Suggested Problems (L12-15 Failure)

Suggested Problem Sets for Lectures 12-15 (Failure and Fatigue)
1) An aluminum alloy that has a plane strain fracture toughness of 25,000 fails when a stress of 42,000 psi is
applied. Observation of the fracture surface indicates that fracture began at the surface of the part. Estimate the size
of the flaw that initiated fracture. Assume that Y=1.1.
Solution: 0.093 inches
2) A polymer that contains internal flaws 1 mm in length fails at a stress of 25 MPa. Determine the plane strain
fracture toughness of the polymer. Assume that Y=1.
Solution: 0.99 MPa√m

3) What is the magnitude of the maximum stress that exists at the tip of an internal crack having a radius of
curvature of 1.9 × 10–4 mm (7.5 × 10–6 in.) and a crack length of 3.8 × 10–2 mm (1.5 × 10–3 in.) when a tensile stress
of 140 MPa (20,000 psi) is applied?
Solution: 2800 MPA
4) If the specific surface energy for aluminum oxide is 0.90 J/m2, then using data in Table 12.5, compute the critical
stress required for the propagation of an internal crack of length 0.40 mm.
Solution: 33.6 MPa
5) A specimen of a 4340 steel alloy with a plane strain fracture toughness of 54.8 MPa (50 ksi ) is exposed
to a stress of 1030 MPa (150,000 psi). Will this specimen experience fracture if the largest surface crack is 0.5 mm
(0.02 in.) long? Why or why not? Assume that the parameter Y has a value of 1.0.
Solution: 1380 MPa , No

6) An aircraft component is fabricated from an aluminum alloy that has a plane strain fracture toughness of 40 MPa
(36.4 ksi ). It has been determined that fracture results at a stress of 300 MPa (43,500 psi) when the
maximum (or critical) internal crack length is 4.0 mm (0.16 in.). For this same component and alloy, will fracture
occur at a stress level of 260 MPa (38,000 psi) when the maximum internal crack length is 6.0 mm (0.24 in.)? Why
or why not?
Solution: Yes, Kic = 42.4 MPa√m
7) Suppose that a wing component on an aircraft is fabricated from an aluminum alloy that has a plane-strain
fracture toughness of 26.0 MPa (23.7 ksi ). It has been determined that fracture results at a stress of 112
MPa (16,240 psi) when the maximum internal crack length is 8.6 mm (0.34 in.). For this same component and alloy,
compute the stress level at which fracture will occur for a critical internal crack length of 6.0 mm (0.24 in.).
Solution: 134 MPa
8) A structural component in the form of a wide plate is to be fabricated from a steel alloy that has a plane-strain
fracture toughness of ( ) and a yield strength of 860 MPa (125,000 psi). The flaw size
resolution limit of the flaw detection apparatus is 3.0 mm (0.12 in.). If the design stress is one-half the yield strength
and the value of Y is 1.0, determine whether a critical flaw for this plate is subject to detection.
Solution: Yes, ac = 16.8mm
9) A cylindrical 2014-T6 aluminum alloy bar is subjected to compression-tension stress cycling along its axis;
results of these tests are shown in Figure 8.20. If the bar diameter is 12.0 mm, calculate the maximum allowable
load amplitude (in N) to ensure that fatigue failure will not occur at 107 cycles. Assume a factor of safety of 3.0,
data in Figure 8.20 were taken for reversed axial tension-compression tests, and that S is stress amplitude.
Solution: F = 6400 N
10) A cylindrical rod of diameter 6.7 mm fabricated from a 70Cu-30Zn brass alloy is subjected to rotating-bending
load cycling; test results (as S-N behavior) are shown in Figure 8.20. If the maximum and minimum loads are +120
N and –120 N, respectively, determine its fatigue life. Assume that the separation between loadbearing points is 67.5
mm.
Solution: 3 x 106 cycles
11) A cylindrical component 50 mm long constructed from an S-590 alloy (Figure 8.32) is to be exposed to a tensile
load of 70,000 N. What minimum diameter is required for it to experience an elongation of no more than 8.2 mm
after an exposure for 1,500 h at 650°C? Assume that the sum of instantaneous and primary creep elongations is 0.6
mm.
Solution: 17.2 mm
12) Steady-state creep rate data are given in the following table for some alloy taken at 200°C (473 K):
(h–1) σ [MPa (psi)]

2.5 × 10 –3
55 (8000)
2.4 × 10–2 69 (10,000)
If it is known that the activation energy for creep is 140,000 J/mol, compute the steady-state creep rate at a temperature
of 250°C (523 K) and a stress level of 48 MPa (7000 psi).
Solution: 1.94 x 10 -2h-1

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Suggested Problem Sets for Lectures 12-15 (Failure and Fatigue)

Solution: 0.99 MPa√m

Solution: 1380 MPa , No

Solution: Yes, Kic = 42.4 MPa√m

Solution: 3 x 106 cycles

(h–1) σ [MPa (psi)]

Solution: 1.94 x 10 -2h-1

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