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Mechanical failure modes
Buckling
Corrosion
Creep
Fatigue
Fracture
Impact
Melting
Mechanical overload
Thermal shock
Wear
Yielding
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In materials science, fatigue is the progressive and localized structural damage that occurs when a material is subjected to cyclic loading. In Engineering, buckling is a failure mode characterized by a sudden failure of a structural member subjected to high Compressive stresses where Corrosion means the breaking down of essential properties in a material due to Chemical reactions with its surroundings Creep is the tendency of a solid material to slowly move or deform permanently under the influence of stresses It occurs as a result of long term exposure to levels of A fracture is the (local separation of an object or material into two or more pieces under the action of stress. An impact force is a high Force or shock applied over a short time period Melting is a process that results in the phase change of a substance from a Solid to a Liquid. The failure or fracture of a product or component in a single event is known as mechanical overload. Thermal shock is the name given to cracking as a result of rapid temperature change In Materials science, wear is the erosion of material from a Solid Surface by the action of another substance The yield strength or yield point of a Material is defined in Engineering and Materials science as the stress at which a material Materials Science or Materials Engineering is an interdisciplinary field involving the properties of matter and its applications to various areas of Science and The maximum stress values are less than the ultimate tensile stress limit, and may be below the yield stress limit of the material. Stress is a measure of the average amount of Force exerted per unit Area. Tensile strength \sigma_{UTS} or S_U is the Stress at which a material breaks or permanently deforms Tensile strength \sigma_{UTS} or S_U is the Stress at which a material breaks or permanently deforms

Contents

Fatigue life

ASTM defines fatigue life, Nf, as the number of stress cycles of a specified character that a specimen sustains before failure of a specified nature occurs. ASTM International ( ASTM) originally known as the American Society for Testing and Materials is an international Standards organization that develops and publishes [1]

Characteristics of fatigue

Fracture of an Aluminium Crank Arm. Dark area: slow crack growth. Bright area: sudden fracture.
Fracture of an Aluminium Crank Arm. Dark area: slow crack growth. Bright area: sudden fracture.

Timeline of early fatigue history

Micrographs showing how surface fatigue cracks grow as material is further cycled. From Ewing & Humfrey (1903)
Micrographs showing how surface fatigue cracks grow as material is further cycled. From Ewing & Humfrey (1903)

High-cycle fatigue

Historically, most attention has focused on situations that require more than 104 cycles to failure where stress is low and deformation primarily elastic. A material is said to be elastic if it deforms under stress (e

The S-N curve

In high-cycle fatigue situations, materials performance is commonly characterised by an S-N curve, also known as a Wöhler curve. This is a graph of the magnitude of a cyclical stress (S) against the logarithmic scale of cycles to failure (N). Definition and base Logarithmic scales are either defined for ratios of the underlying quantity or one has to agree to measure

Image:BrittleAluminium320MPA S-N Curve.jpg

S-N curves are derived from tests on samples of the material to be characterised (often called coupons) where a regular sinusoidal stress is applied by a testing machine which also counts the number of cycles to failure. This process is sometimes known as coupon testing. Each coupon test generates a point on the plot though in some cases there is a runout where the time to failure exceeds that available for the test (see censoring). In Statistics and Engineering, censoring occurs when the value of an observation is only partially known Analysis of fatigue data requires techniques from statistics, especially survival analysis and linear regression. Statistics is a mathematical science pertaining to the collection analysis interpretation or explanation and presentation of Data. In statistics linear regression is a form of Regression analysis in which the relationship between one or more Independent variables and another variable called

Probabilistic nature of fatigue

As coupons sampled from a homogeneous frame will manifest variation in their number of cycles to failure, the S-N curve should more properly be an S-N-P curve capturing the probability of failure after a given number of cycles of a certain stress. Probability distributions that are common in data analysis and in design against fatigue include the lognormal distribution, extreme value distribution, Birnbaum-Saunders distribution, and Weibull distribution. In Probability and Statistics, the log-normal distribution is the single-tailed Probability distribution of any Random variable whose Extreme value theory is a branch of Statistics dealing with the extreme Deviations from the Median of Probability distributions The general The Birnbaum-Saunders distribution (also known as the fatigue life distribution) is used extensively in reliability applications to model failure times In Probability theory and Statistics, the Weibull distribution (named after Waloddi Weibull) is a continuous Probability distribution.

