Metal Failures Mechanisms, Analysis, Prevention

by McEvily, Arthur J.; Kasivitamnuay, Jirapong

• ISBN13: 9781118163962
• ISBN10: 1118163966
• Edition: 2nd
• Format: Hardcover
• Copyright: 2013-09-16
• Publisher: Wiley-Interscience

Summary

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.

Author Biography

ARTHUR J. McEVILY, DEngSc, is Professor Emeritus in the Department of Metallurgy and Materials Engineering at the University of Connecticut.

Table of Contents

PREFACE TO SECOND EDITION

CHAPTER 1 Failure Analysis

I. Introduction

II. Examples of case studies involving structural failures

III. Summary

References

Problems

Chapter 2 Elements of Elastic Deformation

I. Introduction

II. Stress

III. Strain

IV. Elastic Constitutive relationships

V. State of stress ahead of a notch

VI. Summary

References

Appendix 2-1

Mohr Circle Equations for a plane problem

Reference

Appendix 2-2

Three-dimensional stress analysis

I. Principal Stresses and Stress Invariants

II. Maximum and Octahedral Shear Stresses

III. Stress Deviator Tensor

Appendix 2-3

Stress formulas under simple loading cases

I.  Bending of beam

II. Torsion of a circular shaft

III. thin-walled cylinder

Problems

Chapter 3 Elements of Plastic Deformation

I. Introduction

II. Theoretical shear strength

III. Dislocations

IV. Yield criteria for multiaxial stress

V. State of Stress in the plastic zone ahead of a notch in plane-strain deformation

IV. Summary

References

Appendix 3-1

The von Mises Yield Criterion

Reference

Problems

Chapter 4 Elements of Fracture Mechanics

I. Introduction

II. Griffith’s analysis of the critical stress for brittle fracture

III. Alternative Derivation of the Griffith Equation

IV. Orowan-Irwin Modification of the Griffith Equation

V. Stress Intensity Factors

VI. The Three Loading Modes

VII. Determination of the Plastic Zone Size

VIII. Effect of Thickness on Fracture Toughness

IX. The R-Curve

X. Short Crack Limitation

XI. Case Studies

XII. The Plane-Strain Crack Arrest Fracture Toughness, KIa, of Ferritic Steels

XIII. Elastic-Plastic Fracture Mechanics

XIV. Failure Assessment Diagrams

XV. Summary

References

Problems

Chapter 5 Alloys and Coatings

I. Introduction

II. Phase Diagrams

III. Coatings (9)

IV. Summary

References

Problems

Chapter 6 Examination and Reporting Procedures

I. Introduction

II. Tools for Examinations in the Field

III. Preparation of Fracture Surfaces for Examination

IV. Visual Examination

V. Case Study: Failure of a Steering Column Component

VI. Optical Examination

VII. Case Study: Failure of a Helicopter Tail Rotor

VIII. The Transmission Electron Microscope (TEM)

IX. The Scanning Electron Microscope (SEM)

X. Replicas

XI. Spectrographic and Other Types of Chemical Analysis

XII. Case Study: Failure of a Zinc Die Casting

XIII. Specialized Analytical Techniques

XIV. Stress Measurement by X-rays (4)

XV. Case Study: Residual Stress in a Train Wheel

XVI. The Technical Report

XVII. Record Keeping and Testimony

Summary

References

Problem

Chapter 7 Brittle and Ductile Fractures

I. Introduction

II. Brittle Fracture

III. Some Examples of Brittle Fracture in Steel

IV. Ductile-Brittle Behavior of Steel

V. Case Study: The Nuclear Pressure Vessel Design Code

VI. Case Study: Examination of Samples from the Royal Mail Ship (RMS) Titanic (6)

VII. Ductile Fracture

VIII. Ductile Tensile Failure, Necking

IX. Fractographic Features Associated with Ductile Rupture

