Callister - An introduction - 8th edition

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260 • Chapter 8 / Failure Figure 8.21 Fracture surface of a rotating steel shaft that experienced fatigue failure. Beachmark ridges are visible in the photograph. (Reproduced with permission from D. J. Wulpi, Understanding How Components Fail, American Society for Metals, Materials Park, OH, 1985.) “clamshell marks”) are of macroscopic dimensions (Figure 8.21), and may be observed with the unaided eye. These markings are found for components that experienced interruptions during the crack propagation stage—for example, a machine that operated only during normal work-shift hours. Each beachmark band represents a period of time over which crack growth occurred. On the other hand, fatigue striations are microscopic in size and subject to observation with the electron microscope (either TEM or SEM). Figure 8.22 is an electron fractograph that shows this feature. Each striation is thought to represent the Figure 8.22 Transmission electron fractograph showing fatigue striations in aluminum. 9000. (From V. J. Colangelo and F. A. Heiser, Analysis of Metallurgical Failures, 2nd edition. Copyright © 1987 by John Wiley & Sons, New York. Reprinted by permission of John Wiley & Sons, Inc.) 1 m
8.9 Crack Initiation and Propagation • 261 Region of slow crack propagation Figure 8.23 Fatigue failure surface. A crack formed at the top edge. The smooth region also near the top corresponds to the area over which the crack propagated slowly. Rapid failure occurred over the area having a dull and fibrous texture (the largest area). Approximately 0.5. [Reproduced by permission from Metals Handbook: Fractography and Atlas of Fractographs, Vol. 9, 8th edition, H. E. Boyer (Editor), American Society for Metals, 1974.] Region of rapid failure advance distance of a crack front during a single load cycle. Striation width depends on, and increases with, increasing stress range. At this point it should be emphasized that although both beachmarks and striations are fatigue fracture surface features having similar appearances, they are nevertheless different, both in origin and size. There may be thousands of striations within a single beachmark. Often the cause of failure may be deduced after examination of the failure surfaces. The presence of beachmarks and/or striations on a fracture surface confirms that the cause of failure was fatigue. Nevertheless, the absence of either or both does not exclude fatigue as the cause of failure. One final comment regarding fatigue failure surfaces: Beachmarks and striations will not appear on that region over which the rapid failure occurs. Rather, the rapid failure may be either ductile or brittle; evidence of plastic deformation will be present for ductile, and absent for brittle, failure. This region of failure may be noted in Figure 8.23. Concept Check 8.4 Surfaces for some steel specimens that have failed by fatigue have a bright crystalline or grainy appearance. Laymen may explain the failure by saying that the metal crystallized while in service. Offer a criticism for this explanation. [The answer may be found at www.wiley.com/college/callister (Student Companion Site).]
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Characteristics of Selected Element
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E IGHTH E DITION Materials Science
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Dedicated to our wives, Nancy and E
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viii • Preface FEATURES THAT ARE
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x • Preface 2. Answers to Concept
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Appreciation is expressed to those
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xiv • Contents 3. The Structure o
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xvi • Contents 9.12 Development o
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xviii • Contents 15.14 Factors Th
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xx • Contents 21.14 Optical Fiber
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xxii • List of Symbols HK Knoop
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Chapter 1 Introduction A familiar i
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1.2 Materials Science and Engineeri
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1.4 Classification of Materials •
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1.5 Advanced Materials • 11 aeros
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1.6 Modern Materials’ Needs • 1
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STEELS Processing Diffusion ➣ Rec
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Question • 17 REFERENCES Ashby, M
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WHY STUDY Atomic Structure and Inte
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2.3 Electrons in Atoms • 21 Orbit
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2.3 Electrons in Atoms • 23 Table
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2.3 Electrons in Atoms • 25 Table
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2.4 The Periodic Table • 27 Metal
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2.5 Bonding Forces and Energies •
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2.6 Primary Interatomic Bonds • 3
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2.6 Primary Interatomic Bonds • 3
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2.7 Secondary Bonding or van der Wa
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2.7 Secondary Bonding or van der Wa
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Summary • 39 Primary Interatomic
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Questions and Problems • 41 QUEST
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Questions and Problems • 43 Sprea
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WHY STUDY The Structure of Crystall
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lattice 3.4 Metallic Crystal Struct
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3.4 Metallic Crystal Structures •
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3.5 Density Computations • 51 EXA
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3.7 Crystal Systems • 53 Another
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3.8 Point Coordinates • 55 Concep
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3.9 Crystallographic Directions •
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3.10 Crystallographic Planes • 63
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3.12 Close-Packed Crystal Structure
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3.12 Close-Packed Crystal Structure
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3.15 Anisotropy • 73 (a) (b) grai
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3.16 X-Ray Diffraction: Determinati
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0° 3.16 X-Ray Diffraction: Determi
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3.17 Noncrystalline Solids • 79 (
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Summary • 81 Point Coordinates Cr
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Processing/Structure/Properties/Per
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Questions and Problems • 85 118.7
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Questions and Problems • 89 Inten
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WHY STUDY Imperfections in Solids?
