Introduction to Material Failure
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Questions and Answers

What primarily causes the amplification of tensile stress at the tip of a small incision or notch?

  • The environmental conditions during packaging
  • The type of material used in packaging
  • The applied tensile stress (correct)
  • The size of the incision or notch
  • What type of failure does creep represent?

  • Brittle failure
  • Tensile failure
  • Dynamic failure (correct)
  • Static failure
  • Which case study illustrates brittle fracture due to crack propagation?

  • A bridge collapse during a storm
  • An oil tank fracturing around its girth (correct)
  • A water pipe bursting in freezing temperatures
  • A commercial aircraft experiencing explosive decompression
  • What contributed to the metal fatigue in the Boeing 737-200 aircraft?

    <p>Compression and decompression of the cabin chamber (C)</p> Signup and view all the answers

    What is one of the characteristics of ductile fractures?

    <p>They exhibit significant energy absorption before failure (B)</p> Signup and view all the answers

    What environmental factor aggravated the metal fatigue in the Boeing 737-200?

    <p>Humid and salty coastal conditions (D)</p> Signup and view all the answers

    What is the primary distinction between static failures and dynamic failures?

    <p>Static failures occur under constant load while dynamic failures occur under fluctuating loads (A)</p> Signup and view all the answers

    How did the small notch on the oil tank contribute to its failure?

    <p>It amplified stress leading to crack formation (D)</p> Signup and view all the answers

    What is the primary cause of deformation in elastic failure?

    <p>Return to original shape after load removal (D)</p> Signup and view all the answers

    Which material failure type is characterized by non-recoverable deformation?

    <p>Plastic failure (B)</p> Signup and view all the answers

    What primarily distinguishes static from dynamic loading in fracture types?

    <p>Rate of stress application (B)</p> Signup and view all the answers

    What type of fracture involves varying cycle and loading magnitude?

    <p>Fatigue fracture (D)</p> Signup and view all the answers

    Which of the following best describes fretting corrosion?

    <p>Induced by repetitive mechanical contact (D)</p> Signup and view all the answers

    What happens to a piece of paper when it is notched before applying force?

    <p>It breaks more easily than an intact paper (B)</p> Signup and view all the answers

    In the context of tensile tests, what does a simple fracture indicate?

    <p>Separation into pieces due to imposed stress (B)</p> Signup and view all the answers

    Which factor can accelerate the process of creep in materials?

    <p>Elevated temperatures (C)</p> Signup and view all the answers

    What determines the fracture pattern of a folded paper compared to an intact paper?

    <p>It starts at the fold and continues on that line (B)</p> Signup and view all the answers

    Which of the following statements about ductile and brittle fracture is correct?

    <p>Ductile fractures can show significant plastic deformation before failure. (A)</p> Signup and view all the answers

    What type of loading is primarily associated with fatigue failure?

    <p>Dynamic loading over multiple cycles (C)</p> Signup and view all the answers

    What is a potential consequence of excessive deformation in a rubber band?

    <p>Loss of functionality (B)</p> Signup and view all the answers

    Under which condition would a material exhibit the least resistance to fracture?

    <p>When notched or damaged (D)</p> Signup and view all the answers

    How does relaxation occur in materials over time?

    <p>Constant load shows decreasing deformation (D)</p> Signup and view all the answers

    What characterizes the fracture surface of ductile materials?

    <p>Irregular and fibrous appearance (D)</p> Signup and view all the answers

    Which materials are noted for showing nearly 100% necking before fracture?

    <p>Lead and pure gold (B)</p> Signup and view all the answers

    The crack in ductile materials grows primarily due to which mechanism?

    <p>Microvoid coalescence (C)</p> Signup and view all the answers

    What does a brittle fracture typically lack?

    <p>Plastic deformation (B)</p> Signup and view all the answers

    Which type of fracture exhibits a characteristic 'cup-and-cone' surface?

