MSE 212 Deformation and Fracture

Lecturer Najam ul Qadir Spring 2012

Course Outline
Deformation

Introduction, Engg. Stress/strain, True stress/strain, Poisson ratio, Plastic

deformation in tension / compression, Bauschinger Effect, Flow, Yield and Necking criteria, Flow Complex State of stresses, Mohr Circles, Viscoelasticity Defects or imperfections in crystalline materials (Point Defects, Line Defects, Stacking faults) Dislocations (Characteristic of dislocations, Dislocation density, Partial dislocations,Dislocation-dislocation interaction, Dislocation Multiplication, Method of observation of dislocations, , Dislocation in FCC, BCC, HCP Lattice) Slip / Glide (Slip System, deformation by slip, Slip in a perfect crystal, Slip by dislocation Movements, CRSS for slip) Twinning (Deformation by Twinning, Twinning in BCC, FC & HCP Lattice) Strengthening Mechanism (Strain Hardening, Grain-Boundary Strengthening, Solid Solution Strengthening, Precipitation Hardening)

Course Outline
Fracture

Introduction (Classification, Theoretical cohesive strength, Stress

concentration factor ) Quiz 10% Fracture (By easy glide, twinning) Assignments 15% Griffith crack theory Fracture Mechanics (Introduction, Modes Case studies Stress Intensity of fracture, 5% factor, Design Philosophy, Fracture toughness) Mid term 30 Fracture of Ferrous & Non-ferrous alloys, Ceramics, Polymers, Final 40 Composites. Analysis of Engineering failure( Introduction, Macroscopic fracture surface examination, Metallography & Fractography) Case Studies Suggested Books

Mechanical Metallurgy, G.E.Dieter, New York, McGraw Hill Deformation and Fracture of Engineering Materials, R.W.Hertzberg, 4th
Ed., John Wiley and Sons, New York 1996

Introduction
Deformation The collaborative motion of atoms relative to one another under the influence of applied strain in a predefined direction The atoms might return to their original configurations over a period of time after the strain is removed, or they might store a certain amount of permanent displacement from their mean positions depending upon the magnitude of applied strain Fracture If the applied strain generates a stress inside a material greater than its ultimate strength, crack nucleates and on application of further strain, starts propagating normal to the direction of applied strain On atomic scale, the applied strain energy is greater than the bond energy of atoms leading to bond rupture initiating from the weakest bonds and propagating by successive rupture of more stronger bonds

Stress Strain curve

lastic Deformation

1. True Elastic Limit 2. Proportional limit 3. Elastic Limit 4. Offset Yield Strength W : Engineering Stress I : Engineering Strain A : Undeformed Cross sectional area F: Uniaxial Load L: Undeformed Length l : increment in length

Deformation behavior of Engineering Materials

Metals and Alloys Ceramics Polymers

Thermosets Thermoplastics Rubbers

Composites
Metal Matrix Composites Polymer Matrix Composites Ceramic Matrix Composites

Deformation behavior of Metals and Alloys

Linear Elastic Region Non-discernible yield point Continuous Plastic

Deformation Stress decreases continuously after UTS till fracture

Deformation behavior of Thermoplastic Polymer

Non linear Elastic Region Discernible yield point Discontinuous Plastic

Deformation Stress starts to increases after a certain point during plastic deformation till fracture

Deformation behavior of Thermoset Polymer

Nearly linear Elastic Region Nondiscernible yield point Continuous Plastic

Deformation Stress decreases continuously after UTS till fracture

Deformation behavior of Rubber

Only nonlinear Elastic

Region No yield point No strain hardening No Plastic Deformation Stress decreases continuously from start of deformation till fracture Stress-strain curve exhibits hysterisis behavior Hookes law is not obeyed

Deformation behavior of Ceramics

Linear Elastic Region No yield point No strain hardening No Plastic Deformation UTS and fracture stress coincide

Linear Elastic Deformation

When the material is

unloaded in the elastic region, it retraces its original path which it produced during loading Volume of the material increases slightly during elastic tensile deformation and decreases slightly during elastic compression

Linear Elastic Deformation

- Generalized Hooke s Law -

A generalized state of
stress is composed of Principal stresses and principal strains Shear stresses and Shear strains Principal strains are responsible for tensile or compressive deformation Shear strains are responsible for torsional or rotational deformation

