Mechanical Metallurgy

Table of Contents
List of Symbols
1. Introduction
	1-1 Scope of this Book
	1-2 Strength of Materials - Basic Assumptions
	1-3 Elastic and Plastic Behavior
	1-4 Average Stress and Strain
	1-5 Tensile Deformation of Ductile Metal
	1-6 Ductile vs. Brittle Behavior
	1-7 What Constitutes Failure ?
	1-8 Concept of Stress and the Types of Stresses
	1-9 Concept of Strain and the Types of Strain
	1-10 Units of Stress and Other Quantities
	Bibliography
2. Stress and Strain Relationships for Elastic Behavior
	2-1 Introduction
	2-2 Description of Stress at a Point
	2-3 State of Stress in Two Dimensions (Plane Stress)
	2-4 Mohr's Circle of Stress-- Two Dimensions
	2-5 State of Stress in Three Dimensions
	2-6 Stress Tensor
	2-7 Mohr's Circle-- Three Dimensions
	2-8 Description of Strain at a Point
	2-9 Mohr's Circle of Strain
	2-10 Hydrostatic and Deviator Components of Stress
	2-11 Elastic Stress-Strain Relations
	2-12 Calculation of Stresses from Elastic Strains
	2-13 Strain Energy
	2-14 Anisotropy of Elastic Behavior
	2-15 Stress Concentration
	2-16 Finite Element Method
	Bibliography
3. Elements of the Theory of Plasticity
	3-1 Introduction
	3-2 The Flow Curve
	3-3 True Stress and True Strain
	3-4 Yielding Criteria for Ductile Metals
	3-5 Combined Stress Tests
	3-6 The Yield Locus
	3-7 Anisotropy in Yielding
	3-8 Yield Surface and Normality
	3-9 Octahedral Shear Stress and Shear Strain
	3-10 Invariants of Stress and Strain
	3-11 Plastic Stress-Strain Relations
	3-12 Two-Dimensional Plastic Flow-- Slip-Line Field Theory
	Bibliography
4. Plastic Deformation of Single Crystals
	4-1 Introduction
	4-2 Concepts of Crystal Geometry
	4-3 Lattice Defects
	4-4 Deformation by Slip
	4-5 Slip in a Perfect Lattice
	4-6 Slip by Dislocation Movement
	4-7 Critical Resolved Shear Stress for Slip
	4-8 Deformation of Single Crystals
	4-9 Deformation of Face-Centered Cubic Crystals
	4-10 Deformation by Twinning
	4-11 Stacking Faults
	4-12 Deformation Bands and Kink Bands
	4-13 Microstrain Behavior
	4-14 Strain Hardening of Single Crystals
	Bibliography
5. Dislocation Theory
	5-1 Introduction
	5.2 Observation of Dislocations
	5-3 Burger's Vector and the Dislocation Loop
	5-4 Dislocations in the Face-Centered Cubic Lattice
	5-5 Dislocations in the Hexagonal Close-Packed Lattice
	5-6 Dislocations in the Body-Centered Cubic Lattice
	5-7 Stress Fields and Energies of Dislocations
	5-8 Forces on Dislocations
	5-9 Forces Between Dislocations
	5-10 Dislocation Climb
	5-11 Intersection af Dislocations
	5-12 Jogs
	5-13 Dislocation Sources
	5-14 Multiplication of Dislocations
	5-15 Dislocation-Point Defect Interactions
	5-16 Dislocation Pile-Ups
	Bibliography
6. Strengthening Mechanisms
	6-1 Introduction
	6-2 Grain Boundaries and Deformation
	6-3 Strengthening From Grain Boundaries
	6-4 Low-Angle Grain Boundaries
	6-5 Yield-Point Phenomenon
	6-6 Strain Aging
	6-7 Solid-Solution Strengthening
	6-8 Deformation of Two-Phase Aggregates
	6-9 Strengthening from Fine Particles
	6-10 Fiber Strengthening
	6-11 Strengthening Due to Point Defects
	6-12 Martensite Strengthening
	6-13 Cold-Worked Structure
	6-14 Strain Hardening
