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Lecture 8
Materials Science and
Engineering

International University
National University – HCMC
Dr. Nguyen Dinh Uyen
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Chapter 8
Mechanical Failure

Dr. Uyen Nguyen

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Chapter 8: Mechanical Failure

ISSUES TO ADDRESS...
• How do flaws in a material initiate failure?
• How is fracture resistance quantified; how do different
material classes compare?
• How do we estimate the stress to fracture?
• How do loading rate, loading history, and temperature
affect the failure stress?

Ship-cyclic loading Computer chip-cyclic Hip implant-cyclic

from waves. thermal loading. loading from walking.
Adapted from chapter-opening Adapted from Fig. 22.30(b), Callister 7e. Adapted from Fig. 22.26(b),
photograph, Chapter 8, Callister 7e. (by (Fig. 22.30(b) is courtesy of National Callister 7e.
Neil Boenzi, The New York Times.) Semiconductor Corporation.)
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Fracture mechanisms

Two types of fracture for metal:

1. Ductile fracture
1. Occurs with plastic deformation
2. Brittle fracture
1. Little or no plastic deformation
2. Catastrophic

https://www.youtube.com/watch?v=LRKzOui_kS8&t=164s
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Ductile vs Brittle Failure for Metal

• Classification:
Fracture Very Moderately
Brittle
behavior: Ductile Ductile

Adapted from Fig. 8.1,

Callister 7e.

%AR or %EL Large Moderate Small

• Ductile Ductile: Brittle:
fracture is usually warning before No
desirable! fracture warning
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Example: Failure of a Pipe

• Ductile failure:
--one piece
--large deformation
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Example:

• Brittle Failure:
--no warning
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Moderately Ductile Failure

• Evolution to failure:
void void growth shearing
necking and linkage fracture
nucleation at surface


• Resulting 50
50mm
mm
fracture
surfaces
(steel)
100 mm
particles From V.J. Colangelo and F.A. Heiser, Fracture surface of tire cord wire
serve as void Analysis of Metallurgical Failures (2nd loaded in tension. Courtesy of F.
ed.), Fig. 11.28, p. 294, John Wiley and Roehrig, CC Technologies, Dublin,
nucleation Sons, Inc., 1987. (Orig. source: P. OH. Used with permission.
sites. Thornton, J. Mater. Sci., Vol. 6, 1971,
pp. 347-56.)
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Ductile vs. Brittle Failure

cup-and-cone fracture brittle fracture

Adapted from Fig. 8.3, Callister 7e.

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Brittle Fracture Surfaces

• Intergranular • Intragranular
(between grains) 304 S. Steel (within grains)
(metal) 316 S. Steel
Reprinted w/permission (metal)
from "Metals Handbook", Reprinted w/ permission
9th ed, Fig. 633, p. 650. from "Metals Handbook",
Copyright 1985, ASM 9th ed, Fig. 650, p. 357.
International, Materials Copyright 1985, ASM
Park, OH. (Micrograph by International, Materials
J.R. Keiser and A.R. Park, OH. (Micrograph by
Olsen, Oak Ridge D.R. Diercks, Argonne
National Lab.)
160 mm
4 mm National Lab.)

Polypropylene Al Oxide
(polymer) (ceramic)
Reprinted w/ permission Reprinted w/ permission
from R.W. Hertzberg, from "Failure Analysis of
"Defor-mation and Brittle Materials", p. 78.
Fracture Mechanics of Copyright 1990, The
Engineering Materials", American Ceramic
(4th ed.) Fig. 7.35(d), p. Society, Westerville, OH.
303, John Wiley and (Micrograph by R.M.
Sons, Inc., 1996. Gruver and H. Kirchner.)
3 mm
1 mm
(Orig. source: K. Friedrick, Fracture 1977, Vol.
3, ICF4, Waterloo, CA, 1977, p. 1119.)
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Ideal vs Real Materials

• Stress-strain behavior (Room T):

 perfect mat’l-no flaws
E/10 TSengineering << TS perfect
materials materials
carefully produced glass fiber

E/100 typical ceramic typical strengthened metal

typical polymer
0.1 

Reasons:
•Flaws cause premature failure.
•Larger samples contain more flaws
•The presence of microscopic flaws or
cracks

https://www.youtube.com/watch?v=jJMSvgcZaGA
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Flaws are Stress Concentrators!

Results from crack propagation

 Griffith Crack
 Maximum stress
1/ 2
a 
 m 2o   K t o
 t 

t where
t = radius of curvature
o = applied stress
m = stress at crack tip
t= stress concentration
factor
a = ½ length of the crack
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Flaws are Stress Concentrators!

Results from crack propagation

 Griffith Crack
 Critical stress
1/ 2
 2 Ey s 
 c  
 a 

t where
t = radius of curvature
ys = Specific Surface
Energy
= Modulus of Elasticity
a = ½ length of the crack
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1/ 2
 2 Ey s 
 c  
 a 
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MATLAB

 Use Matlab to solve 8.1

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SUMMARY

• Engineering materials don't reach theoretical strength.

• Flaws produce stress concentrations that cause
premature failure.
• Sharp corners produce large stress concentrations
and premature failure.
• Failure type depends on T and stress:
- for noncyclic  and T < 0.4Tm, failure stress decreases with:
- increased maximum flaw size,
- decreased T,
- increased rate of loading.
- for cyclic :
- cycles to fail decreases as  increases.
- for higher T (T > 0.4Tm):
- time to fail decreases as  or T increases.
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HW

Reading: Chapter 9: Phase Diagrams

Read chapter 8

HW
8.1
Core
8.3 (plotProblems:
the critical stressHW:
for the Ch7 # 6,9,11,
crack 0.01 – 0.10, CH8 #16, 29
increment by 0.001)
8.4 (use matlab to calculate the results)

Self-help Problems: