Engineering materials 1: an introduction to properties, applications and design

Cover
Inside Front Cover
	Physical constants (SI units)
	Conversion of units - general
Engineering Materials 1:

An Introduction to Properties,
Applications and Design
Copyright
Preface to the Fifth Edition
Acknowledgments
General Introduction
	To the Student
	To the Lecturer
	Accompanying Resources
		Instructor\'s Manual
		Image Bank
		Online Materials Science Tutorials
			About the authors of the tutorials
1
Engineering Materials and Their Properties
	1.1. Introduction
	1.2. Examples of Materials Selection
Part A: Price and Availability
2
Price and Availability of Materials
	Introduction
	Data for material prices
	Use-pattern of materials
	Ubiquitous materials
		Composition of the earth\'s crust
	Exponential Growth and Doubling-Time
	Resource availability
	The future
		Material-efficient design
		Substitution
		Recycling
	Conclusion
		Environmental impact
	Worked Example
	Examples
	Answers
Part B: Elastic Moduli
3
Elastic Moduli
	Introduction
	Definition of Stress
		Ways of writing stress (SI metric system)
		Common states of stress
	Definition of Strain
	Hooke\'s Law
	Measurement of Young\'s Modulus
	Data for Young\'s Modulus
	Worked Example 1
	Worked Example 2
	Examples
	Answers
4
Bonding between Atoms
	Introduction
	Primary Bonds
	Secondary Bonds
	Condensed states of matter
	Interatomic Forces
	Examples
	Answers
5
Packing of Atoms in Solids
	Introduction
	Atom Packing in Crystals
	Close-Packed Structures and Crystal Energies
	Crystallography
	Plane Indices
	Direction Indices
	Worked Example 1
	Other Crystal Structures
	Worked Example 2
	Atom Packing in Polymers
	Atom Packing in Inorganic Glasses
	Density of Solids
	Examples
	Answers
6
Physical Basis of Young\'s Modulus
	Introduction
	Moduli of Crystals
	Rubbers and Glass Transition Temperature
	Composites
	Worked Example
	Examples
	Answers
7
Applications of Elastic Deformation
	Introduction
	Bending
	Worked Example 1
	Vibration
	Worked Example 2
	Buckling
	Worked Example 3
	Stress and Strain in Three Dimensions
	Examples
	Answers
	Bending of Beams
	Second Moments of Area
	Vibration of Beams
	Buckling of Beams
8
Case Studies in Modulus-Limited Design
	Case Study 1: Selecting Materials for Racing Yacht Masts
	Case Study 2: Designing a Mirror for a Large Reflecting Telescope
	Case Study 3: The Challenger Space Shuttle Disaster
		Postscript
	Worked example
	Examples
	Answers
Part C: Yield Strength, Tensile Strength, and Ductility
9
Yield Strength, Tensile Strength, and Ductility
	Introduction
	Linear and Nonlinear Elasticity
	Load-Extension Curves for Nonelastic (Plastic) Behavior
	True Stress-Strain Curves for Plastic Flow
	Plastic Work
	Tensile Testing
	Data
	Worked Example
	Examples
	Answers
	Revision of Terms and Useful Relations
10
Dislocations and Yielding in Crystals
	Introduction
	Strength of a Perfect Crystal
	Dislocations in Crystals
	Force Acting on a Dislocation
	Other Properties of Dislocations
	Examples
	Answers
11
Strengthening and Plasticity of Polycrystals
	Introduction
	Strengthening Mechanisms
	Solid Solution Hardening
	Precipitate and Dispersion Strengthening
	Work-Hardening
	Dislocation Yield Strength
	Yield in Polycrystals
		Grain-boundary strengthening (Hall-Petch effect)
	Final Remarks
	Examples
	Answers
12
Continuum Aspects of Plastic Flow
	Introduction
	Onset of yielding and shear yield strength, k
	Analyzing the hardness test
	Plastic instability: necking in tensile loading
		Consequences of plastic instability
	Worked example
	Examples
	Answers
	Plastic bending of beams, torsion of shafts, buckling of struts
		Bending of beams
		Plastic moments
		Shearing torques
		Plastic buckling
13
Case Studies in Yield-Limited Design
	Introduction
	Case Study 1: Elastic Design-Materials for Springs
		The leaf spring
	Worked Example
		Mechanics
		Metallic materials for the clutch springs
		Nonmetallic materials
	Case Study 2: Plastic Design-Materials for Pressure Vessels
	Case Study 3: Large-Strain Plasticity-Metal Rolling
	Examples
	Answers
Part D: Fast Fracture, Brittle Fracture, and Toughness
14
Fast Fracture and Toughness
	Introduction
	Energy Criterion for Fast Fracture
	Worked example
		Fast fracture at fixed displacements
		Fast fracture at fixed loads
		Fast-fracture condition
	Data for Gc and Kc
		Note on the stress intensity factor, K
	Examples
	Answers
	Y Values
	K Conversions
15
Micromechanisms of Fast Fracture
	Introduction
	Mechanisms of Crack Propagation 1: Ductile Tearing
	Mechanisms of Crack Propagation 2: Cleavage
	Composites, Including Wood
	Avoiding Brittle Alloys
	Worked Example
	Examples
	Answers
16
Fracture Probability of Brittle Materials
	Contents
	Introduction
	Statistics of Strength
	Weibull Distribution
	Worked Example 1
	Worked Example 2
	Modulus of Rupture
	Worked Example 3
	Worked Example 4
	Examples
	Answers
17
Case Studies in Fracture
	Introduction
	Case Study 1: Fast Fracture of an Ammonia Tank
		Details of the failure
		Material properties
		Calculation of critical stress for fast fracture
		Conclusions
	Case Study 2: Explosion of a Perspex Pressure Window during Hydrostatic Testing
		Design data
		Failure analysis
		Conclusions
	Case Study 3: Cracking of a Foam Jacket on a Liquid Methane Tank
		Thermal stresses in the foam
		Conclusions
	Worked Example
	Examples
	Answers
Part E: Fatigue Failure
18
Fatigue Failure
	Introduction
	Fatigue of Uncracked Components
	Fatigue of Cracked Components
	Fatigue Mechanisms
	Worked Example 1
	Worked example 2
	Examples
	Answers
19
Fatigue Design
	Introduction
	Fatigue Data for Uncracked Components
	Stress Concentrations
	Notch Sensitivity Factor
	Fatigue Data for Welded Joints
	Fatigue Improvement Techniques
	Designing Out Fatigue Cycles
	Worked Example
	Examples
	Answers
20
Case Studies in Fatigue Failure
	Case Study 1: The Comet Air Disasters
	Case Study 2: The Eschede Railway Disaster
	Case Study 3: Safety of the Stretham Engine
		Mechanics
		Failure by fast fracture
		Failure by fatigue
	Examples
	Answers
Part F: Creep Deformation and Fracture
21
Creep and Creep Fracture
	Introduction
	Creep Testing and Creep Curves
	Creep Relaxation
	Creep Damage and Creep Fracture
	Creep-Resistant Materials
	Worked Example
	Examples
	Answers
22
Kinetic Theory of Diffusion
	contents
	Introduction
	Diffusion and Fick\'s Law
	Data for Diffusion Coefficients
	Mechanisms of Diffusion
		Bulk diffusion: Interstitial and vacancy diffusion
		Fast diffusion paths: Grain boundary and dislocation core diffusion
		A useful approximation
	Worked example
	Examples
	Answers
23
Mechanisms of Creep, and Creep-Resistant Materials
	Introduction
	Creep Mechanisms: Metals and Ceramics
		Dislocation creep (giving power-law creep)
		Diffusion creep (giving linear-viscous creep)
		Deformation mechanism diagrams
		Creep fracture
		Designing metals and ceramics to resist power-law creep
		Designing metals and ceramics to resist diffusional flow
	Creep Mechanisms: Polymers
		Designing polymers to resist creep
	Selecting Materials to Resist Creep
	Worked Example
	Examples
	Answers
24
The Turbine Blade-A Case Study in Creep-Limited Design
	Introduction
	Properties Required of a Turbine Blade
	Nickel-Based Super-Alloys
	Engineering Developments-Blade Cooling
	Future Developments: High-Temperature Ceramics
	Cost Effectiveness
	Worked Example
	Examples
	Answers
Part G: Oxidation and Corrosion
25
Oxidation of Materials
	Introduction
	Energy of Oxidation
	Rates of Oxidation
	Data
	Micromechanisms
	Examples
	Answers
26
Case Studies in Dry Oxidation
	Introduction
	Case Study 1: Making Stainless Alloys
	Case Study 2: Protecting Turbine Blades
		Influence of coatings on mechanical properties
		Protecting future blade materials
	Case study 3: Joining Metals by Soldering and Brazing
	Examples
	Answers
27
Wet Corrosion of Materials
	Introduction
	Wet Corrosion
	Voltage Differences as the Driving Force for Wet Oxidation
	Pourbaix (Electrochemical Equilibrium) Diagrams
	Some Examples
		Copper
		Steel
		Aluminum
	Standard Electrode Potentials
	Localized Attack
	Examples
	Answers
	Rates of Uniform Metal Loss
28
Case Studies in Wet Corrosion
	Case Study 1: Protecting Ships\' Hulls from Corrosion
	Case Study 2: Rusting of a Stainless Steel Water Filter
	Case Study 3: Corrosion in Reinforced Concrete
	Small Anodes and Large Cathodes
	Worked Example 1
	Worked Example 2
	Examples
	Answers
Part H: Friction and Wear
29
Friction and Wear
	Introduction
	Friction between Materials
	Coefficients of Friction
	Lubrication
	Wear of Materials
		Adhesive wear
		Abrasive wear
	Surface and Bulk Properties
	Worked Example
	Examples
	Answers
30
Case Studies in Friction and Wear
	Introduction
	Case Study 1: Design of Journal Bearings
		Embeddability
		Conformability
		Preventing seizure
	Case Study 2: Materials for Skis and Sledge Runners
	Case Study 3: High-Friction Rubber
	Examples
	Answers
Part I: Thermal Properties
31
Thermal Expansion
	Introduction
	Worked Example 1
	Coefficients of Thermal Expansion
	Physical Basis of Thermal Expansion
	Worked Example 2
	Thermal Expansion of Composites
	Case Studies
		Temperature switches
		Continuous welded railroad track
		Glass-to-metal seals
	Examples
	Answers
32
Thermal Conductivity and Specific Heat
	Introduction
	Worked Example 1
	Thermal Conductivities and Specific Heats
	Physical Basis of Specific Heat
	Physical Basis of Thermal Conductivity
	Worked Example 2
	Worked Example 3
	Worked Example 4
	Case Studies
		Distortion and cracking of a heat exchanger
		Getting rid of frictional heat
		Seats that feel ``warm´´ and seats that feel ``cold´´
	Worked Example 5
	Examples
	Answers
33 Final Case Study: Materials and Energy in Car Design
	Introduction
	Energy and Carbon Emissions
	Achieving Energy Economy
	Material Content of a Car
	Alternative Materials
		Primary mechanical properties
		Secondary properties
	Production Methods
	Conclusions
APPENDIX.
Symbols and Formulae
	Principal Symbols
	Other Symbols
	Principal Formulae
		Chapter 2
		Chapter 3
		Chapter 6
		Chapter 7
		Chapter 9
		Chapters 10 and 11
		Chapter 12
		Chapters 14 and 15
		Chapter 16
		Chapters 18 and 19
		Chapter 21
		Chapter 22
		Chapter 23
		Chapter 25
		Chapter 27
		Chapter 29
		Chapter 31
		Chapter 32
	Magnitudes of Properties
References
Index
	A
	B
	C
	D
	E
	F
	G
	H
	I
	J
	K
	L
	M
	N
	O
	P
	R
	S
	T
	U
	V
	W
	Y
	Z
Inside Back Cover
	Conversion of units - stress and pressure
	Conversion of units - energy
	Conversion of units - power