X. Failure in Torsion

XI. Case Study: Failure of a Helicopter Bolt (12)

XII. Summary

References

Problems

Chapter 8 Thermal and Residual Stresses

I. Introduction

II. Thermal Stresses, Thermal Strain, and Thermal Shock

III. Residual Stresses Caused by NonUniform Plastic Deformation

IV. Residual Stresses due to Quenching

V. Residual Stress Toughening

VI. Residual Stresses Resulting from Carburizing, Nitriding and Induction Hardening

VII. Residual Stresses Developed in Welding

VIII. Measurement of Residual Stresses

IX. SUMMARY

References

Problems

Chapter 9 Creep

I. Introduction

II. Background

III. Characteristics of Creep

IV. Creep Parameters

V. Creep Fracture Mechanisms

VI. Fracture Mechanism Maps (6)

VII. Case Studies

C. An Ovalized Tube (8)

VIII. Residual Life Assessment

IX. Stress Relaxation

X. Elastic follow-up

XIII. Summary

References

Problems

Chapter 10 FATIGUE

I. Introduction

II. Background

III. Design Considerations

IV. Mechanisms of Fatigue

V. Factors Affecting Fatigue Crack Initiation

VI. Factors Affecting Fatigue Crack Growth

VII. Analysis of the Rate of Fatigue Crack Propagation

VIII. Fatigue Failure Analysis

IX. Case Studies

X. Thermal-Mechanical Fatigue

XI. Cavitation

XII. Composite Materials

XIII. Summary

XIV. For Further Reading

References

Problems

Chapter 11 Statistical Distributions

I. Introduction

II. Distribution Functions

III. The Normal Distribution

IV. Statistics of Fatigue; Statistical Distributions

V. The Weibull Distribution (2)

VI. The Gumbel Distribution (3)

VII. The staircase method

VI. Summary

References

Appendix 11-1 Method of linear least square (C.F. Gauss, 1794)

Problems

Chapter 12 Defects

I. Introduction

II. Weld Defects

III. Case Study: Welding Defect

IV. Casting Defects

V. Case Study: Corner Cracking during Continuous Casting

VI. Forming Defects (6)

VII. Case Studies: Forging Defects

VIII. Case Study: Counterfeit Part (8)

IX. The Use of the Wrong Alloys; Errors in Heat Treatment, and so on

X. Summary

References

Problems

Chapter 13 Environmental Effects

I. Introduction

II. Definitions

III. Fundamentals of Corrosion Processes

IV. Environmentally-Assisted Cracking Processes

V. Case Studies

VI. Cracking in Oil and Gas Pipelines

VII. Crack Arrestors and Pipeline Reinforcement

VIII. Plating Problems

IX. Case Studies

X. Pitting Corrosion of Household Copper Tubing

XI. Problems with Hydrogen at Elevated Temperatures

XII. Hot Corrosion (Sulfidation)

XIII. Summary

References

Problems

Chapter 14 Flaw Detection

I. Introduction

II. Inspectability

III. Visual Examination (VE)

IV. Penetrant Testing (PT)

V. Case Study: Sioux City DC-10 Aircraft (2)

VI. Case Study: MD 88 Engine Failure (3)

VII. Magnetic Particle Testing (MT)

VIII. Case Study: Failure of an Aircraft Crankshaft

IX. Eddy Current Testing (ET)

X. Case Study: Aloha Airlines

XI. Ultrasonic Testing (UT)

XII. Case Study: B747

XIII. Radiographic Testing (RT)

XIV. Acoustic Emission Testing (AET)

XV. Cost of Inspections

XVI. Summary

References

Problems

Chapter 15 Wear

I.  Wear

II. The Coefficient of Friction

III. The Archard Equation (1)

IV. An Example of Adhesive Wear

V. Fretting Fatigue

VI. Case Study: Friction and Wear; Bushing Failure

VII. Roller Bearings

VIII. Case Study: Failure of a Railroad Car Axle

IX. Gear Failures

X. Summary

References

Problems

Solutions to Homework Problems

Index