	6-15 Annealing of Cold-Worked Metal
	6-16 Bauschinger Effect
	6-17 Preferred Orientation (Texture)
	Bibliography
7. Fracture
	7-1 Introduction
	7-2 Types of Fracture in Metals
	7-3 Theoretical Cohesive Strength of Metals
	7-4 Griffith Theory of Brittle Fracture
	7-5 Fracture of Single Crystals
	7-6 Metallographic Aspects of Fracture
	7-7 Fractography
	7-8 Dislocation Theories of Brittle Fracture
	7-9 Ductile Fracture
	7-10 Notch Effects
	7-11 Concept of the Fracture Curve
	7-12 Fracture Under Combined Stresses
	7-13 Effect of High Hydrostatic Pressure on Fracture
	Bibliography
8. The Tension Test
	8-1 Engineering Stress-Strain Curve
	8-2 True-Stress - True-Strain Curve
	8-3 Instability in Tension
	8-4 Stress Distribution at the Neck
	8-5 Ductility Measurement in Tension Test
	8-6 Effect of Strain Rate on Flow Properties
	8-7 Effect of Temperature on Flow Properties
	8-8 Influence of Testing Machine on Flow Properties
	8-9 Constitutive Equations
	8-10 Further Consideration of Instability
	8-11 Stress-Relaxation Testing
	8-12 Thermally Activated Deformation
	8-13 Notch Tensile Test
	8-14 Tensile Properties of Steel
	8-15 Anisotropy of Tensile Properties
	Bibliography
9. The Hardness Test
	9-1 Introduction
	9-2 Brinell Hardness
	9-3 Meyer Hardness
	9-4 Analysis of Indentation by an Indenter
	9-5 Relationship Between Hardness and the Flow Curve
	9-6 Vickers Hardness
	9-7 Rockwell Hardness Test
	9-8 Microhardness Tests
	9-9 Hardness-Conversion Relationships
	9-10 Hardness at Elevated Temperatures
	Bibliography
10. The Torsion Test
	10-1 Introduction
	10-2 Mechanical Properties in Torsion
	10-3 Torsional Stresses for Large Plastic Strains
	10-4 Types of Torsion Failures
	10-5 Torsion Test vs. Tension Test
	10-6 Hot Torsion Testing
	Bibliography
11. Fracture Mechanics
	11-1 Introduction
	11-2 Strain-Energy Release Rate
	11-3 Stress Intensity Factor
	11-4 Fracture Toughness and Design
	11-5 Kic Plane-Strain Toughness Testing
	11-6 Plasticity Corrections
	11-7 Crack-Opening Displacement
	11-8 J-Integral
	11-9 R-Curve
	11-10 Probabalistic Aspects of Fracture Mechanics
	11-11 Toughness of Materials
	Bibliography
12. Fatigue of Metals
	12-1 Introduction
	12-2 Stress Cycles
	12-3 The S-N Curve
	12-4 Statistical Nature of Fatigue
	12-5 Effect of Mean Stress on Fatigue
	12-6 Cyclic Stress-Strain Curve
	12-7 Low-Cycle Fatigue
	12-8 Strain-Life Equation
	12-9 Structural Features of Fatigue
	12-10 Fatigue Crack Propagation
	12-11 Effect of Stress Concentration on Fatigue
	12-12 Size Effect
	12-13 Surface Effects and Fatigue
	12-14 Fatigue Under Combined Stresses
	12-15 Cumulative Fatigue Damage and Sequence Effects
	12-16 Effect of Metallurgical Variables on Fatigue
	12-17 Design for Fatigue
	12-18 Machine Design Approach - Infinite-Life Design
	12-19 Local Strain Approach
	12-20 Corrosion Fatigue
	12-21 Effect of Temperature on Fatigue
	Bibliography
13. Creep and Stress Rupture
	13-1 The High-Temperature Materials Problem
	13-2 Time-Dependent Mechanical Behavior
	13-3 The Creep Curve
	13-4 The Stress-Rupture Test
	13-5 Structural Changes During Creep
	13-6 Mechanisms of Creep Deformation
	13-7 Deformation Mechanism Maps