    <p>Ductile fracture (A)</p> Signup and view all the answers

    The direction of crack motion in brittle materials is primarily:

    <p>Perpendicular to applied tensile stress (A)</p> Signup and view all the answers

    What is one of the key indicators of a brittle material's fracture surface?

    <p>Flat surfaces with chevron markings (C)</p> Signup and view all the answers

    How can ductility in certain metals be improved?

    <p>By elevating their temperatures (C)</p> Signup and view all the answers

    What is a feature of brittle fracture in amorphous materials?

    <p>Low energy absorption (D)</p> Signup and view all the answers

    What happens during the initial necking stage in ductile fracture?

    <p>Microvoids begin to form (B)</p> Signup and view all the answers

    How do the fracture surfaces of very hard and fine-grained metals typically appear?

    <p>Shiny and smooth with visible patterns (D)</p> Signup and view all the answers

    What term is used to describe the fracture process that passes through the grains in brittle materials?

    <p>Transgranular (C)</p> Signup and view all the answers

    What defines the distinctive pattern of a brittle fracture?

    <p>Ridges radiating from crack's origin (C)</p> Signup and view all the answers

    What happens after the microvoids coalesce in ductile fracture?

    <p>An elliptical crack forms (C)</p> Signup and view all the answers

    Flashcards

    Material Failure

    The failure of a material due to stress, environmental conditions or flaws.

    Ductile Fracture

    A type of fracture characterized by significant plastic deformation before failure.

    Brittle Fracture

    A type of fracture that occurs without any significant plastic deformation; sudden and rapid breaks.

    Crack Propagation

    The growth of a crack in a material under applied stress, often leading to failure.

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    Creep

    The slow deformation of materials under sustained load over time, often at high temperatures.

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    Stress Relaxation

    The decrease in stress in a material over time under constant strain.

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    Fatigue

    The weakening of a material caused by repeated cycles of stress, eventually leading to failure.

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    Corrosion

    The gradual destruction of materials, often metal, due to chemical reactions with their environment.

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    Ductility

    The ability of a material to undergo significant plastic deformation before rupture.

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    Necking

    A stage in plastic deformation where the material becomes localized in a narrow region before fracture.

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    Microvoids

    Small cavities formed within the material during deformation leading to fracture.

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    Cup-and-Cone Fracture

    A type of ductile fracture characterized by a cup-shaped surface and a conical projection.

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    Chevron Markings

    V-shaped markings found on brittle fracture surfaces, indicating crack initiation.

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    Cleavage

    The process of fracture where cracks propagate along specific crystallographic planes in brittle materials.

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    Transgranular Fracture

    A type of fracture that passes through the grains of a material.

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    Fracture Surface Patterns

    Distinctive visual features on a fracture surface indicating the type of failure (ductile vs. brittle).

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    Energy Absorption in Fractures

    The capacity of a material to absorb energy before fracture occurs.

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    Moderate Ductility

    Refers to materials that exhibit a certain degree of ductility, allowing for necking and some deformation before fracture.

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    High Ductility Examples

    Materials like pure gold and lead that can show nearly 100% necking before fracture.

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    Flat Fracture Surfaces

    The characteristic surface of a brittle fracture, showing little plastic deformation.

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    Maintenance Program

    A system used to ensure aircraft safety by detecting fatigue damage.

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    Material Failure Types

    Categories of failures in materials, primarily deformation and fracture.

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    Deformation Failure

    Failure due to changes in shape under stress, which may be elastic or plastic.

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    Elastic Deformation

    Temporary change in shape; returns to original form after load removal.

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    Plastic Deformation

    Permanent change in material shape due to excessive stress.

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    Creep Failure

    Slow, time-dependent deformation under constant stress over time.

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    Fracture Types

    Breaks in materials classified as ductile or brittle based on loading type.

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    Dynamic Loading

    Changing forces applied to materials, leading to fatigue and eventual failure.