Generalized Hooke s Law in Compliance Form

!S

S is compliance tensor

Generalized Hooke s Law in Stiffness Form

!Q

Q is stiffness tensor

Dimensionality of Stress States

3-D stress state

1 E I 1 R I E 2 R I3 E ! K 23 K 31 K 12 R E 1 E R E R E R E 1 E 1 G 1 G W 1 W 2 W 3 X 23 X 31 X 12 1 G

Plane stress state

1-D stress state

1 I1 E I ! R 2 E K 12

R E 1 E

W 1 W 2 1 X 12 G

! /E E G ! 2 R 1

Engineering and True Stress Strain curve

1. Ultimate Strength 2. Yield Strength (Elastic Limit) 3. Fracture (Rupture) 4. Strain hardening Region 5. Necking Region The portion of the true stress strain curve from the onset of yielding to the maximum load may be described by the relation W = KIn where n is the strain hardening exponent

Yielding
Yield strength or yield point of a material is defined as the stress at which
it begins to deform plastically some fraction of the deformation is permanent or nonreversible Most important design parameter Dislocations start to move along the most favorably oriented slip system Onset of yielding corresponds to the yield stress or the flow stress Dislocations move in particular directions on specific planes in response to the shear stress applied along these planes and directions

Slip in Single Crystals

One of the ways in which plastic flow

begins is slip; hence we need to understand how the externally applied stress is resolved onto the slip systems Let us define the resolved shear stress XR which initiates plastic deformation resulting from the application of a tensile stress W
R

! cos cos

Onset of Yielding
When the resolved stress becomes sufficiently large, the crystal will start
to yield, i.e., dislocations start to move along the most favorably oriented slip system The onset of yielding corresponds to the yield stress Wy The minimum shear stress required to initiate slip is termed the critical resolved shear stress
RCSS y

cos cos RCSS / 

!
y

cos cos

max max

Max. value of cosJcosP corresponds to J = P = 45o cosJcosP = 0.5

!2

RCSS

Slip will first occur in slip systems oriented close to these angles
(J = P = 45o) with respect to the applied stress

Slip in Polycrystalline Materials

Grain orientations with respect to the applied stress are random Slip directions vary from crystal to crystal; some grains are unfavorably
oriented with respect to the applied stress, i.e., low cosJcosP Even those grains for which cosJcosP is high may be limited in deformation by adjacent grains which cannot deform so easily The dislocation motion occurs along the slip systems with favorable orientation, i.e., with highest resolved shear stress Dislocations cannot easily cross grain boundaries because changes in direction of slip plane and atomic disorder at grain boundaries As a result polycrystalline metals are stronger than single crystals (the exception is the perfect single crystal without any defects as in whiskers)

Yield criteria for isotropic materials

Maximum Principal Stress theory Yielding occurs when the largest principal stress exceeds the uniaxial
tensile yield strength

W1 " W y
2

W x W y 2 For a 2D stress X xy W1 !  2 state 2 Maximum Principal Strain theory Yielding occurs when the maximum principal strain exceeds the strain corresponding to the yield point during a simple tensile test W x W y

W 1 R W 2  W 3 " W y
Maximum Shear Stress theory Yielding occurs when the maximum shear stress exceeds the critical

W1  W 3 X! "X CRSS 2 Total Strain Energy theory

resolved shear stress

Plastic Instability and Necking

When the stress reaches the value of flow stress, plastic deformation begins
at the weakest part of the test sample somewhere along the gauge length The local extension under tensile loading causes a simultaneous area contraction so that true local stress is higher at this location than anywhere else along the gauge length In an ideally plastic material, all further deformation would be expected to be concentrated in this most highly stressed region In all other materials, this localized plastic deformation strain hardens the material, making it more resistant to further deformation The applied stress must be increased to produce further plastic deformation at the second weakest position along the gauge length The second position now undergoes strain hardening and this process repeats, until the applied stress becomes high enough to exceed the strain hardening capacity of the material, leading to the onset of necking Further plastic deformation is localized in the necked region since the stress increases continually with area contraction even though the applied load is decreasing as a result of elastic unloading outside the necked region This accounts for the difference in true and engineering stress strain curves