	13-8 Activation Energy for Steady-State Creep
	13-9 Superplasticity
	13-10 Fracture at Elevated Temperature
	13-11 High-Temperature Alloys
	13-12 Presentation of Engineering Creep Data
	13-13 Prediction of Long-Time Properties
	13-14 Creep Under Combined Stress
	13-15 Creep-Fatigue Interaction
	Bibliography
14. Brittle Fracture and Impact Testing
	14-1 The Brittle-Fracture Problem
	14-2 Notched-Bar Impact Tests
	14-3 Instrumented Charpy Test
	14-4 Significance of Transition-Temperature Curve
	14-5 Metallurgical Factors Affecting Transition Temperature
	14-6 Drop-Weight Test and Other Large-Scale Tests
	14-7 Fracture Analysis Diagram
	14-8 Temper Embrittlement
	14-9 Environment Sensitive Fracture
	14-10 Flow and Fracture Under Very Rapid Rates of Loading
	Bibliography
15. Fundamentals of Metalworking
	15-1 Classification of Forming Processes
	15-2 Mechanics of Metalworking
	15-3 Flow-Stress Determination
	15-4 Temperature in Metalworking
	15-5 Strain-Rate Effects
	15-6 Metallurgical Structure
	15-7 Friction and Lubrication
	15-8 Deformation-Zone Geometry
	15-9 Hydrostatic Pressure
	15-10 Workability
	15-11 Residual Stresses
	15-12 Experimental Techniques for Metalworking Processes
	15-13 Computer-Aided Manufacturing
	Bibliography
16. Forging
	16-1 Classification of Forging
	16-2 Forging Equipment
	16-3 Forging in Plane Strain
	16-4 Open-Die Forging
	16-5 Closed-Die Forging
	16-6 Calculation of Forging Loads in Closed-Die Forging
	16-7 Forging Defects
	16-8 Powder Metallurgy Forging
	16-9 Residual Stresses in Forgings
	Bibliography
17. Rolling of Metals
	17-1 Classification of Rolling Processes
	17-2 Rolling Mills
	17-3 Hot-Rolling
	17-4 Cold-Rolling
	17-5 Rolling of Bars and Shapes
	17-6 Forces and Geometrical Relationships in Rolling
	17-7 Simplified Analysis of Rolling Load: Rolling Variables
	17-8 Problems and Defects in Rolled Products
	17-9 Rolling-Mill Control
	17-10 Theories of Cold Rolling
	17-11 Theories of Hot Rolling
	17-12 Torque and Power
	Bibliography
18. Extrusion
	18-1 Classification
	18-2 Extrusion Equipment
	18-3 Hot Extrusion
	18-4 Deformation, Lubrication, and Defects in Extrusion
	18-5 Analysis of the Extrusion Process
	18-6 Cold Extrusion and Cold-Forming
	18-7 Hydrostatic Extrusion
	18-8 Extrusion of Tubing
	Bibliography
19. Drawing of Rods, Wires, and Tubes
	19-1 Introduction
	19-2 Rod and Wiredrawing
	19-3 Analysis of Wiredrawing
	19-4 Tube-Drawing Processes
	19-5 Analysis of Tube Drawing
	19-6 Residual Stresses in Rod, Wire, and Tubes
	Bibliography
20. Sheet-Metal Forming
	20-1 Introduction
	20-2 Forming Methods
	20-3 Shearing and Blanking
	20-4 Bending
	20-5 Stretch Forming
	20-6 Deep Drawing
	20-7 Forming Limit Criteria
	20-8 Defects in Formed Parts
	Bibliography
21. Machining of Metals
	21-1 Types of Machining Operations
	21-2 Mechanisms of Machining
	21-3 Three-Dimensional Machining
	21-4 Temperature in Metal Cutting
	21-5 Cutting Fluids
	21-6 Tool Materials and Tool Life
	21-7 Grinding Processes
	21-8 Nontraditional Machining Processes
	21-9 Economics of Machining
	Bibliography
A. The International System of Units
B. Problems
Answers to Selected Problems
Name Index
Subject Index