Complex loadings

Spectrum loading
Spectrum loading

In practice, a mechanical part is exposed to a complex, often random, sequence of loads, large and small. Randomness is a lack of order Purpose, cause, or predictability In order to assess the safe life of such a part:

  1. Reduce the complex loading to a series of simple cyclic loadings using a technique such as rainflow analysis;
  2. Create an histogram of cyclic stress from the rainflow analysis;
  3. For each stress level, calculate the degree of cumulative damage incurred from the S-N curve; and
  4. Combine the individual contributions using an algorithm such as Miner's rule. The rainflow-counting algorithm (also known as the "rain-flow counting method" is used in the analysis of fatigue data in order to reduce a spectrum of varying In Statistics, a histogram is a Graphical display of tabulated frequencies, shown as Bars It shows what proportion of cases fall into each of

Miner's rule

In 1945, M. Year 1945 ( MCMXLV) was a Common year starting on Monday (link will display the full calendar A. Miner popularised a rule that had first been proposed by A. Palmgren in 1924. Year 1924 ( MCMXXIV) was a Leap year starting on Tuesday (link will display the full calendar of the Gregorian calendar. The rule, variously called Miner's rule or the Palmgren-Miner linear damage hypothesis, states that where there are k different stress magnitudes in a spectrum, Si (1 ≤ ik), each contributing ni(Si) cycles, then if Ni(Si) is the number of cycles to failure of a constant stress reversal Si, failure occurs when:

\sum_{i=1}^k \frac {n_i} {N_i} = C

C is experimentally found to be between 0. 7 and 2. 2. Usually for design purposes, C is assumed to be 1.

This can be thought of as assessing what proportion of life is consumed by stress reversal at each magnitude then forming a linear combination of their aggregate.

Though Miner's rule is a useful approximation in many circumstances, it has two major limitations:

  1. It fails to recognise the probabilistic nature of fatigue and there is no simple way to relate life predicted by the rule with the characteristics of a probability distribution.
  2. There is sometimes an effect in the order in which the reversals occur. In some circumstances, cycles of low stress followed by high stress cause more damage than would be predicted by the rule. It does not consider the effect of overload or high stress which may result in a compressive residual stress. High stress followed by low stress may have less damage due to the presence of compressive residual stress.

Paris' Relationship

Anderson, Gomez and Paris derived relationships for the stage II crack growth with cycles N, in terms of the cyclical component ΔK of the Stress Intensity Factor K

\frac {da} {dN} = C (\Delta K)^m

where a is the crack length and m is typically in the range 3 to 5 (for metals). Stress Intensity Factor, K is used in Fracture mechanics to more accurately predict the stress state ("stress intensity" near the tip of a crack caused

This relationship was later modified (by Forman, 1967[1]) to make better allowance for the mean stress, by introducing a factor depending on (1-R) where R = min. stress/max stress, in the denominator.

Low-cycle fatigue

Where the stress is high enough for plastic deformation to occur, the account in terms of stress is less useful and the strain in the material offers a simpler description. Low-cycle fatigue is usually characterised by the Coffin-Manson relation (published independently by L. F. Coffin in 1954 and S. Year 1954 ( MCMLIV) was a Common year starting on Friday (link will display full 1954 Gregorian calendar) S. Manson 1953):

\frac {\Delta \epsilon_p} {2} = \epsilon_f '(2N)^c

-where:

A similar relationship for materials such as Zirconium, used in the nuclear industry, is due to W. J. O'Donnell and B. F. Langer (Nuclear Science and Engineering, vol 20, pp 1-12, 1964).

Fatigue and fracture mechanics

The account above is purely phenomenological and, though it allows life prediction and design assurance, it does not enable life improvement or design optimisation. For the latter purposes, an exposition of the causes and processes of fatigue is necessary. Such an explanation is given by fracture mechanics in four stages.