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self-interstitial increases exponen
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2. Crystal structure. For appreciab
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4.4 Specification of Composition
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4.5 Dislocations—Linear Defects
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4.5 Dislocations—Linear Defects
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4.6 Interfacial Defects • 103 Ang
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4.6 Interfacial Defects • 105 MAT
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the order of 10 13 vibrations per s
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4.10 Microscopic Techniques • 109
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4.10 Microscopic Techniques • 111
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4.11 GRAIN SIZE DETERMINATION grain
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Summary • 115 Specification of Co
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Summary • 117 List of Symbols Sym
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Questions and Problems • 119 (a)
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Design Problems • 121 (a) at a ma
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WHY Study Diffusion? Materials of a
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5.2 Diffusion Mechanisms • 125 se
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5.3 Steady-State Diffusion • 127
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5.4 Nonsteady-State Diffusion • 1
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5.4 Nonsteady-State Diffusion • 1
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5.5 Factors That Influence Diffusio
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5.5 Factors That Influence Diffusio
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5.6 Diffusion in Semiconducting Mat
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is only an approximation), then the
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5.6 Diffusion in Semiconducting Mat
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Summary • 143 Diffusion in Semico
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Questions and Problems • 145 QUES
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Diffusion coefficient (m 2 /s) 10 -
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Design Problems • 149 the process
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WHY STUDY The Mechanical Properties
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6.2 Concepts of Stress and Strain
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6.2 Concepts of Stress and Strain
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6.3 Stress-Strain Behavior • 157
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6.4 Anelasticity • 159 Figure 6.8
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6.5 Elastic Properties Of Materials
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6.6 Tensile Properties • 163 Figu
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6.6 Tensile Properties • 165 in F
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6.6 Tensile Properties • 167 Brit
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6.6 Tensile Properties • 169 y F
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6.7 True Stress and Strain • 171
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6.9 Compressive, Shear, and Torsion
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Table 6.5 Hardness-Testing Techniqu
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Brinell Hardness Tests 15 6.10 Hard
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6.10 Hardness • 179 are contained
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6.11 Variability Of Material Proper
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6.12 Design/Safety Factors • 183
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Summary • 185 • For an isotropi
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Summary • 187 6.15 s T F True st
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Questions and Problems • 189 a lo
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Questions and Problems • 191 tens
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Questions and Problems • 193 modu
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Design Problems • 195 (a) Determi
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Chapter 7 Dislocations and Strength
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Dislocations and Plastic Deformatio
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7.3 Characteristics of Dislocations
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7.4 Slip Systems • 203 D B A (a)
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7.5 Slip in Single Crystals • 205
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7.5 Slip in Single Crystals • 207
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Page 241 and 242: 7.9 Solid-Solution Strengthening
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Page 247 and 248: 7.11 RECOVERY recovery 7.12 RECRYST
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Page 251 and 252: 7.12 Recrystallization • 223 DESI
Page 253 and 254: Summary • 225 Figure 7.25 The log
Page 255 and 256: Summary • 227 Strain Hardening
Page 257 and 258: Questions and Problems • 229 Iron
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Page 261 and 262: Design Problems • 233 Spreadsheet
Page 263 and 264: WHY STUDY Failure? The design of a
Page 265 and 266: 8.3 Ductile Fracture • 237 Figure
Page 267 and 268: 8.4 Brittle Fracture • 239 8.4 BR
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Page 271 and 272: 8.5 Principles of Fracture Mechanic
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Page 283 and 284: 8.7 Cyclic Stresses • 255 Most ce
Page 285 and 286: 8.8 The S-N Curve • 257 fatigue l
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Page 293 and 294: 8.12 Generalized Creep Behavior •
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Page 299 and 300: Summary • 271 Ductile Fracture
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Page 307 and 308: Design Problems • 279 8.31 A cyli
Page 309 and 310: Chapter 9 Phase Diagrams The graph
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Page 313 and 314: 9.5 PHASE EQUILIBRIA equilibrium fr
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Page 317 and 318: 9.8 Interpretation of Phase Diagram
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Page 325 and 326: 9.10 Mechanical Properties of Isomo
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9.13 Equilibrium Diagrams Having In
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9.14 Eutectoid and Peritectic React
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9.15 Congruent Phase Transformation
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9.17 The Gibbs Phase Rule • 317 F
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The Iron-Carbon System 9.18 The Iro
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9.18 The Iron-Iron Carbide (Fe-Fe 3
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9.19 Development of Microstructure
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Summary • 331 SUMMARY Introductio
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Summary • 333 Development of Micr
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Questions and Problems • 335 Impo
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Questions and Problems • 337 (b)
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Questions and Problems • 339 Figu
