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