  1. Crack nucleation;
  2. Stage I crack-growth;
  3. Stage II crack-growth; and
  4. Ultimate ductile failure.

Factors that affect fatigue-life

Design against fatigue

Dependable design against fatigue-failure requires thorough education and supervised experience in structural engineering, mechanical engineering, or materials science. Structural engineering is a field of Engineering dealing with the analysis and design of Structures that support or resist loads Structural engineering is Mechanical Engineering is an Engineering discipline that involves the application of principles of physics for analysis Design, Manufacturing Materials Science or Materials Engineering is an interdisciplinary field involving the properties of matter and its applications to various areas of Science and There are three principal approaches to life assurance for mechanical parts that display increasing degrees of sophistication:

  1. Design to keep stress below threshold of fatigue limit (infinite lifetime concept);
  2. Design (conservatively) for a fixed life after which the user is instructed to replace the part with a new one (a so-called lifed part, finite lifetime concept, or "safe-life" design practice);
  3. Instruct the user to inspect the part periodically for cracks and to replace the part once a crack exceeds a critical length. This approach usually uses the technologies of nondestructive testing and requires an accurate prediction of the rate of crack-growth between inspections. Nondestructive testing ( NDT) also called nondestructive examination ( NDE) and nondestructive inspection ( NDI) is testing that does This is often referred to as damage tolerant design or "retirement-for-cause".

Stopping fatigue

Fatigue cracks that have begun to propagate can sometimes be stopped by drilling holes, called drill stops, in the path of the fatigue crack. Drilling is the process of using a Drill bit in a Drill to produce cylindrical holes in solid materials such as wood or metal [5] This is not recommended as a general practice because the hole represents a stress concentration factor which depends on the size of the hole and geometry. A stress concentration (often called stress raisers or stress risers) is a location in an object where stress is concentrated There is thus the possibility of a new crack starting in the side of the hole. It is always far better to replace the cracked part entirely. Several disasters have been caused by botched repairs to cracked structures, such as JAL 123. Japan Airlines Flight 123 was a Japan Airlines domestic flight from Tokyo International Airport (Haneda to Osaka International Airport (Itami

Material change

Changes in the materials used in parts can also improve fatigue life. For example, parts can be made from better fatigue rated metals. Complete replacement and redesign of parts can also reduce if not eliminate fatigue problems. Thus helicopter rotor blades and propellers in metal are being replaced by composite equivalents. A helicopter rotor is the rotating part of a Helicopter which generates an aerodynamic Force. A propeller is essentially a type of fan which transmits power by converting Rotational motion into Thrust for propulsion of a vehicle such as an Composite materials (or composites for short are engineered Materials made from two or more constituent materials with significantly different physical or chemical They are not only lighter, but also much more resistant to fatigue. They are more expensive, but the extra cost is amply repaid by their greater integrity, since loss of a rotor blade usually leads to total loss of the aircraft. A similar argument has been made for replacement of metal fuselages, wings and tails of aircraft.

Infamous fatigue failures

Versailles train crash

Drawing of a fatigue failure in an axle, 1843.
Drawing of a fatigue failure in an axle, 1843. One of the worst rail disasters of the 19th century the Versailles train crash, occurred on May 8 1842 at Meudon ( Versailles) France.

On May 8, 1842 one of the trains carrying revellers on their return from Versailles to Paris, having witnessed the celebrations of the birthday of Louis Philippe, derailed and caught fire. Events 589 - Reccared summons the Third Council of Toledo 1450 - Jack Cade's Rebellion: Kentishmen Year 1842 ( MDCCCXLII) was a Common year starting on Tuesday (link will display the full calendar of the Gregorian Calendar (or a Common Versailles (vɛʀsaj in French) formerly de facto capital of the kingdom of France, is now a wealthy suburb of Paris and is still an important Paris (ˈpærɨs in English; in French) is the Capital of France and the country's largest city Louis Philippe ( 6 October 1773 &ndash 26 August 1850) was King of the French from 1830 to 1848 in what was known as the Fire is the heat and light energy released during a Chemical reaction, in particular a combustion reaction. Though the resulting conflagration mutilated the dead beyond recognition or enumeration, it is estimated that 53 perished and around 40 were seriously injured.