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WHY STUDY Phase Transformations? Th
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10.3 The Kinetics of Phase Transfor
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10.4 Metastable versus Equilibrium
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10.5 Isothermal Transformation Diag
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10.6 Continuous Cooling Transformat
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10.6 Continuous Cooling Transformat
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10.7 Mechanical Behavior of Iron-Ca
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10.7 Mechanical Behavior of Iron-Ca
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10.8 TEMPERED MARTENSITE In the as-
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10.8 Tempered Martensite • 377 (b
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10.9 Review of Phase Transformation
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Summary • 381 Figure 10.37. Of co
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Summary • 383 Spheroidite—is co
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Questions and Problems • 385 Stee
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Questions and Problems • 389 (c)
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Chapter 11 Applications and Process
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11.2 Ferrous Alloys • 393 Types o
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11.2 Ferrous Alloys • 395 Table 1
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11.2 Ferrous Alloys • 397 Table 1
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11.2 Ferrous Alloys • 399 is exte
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11.2 Ferrous Alloys • 401 (c) 20
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Table 11.5 Designations, Minimum Me
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11.2 Ferrous Alloys • 405 is pres
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11.3 Nonferrous Alloys • 407 Tabl
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Table 11.9 Compositions, Mechanical
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11.3 Nonferrous Alloys • 415 or n
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11.4 Forming Operations • 417 Met
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11.5 Casting • 419 that have rath
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11.6 Miscellaneous Techniques • 4
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11.7 Annealing Processes • 423 ox
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modification of mechanical properti
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11.8 Heat Treatment of Steels • 4
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11.9 Precipitation Hardening • 43
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Summary • 443 Forming Operations
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Summary • 445 PROCESSING Recrysta
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Questions and Problems • 447 REFE
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Design Problems • 449 and temperi
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Chapter 12 Structures and Propertie
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12.2 Crystal Structures • 453 Con
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12.2 Crystal Structures • 455 Tab
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12.2 Crystal Structures • 457 Fur
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12.2 Crystal Structures • 459 VMS
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12.2 Crystal Structures • 461 Tet
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12.2 Crystal Structures • 463 EXA
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12.3 Silicate Ceramics • 465 Si 4
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12.3 Silicate Ceramics • 467 Figu
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12.4 Carbon • 469 Figure 12.16 Sc
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Another molecular form of carbon ha
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12.5 Imperfections in Ceramics •
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12.5 Imperfections in Ceramics •
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12.7 Ceramic Phase Diagrams • 477
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12.7 Ceramic Phase Diagrams • 479
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12.8 Brittle Fracture of Ceramics
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12.8 Brittle Fracture of Ceramics
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flexural strength Flexural strength
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12.10 Mechanisms of Plastic Deforma
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viscosities at ambient temperatures
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Summary • 491 Table 12.6 Vickers
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Summary • 493 • Diagrams for Al
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Questions and Problems • 495 visc
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Questions and Problems • 497 does
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Questions and Problems • 499 Stre
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Chapter 13 Applications and Process
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13.3 Glass-Ceramics • 503 Ceramic
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13.5 Refractories • 505 Glass-cer
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13.6 Abrasives • 507 (2910F). Thu
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13.8 Advanced Ceramics • 509 Seve
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13.8 Advanced Ceramics • 511 opti
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13.9 Fabrication and Processing of
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13.11 Powder Pressing • 523 a sca
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13.12 Tape Casting • 525 Figure 1
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Summary • 527 • Requirements fo
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Summary • 529 This chapter also d
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13.12 Compare the softening points
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WHY STUDY Polymer Structures? A rel
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14.3 Polymer Molecules • 535 Tabl
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14.4 The Chemistry of Polymer Molec
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14.4 The Chemistry of Polymer Molec
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Figure 14.3 Hypothetical polymer mo
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14.5 Molecular Weight • 543 Table
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14.7 Molecular Structure • 545 Fi
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14.8 Molecular Configurations • 5
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14.8 Molecular Configurations • 5
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14.10 Copolymers • 551 adjacent c
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14.11 Polymer Crystallinity • 553
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For copolymers, as a general rule,
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14.12 Polymer Crystals • 557 ~ 10
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14.14 Diffusion in Polymeric Materi
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Summary • 561 PET is permeable to