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    Fretting Corrosion

    Wear and corrosion due to repeated mechanical contact and small movements.

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    Simple Fracture

    Separation of a material into parts due to imposed static stress.

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    Notched Paper Experiment

    Experiment demonstrating how notches weaken material for easier breaking.

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    Folded Paper Experiment

    Demonstrates how folding impacts the force needed to break paper.

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    Tensile Test

    A test to measure material strength by applying tension until it breaks.

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    Study Notes

    Introduction to Material Failure

    • Material failure can be static (ductile, brittle) or dynamic (creep, stress relaxation, fatigue)
    • Applied tensile stress amplifies at notch/incision tips, making it easier to tear materials
    • Material failures have caused significant disasters throughout history, highlighting the importance of understanding them.

    Case Studies of Material Failure

    • 300-meter long oil tank fractured due to crack propagation originating from a small flaw, amplified by stress at sea
    • Boeing 737-200 experienced explosive decompression. Metal fatigue, exacerbated by crevice corrosion from a humid and salty coastal environment
    • Stress cycling of the fuselage from compression and decompression during short hops
    • Proper maintenance would have detected and prevented this accident.

    Material Failure Types

    • Mechanical failures categorized into deformation-related (time-dependent, time-independent) and fracture (static, dynamic).
    • Elastic deformation can be a type of failure, as it may fail to achieve desired goals. Examples include a fork bending on wood. Rubber band stretching beyond ability or plastic deformation.
    • Time-dependent failures include creep (increasing deformation under constant stress) and stress relaxation (reducing load under constant deformation). These are sensitive to elevated temperatures.
    • Static fracture is categorized into ductile and brittle.
    • Dynamic failures include fatigue (repeated loading), fretting corrosion (repetitive mechanical contact). Example: hip joint implant, vibration-related scenarios.

    Simple Fracture

    • Simple fracture is the separation of a body into pieces. Due to imposed static stress/constant/minimal changing stress/slow varying with low temperature.
    • Categorized into ductile (substantial plastic deformation, high energy absorption) and brittle (little or no plastic deformation, low energy absorption).
    • Ductile materials have inclined fracture planes; brittle materials have flat fracture surfaces.
    • Ductility is relative and depends on temperature, strain rate, stress state.
    • Burst pipes: cast iron/brass (brittle) fracture into small pieces with little deformation, whereas ductile pipes deform significantly before fracturing.

    Stages of Ductile Fracture

    • Flaws are inevitable.
    • Five stages from necking to fracture: initiation of microvoids/cavities - enlargement and coalescence - formation of crack - crack propagation to exterior - rupture via shear deformation.
    • Shear deformation occurs at 45 degrees to the tensile loading axis(maximum shear stress) yielding a cup-and-cone fracture.
    • Interior regions show irregular/fibrous plastic deformation.

    Features of Brittle Fracture

    • Brittle fracture happens with negligible visible deformation, rapid crack propagation, and flat fracture surfaces.
    • Fracture surfaces have distinctive patterns like V-shaped markings (chevron pattern), radiating lines/ridges, which point back towards the origin of initiation of crack
    • Patterns diminish with reducing grain size (increasing stiffness) and diminish in amorphous material due to the random microstructure.
    • Crack propagation in crystalline materials aligns along specific crystallographic planes (cleavage) through grain (transgranular).
    • Sometimes crack propagation is along grain boundaries (intergranular).

    In-Class Paper Fracture Demonstration

    • Demonstrates how notches/folded papers make it easier to tear paper
    • Fracture patterns differ depending on type of treatment to paper.

    In-class Quiz

    • Revision of previous module/term.

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    Description

    This quiz explores the various types of material failure, including static and dynamic failures. It discusses real-world case studies, such as the Boeing 737-200 incident and the oil tank fracture, emphasizing the importance of material integrity and maintenance. Understand the mechanics behind material failures and their implications in engineering safety.

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