Metal Failures

Mechanisms, Analysis, Prevention

Inbunden, Engelska, 2013

Av Arthur J. McEvily, Jirapong Kasivitamnuay, USA) McEvily, Arthur J. (Ford Motor Company; University of Connecticut, Thailand) Kasivitamnuay, Jirapong (University in Bangkok, Arthur J McEvily

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One of the only texts available to cover not only how failure occurs but also examine methods developed to expose the reasons for failure, Metal Failures has long been considered the most definitive and authoritative resources in metallurgical failure analysis. Now in a completely revised edition, this Second Edition features updates of all chapters plus new coverage of elastic behavior and plastic deformation, localized necking, the phenomenological aspects of fatigue, fatigue crack propagation, alloys and coatings, tensors and tensor notations, and much more.

Produktinformation

Utgivningsdatum2013-11-01
Mått160 x 236 x 31 mm
Vikt816 g
FormatInbunden
SpråkEngelska
Antal sidor496
Upplaga2
FörlagJohn Wiley & Sons Inc
ISBN9781118163962

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Preface xv1. Failure Analysis 1I. Introduction 1II. Examples of Case Studies Involving Structural Failures 6III. Summary 25References 25Problems 262. Elements of Elastic Deformation 27I. Introduction 27II. Stress 27III. Strain 32IV. Elastic Constitutive Relationships 35V. State of Stress Ahead of a Notch 44VI. Summary 46References 46Appendix 2-1: Mohr Circle Equations for a Plane Problem 46Appendix 2-2: Three-Dimensional Stress Analysis 49Appendix 2-3: Stress Formulas Under Simple Loading Conditions 54Problems 573. Elements of Plastic Deformation 59I. Introduction 59II. Theoretical Shear Strength 59III. Dislocations 61IV. Yield Criteria for Multiaxial Stress 68V. State of Stress in the Plastic Zone Ahead of a Notch in Plane-Strain Deformation 70VI. Summary 74For Further Reading 75Appendix 3-1: The von Mises Yield Criterion 75Problems 764. Elements of Fracture Mechanics 80I. Introduction 80II. Griffith’s Analysis of the Critical Stress for Brittle Fracture 80III. Alternative Derivation of the Griffith Equation 83IV. Orowan-Irwin Modification of the Griffith Equation 84V. Stress Intensity Factors 85VI. The Three Loading Modes 88VII. Determination of the Plastic Zone Size 88VIII. Effect of Thickness on Fracture Toughness 89IX. The R-Curve 91X. Short Crack Limitation 92XI. Case Studies 92XII. The Plane-Strain Crack Arrest Fracture Toughness, K I a, of Ferritic Steels 95XIII. Elastic-plastic Fracture Mechanics 96XIV. Failure Assessment Diagrams 98XV. Summary 101References 101Problems 1025. Alloys and Coatings 105I. Introduction 105II. Alloying Elements 106III. Periodic Table 107IV. Phase Diagrams 108V. Coatings 126VI. Summary 130References 130Problems 1306. Examination and Reporting Procedures 132I. Introduction 132II. Tools for Examinations in the Field 132III. Preparation of Fracture Surfaces for Examination 133IV. Visual Examination 133V. Case Study: Failure of a Steering Column Component 134VI. Optical Examination 135VII. Case Study: Failure of a Helicopter Tail Rotor 136VIII. The Transmission Electron Microscope (TEM) 136IX. The Scanning Electron Microscope (SEM) 138X. Replicas 142XI. Spectrographic and Other Types of Chemical Analysis 143XII. Case Study: Failure of a Zinc Die Casting 144XIII. Specialized Analytical Techniques 145XIV. Stress Measurement by X-Rays 146XV. Case Study: Residual Stress in a Train Wheel 149XVI. The Technical Report 150XVII. Record Keeping and Testimony 151XVIII. Summary 154References 155Problem 1557. Brittle and Ductile Fractures 156I. Introduction 156II. Brittle Fracture 156III. Some Examples of Brittle Fracture in Steel 159IV. Ductile-Brittle Behavior of Steel 161V. Case Study: The Nuclear Pressure Vessel Design Code 168VI. Case Study: Examination