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Equation Summary Summary • 563 Po
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Important Terms and Concepts Questi
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Questions and Problems • 567 age
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Chapter 15 Characteristics, Applica
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15.2 Stress-Strain Behavior • 571
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15.3 Macroscopic Deformation • 57
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15.4 Viscoelastic Deformation • 5
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15.4 Viscoelastic Deformation • 5
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15.5 Fracture of Polymers • 579 F
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15.7 Deformation of Semicrystalline
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t 0 t t 0 t 0 Stage 1 Stage 2 (a) (
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15.8 Factors That Influence the Mec
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15.8 Factors That Influence the Mec
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15.9 Deformation of Elastomers •
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15.10 Crystallization • 591 Norma
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15.13 Melting and Glass Transition
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15.14 Factors That Influence Meltin
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15.15 Plastics • 597 Table 15.3 (
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15.16 Elastomers • 599 ing phenol
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15.18 Miscellaneous Applications
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15.19 Advanced Polymeric Materials
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15.19 Advanced Polymeric Materials
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The tensile modulus of this TPE mat
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15.20 Polymerization • 609 Additi
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15.22 Forming Techniques for Plasti
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15.22 Forming Techniques for Plasti
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15.24 Fabrication of Fibers and Fil
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Factors That Influence the Mechanic
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Summary • 619 Equation Summary Eq
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Questions and Problems • 621 McCr
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Questions and Problems • 623 Tens
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Design Questions • 625 Elastomers
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3.1 Hardness • 627 WHY STUDY Comp
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16.1 Introduction • 629 Dispersed
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16.2 Large-Particle Composites •
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16.2 Large-Particle Composites •
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Critical fiber length—dependence
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16.5 Influence of Fiber Orientation
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ut, because s/E, 16.5 Influence o
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16.6 The Fiber Phase • 645 Applic
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eactions with the environment. Such
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16.8 Polymer-Matrix Composites •
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16.8 Polymer-Matrix Composites •
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16.9 Metal-Matrix Composites • 65
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The high-temperature creep and rupt
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16.12 HYBRID COMPOSITES hybrid comp
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16.13 Processing of Fiber-Reinforce
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16.15 Sandwich Panels • 661 Figur
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Summary • 663 they remain separat
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Summary • 665 When l l c , Equat
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References • 667 List of Symbols
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Design Problems • 671 to be align
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Chapter 17 Corrosion and Degradatio
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Corrosion of Metals 17.2 Electroche
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17.2 Electrochemical Considerations
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17.4 Prediction of Corrosion Rates
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17.5 Passivity • 691 to further c
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17.7 Forms of Corrosion • 693 sur
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17.7 Forms of Corrosion • 695 Fig
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sodium chloride. Dilute sulfuric ac
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17.10 Oxidation • 703 Zinc coatin
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17.10 Oxidation • 705 Table 17.3
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Ceramic materials are frequently us
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17.12 Bond Rupture • 709 17.12 BO
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Summary • 711 marily a result of
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Summary • 713 Corrosion Preventio
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Questions and Problems • 715 REFE
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Chapter 18 Electrical Properties (b
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18.3 Electrical Conductivity • 72
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18.5 Energy Band Structures in Soli
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valence band conduction band energy
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covalent) and relatively weak, whic
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18.8 Electrical Resistivity of Meta
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18.9 Electrical Characteristics of
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18.10 Intrinsic Semiconduction •
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18.10 Intrinsic Semiconduction •
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18.11 Extrinsic Semiconduction •
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18.11 Extrinsic Semiconduction •
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18.12 The Temperature Dependence of
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18.13 Factors That Affect Carrier M
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DESIGN EXAMPLE 18.1 Acceptor Impuri
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18.14 The Hall Effect • 747 Depen
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18.15 Semiconductor Devices • 749
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18.16 Conduction in Ionic Materials
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ands that overlap the valence and c
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18.19 Field Vectors and Polarizatio
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18.19 Field Vectors and Polarizatio
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ionic polarization Electric dipole
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18.23 Dielectric Materials • 765
