elevated temperature, T > 0.4 Tm (in K)

    tertiary
    primary

    secondary

    elastic

    Chapter 8 - 16

    Secondary Creep
    Strain rate is constant at a given T,
    -- strain hardening is balanced by recovery
    stress exponent (material parameter)

    Qc

    s K 2 exp

    RT
    n

    strain rate
    material const.

    applied stress
    Stress
    s (MPa)

    S
    Strain rate
    increases
    g
    with increasing
    T,

    activation energy for creep


    ( t i l parameter)
    (material
    t )

    200
    100

    427C
    538C

    40
    20
    10

    10 -2
    10 -1
    Steady state creep rate

    649C
    1
    s (%/1000hr)

    Chapter 8 - 17

    A better & more informative


    Creep Equation
    Material constant
    depending on
    creep mechanism
    h i

    Grain size

    Activation energy
    gy for
    Self-diffusion

    Applied stress

    m & b depend on the creep mechanism


    Chapter 8 - 18

    Mechanisms of Creep
    The mechanism of creep depends on temperature and
    stress. The various methods are:
    Bulk diffusion (Nabarro-Herring creep)
    Dislocation climb -here the strain is actually
    accomplished by climb
    Climb-assisted glide here the climb is an enabling
    mechanism,, allowingg dislocations to gget around obstacles
    Grain boundary diffusion (Coble creep)
    Thermally activated glide e.g., via cross-slip
    Chapter 8 - 19

    Mechanisms of Creep
    p
    Things to know
    Dislocations related creep.. m = 4-6, and b = 0. It has a strong
    dependence on the applied stress and no grain size dependence.
    Nabarro Herring Creep (Bulk
    Nabarro-Herring
    (B lk Diffn)..m
    Diffn)
    = 1,
    1 and b = 2.
    2 Atoms
    At
    diffuse through the lattice causing grains to elongate along the stress axis; it
    creep has a weak stress dependence and a moderate grain size dependence.
    Coble Creep (Grain boundary diffusion).
    diffusion) m = 1,
    1 and b = 3.
    3 Atoms diffuse
    along grain boundaries to elongate the grains along the stress axis. This causes
    Coble creep to have a stronger grain size dependence than Nabarro-Herring
    creep.
    p Here,, Q(g
    Q(grain boundaryy diffusion)
    ff
    ) < Q(self
    Q( f diffusion),
    ff
    ), Coble creepp
    occurs at lower temperatures than Nabarro-Herring creep.
    Thermally activated glide e.g., via cross-slip
    Chapter 8 - 20

    Creep Failure
    Failure: along grain boundaries.
    g.b. cavities
    applied
    stress

    Chapter 8 - 21

    Creep Failure in S-590 Alloy

    fig_08_31

    Chapter 8 -

    Prediction of Creep Rupture Lifetime


    Estimate rupture time
    S-590 Iron, T = 800C, = 20,000 psi

    Ti
    Time
    to
    t rupture,
    t
    tr

    20
    10
    data for

    Strress (103 psi)

    100

    T (20 log t r ) L
    function of
    applied stress
    time to failure (rupture)

    temperature

    S-590 Iron
    12

    16

    20

    24

    1
    28

    (1073 K )(20 log t r ) 24 x103

    103 L (K-h)

    Ans: tr = 233 hr
    Chapter 8 - 23

    Estimate the rupture time for


    S 590 Iron,
    S-590
    Iron T = 750C,
    750C = 20,000
    20 000 psi
    Solution:

    T (20 log t r ) L
    20

    function of
    applied stress
    time to failure
    fail re (rupture)
    (r pt re)

    temperature

    10
    data for

    (1023 K )(20 log


    g t r ) 24 x10 3

    Stre
    ess (103 p
    psi)

    100

    Time to rupture, tr

    S-590 Iron
    1
    12

    Ans: tr = 2890 hr

    16

    20

    24

    28

    103 L (K-h)

    Chapter 8 - 24

    To Increase Creep
    p Rupture
    p
    Resistance:
    1) Use large grain size material, highly
    grains or a single
    g crystal.
    y
    directions g
    2) Use heavy alloying (grain boundary
    g dislocation drag
    g etc.))
    drag,
    3) Use high melting point material
    g modulus of elasticity
    y
    4)) Use high
    material
    Make sure its justifiable ($$$$$...)
    Chapter 8 - 25

    SUMMARY
    Engineering materials not as strong as predicted by theory
    Flaws act as stress concentrators that cause failure at
    stresses lower than theoretical values.
    Sharp corners produce large stress concentrations
    and
    d premature
    t
    failure.
    f il
    Failure type depends on T and :
    -For
    For simple fracture (noncyclic and T < 0.4Tm), failure stress
    decreases with:
    - increased maximum flaw size,
    - decreased T,,
    - increased rate of loading.

    - For fatigue (cyclic :

    - cycles
    y
    to fail decreases as increases.

    - For creep (T > 0.4Tm):

    - time to rupture decreases as or T increases.

    Chapter 8 - 26

    ANNOUNCEMENTS
    Reading: Study chapter 8 thoroughly. Study the
    solutions of Chapter 8 problems very well. Do not
    memorize but try understanding the concepts
    behind the solutions

    Chapter 8 - 27

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