of Samples from the Royal Mail Ship (RMS) Titanic 172VII. Ductile Fracture 177VIII. Ductile Tensile Failure, Necking 177IX. Fractographic Features Associated with Ductile Rupture 183X. Failure in Torsion 185XI. Case Study: Failure of a Helicopter Bolt 185XII. Summary 188References 191Problems 1918. Thermal and Residual Stresses 196I. Introduction 196II. Thermal Stresses, Thermal Strain, and Thermal Shock 196III. Residual Stresses Caused by Nonuniform Plastic Deformation 200IV. Residual Stresses Due to Quenching 204V. Residual Stress Toughening 207VI. Residual Stresses Resulting from Carburizing, Nitriding, and Induction Hardening 207VII. Residual Stresses Developed in Welding 209VIII. Measurement of Residual Stresses 211IX. Summary 211References 211Appendix 8-1: Case Study of a Fracture Due to Thermal Stress 212Problems 2139. Creep 216I. Introduction 216II. Background 216III. Characteristics of Creep 217IV. Creep Parameters 220V. Creep Fracture Mechanisms 222VI. Fracture Mechanism Maps 224VII. Case Studies 225VIII. Residual Life Assessment 230IX. Stress Relaxation 232X. Elastic Follow-up 233XI. Summary 234References 234Problems 23410. Fatigue 237I. Introduction 237II. Background 237III. Design Considerations 240IV. Mechanisms of Fatigue 246V. Factors Affecting Fatigue Crack Initiation 254VI. Factors Affecting Fatigue Crack Growth 257VII. Analysis of the Rate of Fatigue Crack Propagation 261VIII. Fatigue Failure Analysis 273IX. Case Studies 276X. Thermal-Mechanical Fatigue 285XI. Cavitation 285XII. Composite Materials 286XIII. Summary 287References 287For Further Reading 290Problems 29011. Statistical Distributions 293I. Introduction 293II. Distribution Functions 293III. The Normal Distribution 294IV. Statistics of Fatigue; Statistical Distributions 296V. The Weibull Distribution 298VI. The Gumbel Distribution 302VII. The Staircase Method 307VIII. Summary 310References 310Appendix 11-1: Method of Linear Least Squares (C. F. Gauss, 1794) 311Problems 31412. Defects 316I. Introduction 316II. Weld Defects 316III. Case Study: Welding Defect 321IV. Casting Defects 328V. Case Study: Corner Cracking during Continuous Casting 329VI. Forming Defects 329VII. Case Studies: Forging Defects 330VIII. Case Study: Counterfeit Part 332IX. The Use of the Wrong Alloys; Errors in Heat Treatment, etc. 333X. Summary 334References 334Problems 33413. Environmental Effects 336I. Introduction 336II. Definitions 336III. Fundamentals of Corrosion Processes 337IV. Environmentally Assisted Cracking Processes 342V. Case Studies 348VI. Cracking in Oil and Gas Pipelines 350VII. Crack Arrestors and Pipeline Reinforcement 352VIII. Plating Problems 353IX. Case Studies 353X. Pitting Corrosion of Household Copper Tubing 356XI. Problems with Hydrogen at Elevated Temperatures 356XII. Hot Corrosion (Sulfidation) 358XIII. Summary 358References 358Problems 35914. Flaw Detection 360I. Introduction 360II. Inspectability 360III. Visual Examination (VE) 364IV. Penetrant Testing (PT) 364V. Case Study: Sioux City DC-10 Aircraft 367VI. Case Study: MD-88 Engine Failure 374VII. Magnetic Particle Testing (MT) 375VIII. Case Study: Failure of an Aircraft Crankshaft 378IX. Eddy Current Testing (ET) 382X. Case Study: Aloha Airlines 384XI. Ultrasonic Testing (UT) 384XII. Case Study: B747 389XIII. Radiographic Testing (RT) 389XIV. Acoustic Emission Testing (AET) 391XV. Cost of Inspections 393XVI. Summary 393References 394Problems 39415. Wear 396I. Wear 396II. The Coefficient of Friction 397III. The Archard Equation 398IV. An Example of Adhesive Wear 399V. Fretting Fatigue 399VI. Case Study: Friction and Wear; Bushing Failure 403VII. Roller Bearings 404VIII. Case Study: Failure of a Railroad Car Axle 410IX. Gear Failures 410X. Summary 414References 414Problems 415Concluding Remarks 417Solutions to Problems 419Name Index 469Subject Index 473