Problem set #7 MECH 321 Spring 2018

Question 1:
A single crystal of a metal that has the FCC crystal structure is oriented such that a tensile stress
is applied parallel to the [100] direction. If the critical resolved shear stress for this material is
0.5 MPa, calculate the magnitude of applied stress necessary to cause slip to occur on the (111)
plane in the direction [11� 0].
Solution:
The figure below must be used to find the values of λ and φ angles for the slip system.

A
Normal to
slip plane

ϕ
Slip plane
Slip
(111)
direction
O
[110] y
C
B

x D
λ Direction of
applied stress
[100]

λ is the angle between the direction of the applied stress [100] and the slip direction [11� 0]. The
angle λ is one of two equal angles of an isosceles right triangle BCD, and therefore is 45°.
φ is the angle between the direction of the applied stress [100] and the normal to the (111)
� in the triangle AOB which is a right
plane, that is [111] direction. The angle φ is the angle 𝑨𝑨𝑨
triangle. Therefore:

𝐴𝐴 √2𝑎 √2 √2
sin 𝜙 = = = ⇒ 𝜙 = sin−1 � � = 54.7°
𝐴𝐴 √3𝑎 √3 √3
Now:
𝜏𝑐𝑐𝑐𝑐 0.5 𝑀𝑀𝑀
𝜎𝑦 = = = 1.22 𝑀𝑀𝑀
(cos 𝜙 cos 𝜆)𝑚𝑚𝑚 cos(54.7°) cos(45°)

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Problem set #7 MECH 321 Spring 2018

Question 2
a) Briefly describe the microstructural difference between spheroidite and tempered
martensite.
b) Explain why tempered martensite is much harder and stronger.

Solution:
a) Both tempered martensite and spheroidite have sphere-like cementite particles within a
ferrite matrix; however, these particles are much larger for spheroidite.
b) Tempered martensite is harder and stronger inasmuch as there is much more
ferrite/cementite phase boundary area for the smaller particles; thus, there is greater
reinforcement of the ferrite phase, and more phase boundary barriers to dislocation
motion.

Question 3
What is the magnitude of the maximum stress that exists at the tip of an internal crack having a
radius of curvature of 2.5 × 10-4 mm and a crack length of 2.5 × 10-2 mm when a tensile stress of
170 MPa is applied?
Solution:
This problem asks that we compute the magnitude of the maximum stress that exists at the tip
of an internal crack. Equation 8.1 is employed to solve this problem, as:

æ a ö1/ 2
sm = 2s0 ç ÷
è rt ø

é 2.5 ´ 10-2 mm ù1/2

ê ú
= (2)(170 MPa) ê 2 ú = 2404 MPa (354,000 psi)
ê 2.5 ´ 10-4 mm ú
êë úû

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Problem set #7 MECH 321 Spring 2018

Question 4
It is necessary to select a metal alloy for an application that requires a yield strength of at least
310 MPa (45, 000 psi) while maintaining a minimum ductility (% EL) of 28%. If the metal may be
cold worked, decide which of the following are candidates: copper, brass and a 1040 steel.
Why?

Solution:

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Problem set #7 MECH 321 Spring 2018

Question 5
A fatigue test was conducted in which the stress amplitude was 210 MPa and the mean stress
was 70 MPa.

a) Compute the maximum and minimum stresses

b) Compute the stress range
c) If the A= 7.2 x 10-12 and m = 4 for stress in MPa and crack length in m, determine the
crack growth rate for a surface crack of length 1.2 mm. (Y=1.5)
d) How can fatigue wear be reduced?

Solution:
𝜎𝑚𝑚𝑚 − 𝜎𝑚𝑚𝑚
a) 𝜎𝑎 = = 210
2
𝜎𝑚𝑚𝑚 + 𝜎𝑚𝑚𝑚
𝜎𝑚 = = 70
2
𝜎𝑚𝑚𝑚 = 280 MPa , 𝜎𝑚𝑚𝑚 = −140 𝑀𝑀𝑀
b) 𝜎𝑟 = 𝜎𝑚𝑚𝑚 − 𝜎𝑚𝑚𝑚 = 420 MPa
𝑑𝑑 4
c) 𝑑𝑑
= 𝐴(𝛥𝛥)𝑚 = 7.2 ∗ 10−12 �𝜋 𝜎𝑚𝑚𝑚 √𝜋𝜋 − 𝜋 𝜎𝑚𝑚𝑚 √𝜋𝜋 �
𝑑𝑑
With the assumption of 𝜎𝑚𝑚𝑚 = 0 , the crack growth rate is 𝑑𝑑 = 3.18 ∗ 10−6 cycles
d)
i. reducing the load and sliding distance and increasing the hardness
ii. improving the quality of the contacting materials, such as eliminating inclusions,
impurities, and voids;
iii. improving the surface finish and integrity during the manufacturing process;
iv. surface working, such as shot peening or other treatments;
v. reducing contact stresses; and
vi. reducing the number of total cycles.

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Problem set #7 MECH 321 Spring 2018

Question 6
An electrochemical cell is constructed such that on one side a pure nickel electrode is in contact
with a solution containing Ni2+ ions at a concentration of 3 ´ 10-3 M. The other cell half consists
of a pure Fe electrode that is immersed in a solution of Fe2+ ions having a concentration of 0.1
M. At what temperature, will the potential between the two electrodes be +0.140 V?
Solution:
Based on their relative positions in the standard emf series (Table 17.1), assume that Fe is
oxidized and Ni is reduced. Thus, the electrochemical reaction that occurs within this cell is just

Ni2+ + Fe ® Ni + Fe 2+
Thus, Equation 17.20 is written in the form

RT [ Fe 2 + ]
DV = (V Nio - V Feo ) - ln
nF [ Ni 2 + ]

Solving this expression for T gives

é ù
ê o ú
nF DV - (VNi - VFe )
o
T =- ê ú
R ê [ Fe2 + ] ú
ê ln [ Ni 2 + ] ú
ë û
� �
The standard potentials from Table 17.1 are �Fe = – 0.440 V and �
V� Ni = – 0.250 V. Therefore,
V�

é ù
(2)(96,500 C / mol ) 0.140V - {-0.250V - (-0.440V )}ú
ê
T =- ê ú
8.31 J / mol - K ê æ 0.1M ö ú
ê lnç -3 ÷ ú
ë è 3 ´ 10 M ø û
= 331 K = 58°C

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Problem set #7 MECH 321 Spring 2018

Question 7
Consider a pair of common combination pliers as shown
in the picture. Explain what properties are required for
each part of the pliers (the jaws, the pipe grips, the
cutters and the handles) and what materials can provide
these properties.

Solution
The jaws:

· Mainly used for gripping, twisting and bending.

· Requires high stiffness, good wear resistance thus high surface hardness. Surface needs to
be textured to reduce slipping.
The pipe grip:
· Mainly used for gripping pipes and holding.
· Like the jaws. Specifically requires very good wear resistance due to friction while gripping.
The cutters:

· Mainly used to cut wires, small cables and their casing.

· Needs to have a very high hardness and relatively good stiffness.
The handles:
· Handles need to be stiff and somewhat impact resistance to avoid fracture or damage in
case of falling.
· Handles may be coated with grip materials that provide a more comfortable handling a as
well as avoiding electrical shock.
Materials

· Body of the pliers may be machined from forged steel and the best choice for the material is
alloyed tool steel with vanadium and chromium as alloying elements to provide wear
resistance and durability.
· Cutters that are subjected to great localized forces may be improved by hardening
processes such as induction hardening.
· Handles may be covered by a plastic coating that provides better handling and electrical
insulation.