CHE 361 Mid-term exam 2 Fall 2014

Name: ________________ Aggie no.: ________________

1- A machine component made of the ceramic Al2O3 must support a tensile stress in service. The properties of
Al2O3 are given below. If the component is found to have a surface crack of length 0.25 mm, determine the
applied stress at which failure will occur. (10 points)

Properties of Al2O3:
Young’s modulus: 393 GPa; Tensile Strength: 350 MPa; Density: 3.72 g/cm3; Surface Energy: 0.9 J/m2;
Poisson’s ratio: 0.21

Because Al2O3 is a ceramic, we will expect it to display brittle fracture, which may be described by the
Griffith's criterion for brittle failure:

2- The properties of pure aluminum (Al-I) is shown in the following Table. In addition, the properties of three
other different aluminum materials are included. Explain with a few sentences why these aluminum
materials have different mechanical properties. (15 points)

Material Discerption Yield Strength Ductility

Al-I Commercially pure Al 27.6 MPa 43 %EL
Al-II 50% Cold worked pure Al 124.2 MPa 6 %EL
Al-III Al with 2.5% Mg 84.9 MPa 23 %EL
Al-IV 50% Cold worked Al with 2.5%Mg 170.4 MPa 5 %EL

Starting from (a) we can add cold work processing in (b) and see an increase in the yield strength and a
decrease in the ductility. Both of these changes are due to STRAIN HARDENING; the increase in the
density of dislocations making it harder for dislocations to move through the aluminum.

Starting from (a) we can add Mg alloying in (c) and see an increase in the yield strength and a decrease in
the ductility. Both of these changes are due to SOLID SOLUTION HARDENING; the additional Mg
atoms of a different size than the Al atoms provide local elastic strain making it harder for dislocations to
move through the aluminum.

Starting from the solution hardened (c) we can add cold work processing in (d) and see an increase in the
yield strength and a decrease in the ductility. Both of these changes are due to the additional STRAIN
HARDENING; the increase in the density of dislocations making it harder for dislocations to move through
the aluminum. Both solid solution hardening and strain hardening are working together to increase the yield
strength of (d) compared to the pure Al of (a).

3- A metal sample is known to follow the Hall-Petch relation and is found to have a yield strength of 320 MPa
for an average grain size, d, of 5x10-6 m. For a grain size of 1.2x10-4 m the metal has a yield strength of 140
MPa. After a cold working and annealing process the final grain size is measured to be 2.6x10-5 m. What is
the expected yield strength of the metal in this condition? (15 points)

1
CHE 361 Mid-term exam 2 Fall 2014

First, we need to use the problem data to determine the two parameters in the Hall-Petch equation:

4- A cylindrical axle with 0.5 m length is

subjected to reversed rotating-bending stress
cycling with a stress ratio of R = -1 and a
maximum load of F = 4500 N. [NOTE: Use
the data in the figure to the right for your
calculations.]

a) For an estimated fatigue lifetime of 106

cycles and a factor of safety of two on the
load, what is the minimum diameter of
the axle when made of 2014-T6
aluminum? (10 points)

σ=210 MPa; N= 2; F=4500 N; L=0.5 m

 d=0.048 m

2
CHE 361 Mid-term exam 2 Fall 2014

b) Assume in the market 70Cu-30Zn brass is 20% cheaper than 2014-T6 aluminum per m3. So, if we use
70Cu-30Zn brass instead of 2014-T6 aluminum in this application (same maximum load & same
expected fatigue life), will we be able to reduce the cost? (20 points)

Volume of cylinder = π*d0^2*L/4

5- A lead–tin alloy of composition 10 wt% Sn–90 wt% Pb is slowly heated from a temperature of 100°C
(300°F).
a) At what temperature does a one phase solid form (if not at all, explain why)? (5 points)
~ 150°C

b) At what temperature does the first liquid phase form (if not at all, explain why)? (5 points)
~ 280°C

c) What are the compositions of L and α phases at 290°C? (10 points)

~ 13 and 7.5 wt% Sn, respectively.

d) What are the phase weight fractions of L and α phases at 290°C? (10 points)
CL=(10-7.5)/(13-7.5)
Cα=(13-10)/(13-7.5

3
CHE 361 Mid-term exam 2 Fall 2014

6- A typical turbojet engine is shown below [source: http://en.wikipedia.org/wiki/Jet_engine]. What kind of

possible failure(s) should be considered during design stage for the turbine in hot section? Why? (10
points)
Mainly creep, and to some extent fatigue.