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Summary • 767 + + + + + + + + +
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Summary • 769 • With these mate
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Summary • 771 18.11 r i Ac i 11
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Summary • 773 One common use for
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Questions and Problems • 775 Elec
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Questions and Problems • 777 The
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Design Problems • 779 DESIGN PROB
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Chapter 19 Thermal Properties (a) (
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19.2 Heat Capacity • 783 Figure 1
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19.3 Thermal Expansion • 785 Tabl
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19.3 Thermal Expansion • 787 For
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19.4 THERMAL CONDUCTIVITY Thermal c
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19.4 Thermal Conductivity • 791 F
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19.5 Thermal Stresses • 793 speci
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Summary • 795 • Coefficient-of-
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Design Problems • 799 rod be fabr
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WHY STUDY the Magnetic Properties o
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20.2 Basic Concepts • 803 I B 0 =
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20.3 Diamagnetism and Paramagnetism
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20.4 Ferromagnetism • 807 Table 2
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20.5 Antiferromagnetism and Ferrima
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20.5 Antiferromagnetism and Ferrima
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20.6 The Influence of Temperature o
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20.7 Domains and Hysteresis • 815
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20.7 Domains and Hysteresis • 817
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20.9 Soft Magnetic Materials • 81
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20.9 Soft Magnetic Materials • 82
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20.10 Hard Magnetic Materials • 8
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20.11 Magnetic Storage • 825 requ
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20.11 Magnetic Storage • 827 Figu
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20.12 Superconductivity • 829 Ele
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20.12 Superconductivity • 831 Tab
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Summary • 833 • For cubic ferri
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Questions and Problems • 835 List
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Questions and Problems • 837 with
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Design Problems • 839 H C 1T 2 H
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WHY STUDY the Optical Properties of
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21.3 Light Interactions with Solids
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21.4 Atomic and Electronic Interact
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21.5 Refraction • 847 Velocity of
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21.7 ABSORPTION Nonmetallic materia
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21.7 Absorption • 851 Reaction de
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21.9 Color • 853 21.9 COLOR color
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21.11 Luminescence • 855 Figure 2
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21.11 Luminescence • 857 n- and p
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21.13 Lasers • 859 Ruby Flash lam
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21.13 Lasers • 861 Partially refl
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21.4 Optical Fibers in Communicatio
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Summary • 865 Input impulse Outpu
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Summary • 867 Transparent nonmeta
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Questions and Problems • 869 Impo
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Design Problem • 871 fiber glass
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WHY STUDY Economic, Environmental,
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Environmental and Societal Consider
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Environmental and Societal Consider
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22.5 Recycling Issues in Materials
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Page 911 and 912:
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Design Questions • 885 Environmen
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A2 • Appendix A / The Internation
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A4 • Appendix B / Properties of S
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A10 • Appendix B / Properties of
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A32 • Appendix C / Costs and Rela
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A34 • Appendix C / Costs and Rela
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Appendix D Repeat Unit Structures f
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A38 • Appendix D / Repeat Unit St
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Appendix E Glass Transition and Mel
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G2 • Glossary atomic mass units (
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G4 • Glossary according to unit c
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G6 • Glossary Fick’s first law.
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G8 • Glossary J Jominy end-quench
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G10 • Glossary alternating layers
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G12 • Glossary stock; also, elong
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G14 • Glossary tempered martensit
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Answers to Selected Problems Chapte
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S2 • Answers to Selected Problems
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S4 • Answers to Selected Problems
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plane strain fracture toughness, 24
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Clay, characteristics, 518-519 Clay
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Die casting, 419 Dielectric breakdo
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Fatigue life, 258, G4 factors that
Page 985 and 986:
Heat treatable, definition of, 406
Page 987 and 988:
modulus of elasticity, 486 thermal
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Nanotubes, carbon, 13, 471 Natural
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fatigue behavior (PET), 580 magneti
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single crystal, 451 structure of, 4
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Stabilized zirconia, 478, 655 Stabi
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Transparency, 844, G13 Transverse b
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Power 1 W 0.239 cal/s 1 cal/s 4.1
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Callister - An introduction - 8th edition

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