The derailment had been the result of a broken locomotive axle. A locomotive is a railway Vehicle that provides the motive power for a Train. Rankine's investigation of broken axles in Britain highlighted the importance of stress concentration, and the mechanism of crack growth with repeated loading. William John Macquorn Rankine FRS ( July 5, 1820 &ndash December 24, 1872) was a Scottish engineer and A stress concentration (often called stress raisers or stress risers) is a location in an object where stress is concentrated

De Havilland Comet

Metal fatigue became apparent to aircraft engineers in 1954 after three de Havilland Comet passenger jets had broken up in mid-air and crashed within a single year. Year 1954 ( MCMLIV) was a Common year starting on Friday (link will display full 1954 Gregorian calendar) WikipediaWikiProject Aircraft. Please see WikipediaWikiProject Aircraft/page content for recommended layout Investigators from the Royal Aircraft Establishment at Farnborough in England told a public enquiry that the sharp corners around the plane's window openings (actually the forward ADF antenna window in the roof) acted as initiation sites for cracks. The Royal Aircraft Establishment (RAE England, was a British research establishment latterly under the UK Ministry of Defence Farnborough is a Town in the Rushmoor district of Hampshire, England. England is a Country which is part of the United Kingdom. Its inhabitants account for more than 83% of the total UK population whilst its mainland A stress concentration (often called stress raisers or stress risers) is a location in an object where stress is concentrated The skin of the aircraft was also too thin, and cracks from manufacturing stresses were present at the corners. All aircraft windows were immediately redesigned with rounded corners.

Others

See also

References

  1. ^ Stephens, Ralph I. On December 19, 2005, Chalk's Ocean Airways Flight 101 from Fort Lauderdale, Florida, United States to Bimini, Air safety is a term encompassing the theory investigation and categorization of flight failures, and the prevention of such failures through regulation as well as through Corrosion fatigue is fatigue in a corrosive environment It is the mechanical degradation of a material under the joint action of Corrosion and cyclic loading Embedment is a phenomenon in Mechanical engineering in which the surfaces between mechanical members of a loaded joint embed Fracture mechanics is the field of Mechanics concerned with the study of the formation of cracks in materials Forensic Engineering is the investigation of materials, products, Structures or components that fail or do not operate/function as A branch of Forensic engineering, the subject focuses on the material evidence from crime or accident scenes seeking defects in those materials which might explain why an accident occurred Fractography is the study of fracture surfaces of materials Fractographic methods are routinely used to determine the cause of failure in engineering structures especially in product Kalitta Air is an American Cargo airline based in Ypsilanti, Michigan, USA. Materials Science or Materials Engineering is an interdisciplinary field involving the properties of matter and its applications to various areas of Science and Peening is the process of working a Metal 's surface to improve its material properties usually by mechanical means such as hammer blows or by blasting with shot ( A mechanical or physical shock is a sudden Acceleration or deceleration caused for example by impact drop kick Earthquake, or Explosion. Structural failure refers to loss of the load -carrying capacity of a component or member within a Structure or of the structure itself In 1972 the ultrasonic impact technology was developed and has since been perfected by a team of Russian scientists under the leadership of Dr Vibration refers to mechanical Oscillations about an equilibrium point. (2001). Metal Fatigue in Engineering, Second edition, John Wiley & Sons, Inc. , 69. ISBN 0-471-51059-9.  
  2. ^ a b W. Schutz (1996). A history of fatigue. Engineering Fracture Mechanics 54: 263-300. DOI
  3. ^ W. J. M. Rankine. (1842). "On the causes of the unexpected breakage of the journals of railway axles, and on the means of preventing such accidents by observing the law of continuity in their construction". Institution of Civil Engineers, Minutes of Proceedings, 105-108.
  4. ^ F. Braithwaite. (1854). "On the fatigue and consequent fracture of metals". Institution of Civil Engineers, Minutes of Proceedings, 463–474.
  5. ^ Material Technologies, Inc. Completes EFS Inspection of Bridge in New Jersey Press release regarding metal fatigue damage to the Manahawkin Bay Bridge in New Jersey

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