FOURTH EDITION DEFORMATION AND FRACTURE MECHANICS OF ENGINEERING MATERIALS 27了 RICHARD W. HERTZBERG New Jersey Zinc Professo of Materials Science and Engineering and Director, Mechanical Behavior Laboratory Materials Research Center JOHN WILEY SoNS INC
A47 The Liberty Bell/ Bettmann Archive Acquisitions Editor Cliff Robichaud Assistant Editor Catherine Beckham O mETU Production edito bra riege Ken Santor Manufacturing Coordinator Dor lllustration Coordinator Anna Methord 0050355857 This book was set in 10.5/12.5 Times Roman by Ruttle, Shaw Wetherill and printed and bound by Hamilton Printing. The cover was printed by Phoenix Color. Recognizing the importance of preserving what has been written, it is a policy of John Wiley Sons, Inc. to have books of enduring value published in the United States printed on acid-free paper, and we exert our best efforts to that ook was manufactured by a mill whose forest management programs include sustained yield harvesting of its timberlands. Sustained yield harvesting principles ensure that the number of trees cut each year does not exceed the amount of new growth Copyright o 1996 by John wiley Sons, Inc. All rights reserved. Published simultaneously in Canada. No part of this publication may be reproduced, in a retrieval system or transmitted or otherwise, except as permitted under Sections 107 or 108 of the 1976 United States opyright Act, without either the prior written permission of the Publisher, or puyment of the appropriate per- copy fee to the( (978)750-4470. Requests to the Publisher for permission should be addressed to the missions Department, John Wiley Sons, Inc, Ill River Street, Hoboken, NJ07030, (201)748-6011,fax(201)748-6008.E-mail:PermReq@WileY.com. To order books or for customer service please, call 1(800)-CALL-WILEY (225-594 Hertzberg. Richard w.1937- Deformation and fracture mechanics of engineering materials Richard W. Hertzberg 76H461995 9535234
ABOUT THE COVER The Liberty Bell appears on the cover of this textbook because the crack is intema tionally known and recognized more than any other fracture. However, there is con- siderable confusion as to the history of the Bell and how it gained such worldwide recognition. The following is intended to highlight major events in the Bell's existence from the casting foundry to the present. o commemorate the fiftieth anniversary of the granting of william Penns Charter of Liberties, the Pennsylvania Assembly purchased a bell for the Statehouse. Since there were no qualified bell foundries in the region, the bell was cast at the Whitechapel Foundry in London, England. The inscription on the bell was to read"Proclaim liberty through all the land unto all the inhabitants thereof, ""(Leviticus 25: 10). On its ompletion, the bell was shipped to Philadelphia and placed in the Statehouse belfr To the dismay of all, the bell cracked the first time it was struck. John Pass and Charles Stow, two area residents, agreed to recast the bell in time for the Charter of Liberty's jubilee celebration. After adjusting the alloy chemistry and recasting the bell twice, these amateur bell founders produced a bell with an acceptable tone. For their services, Pass and Stow were paid $295.25 and given a free advertisement: note their names on the shoulder of the bell Not leaving anything to chance, the Pennsylvania Assembly commissioned a sec ond bell from the Whitechapel Foundry, which arrived from England when Pass and Stow had completed the third casting of the original bell. What were they to do with two bells? It was ultimately decided that the original bell (also known as the Liberty Bell) be used for grand occasions such as convening townsfolk for the first public reading of the Declaration of Independence and the second Whitechapel bell be used as the town's clockbell During the Revolutionary War, the Liberty Bell was taken to Allentown, Pennsyl vania, to safeguard it from the advancing British armies. The city fathers were less concemed with protecting an American historical treasure(the bell had no historical value at that time)than with preventing the British from melting such bells to produce new artillery pieces. Cannon metal (also known as Admiralty bronze) contains 88% copper and 12%0 tin whereas bell metal contains roughly twice as much tin. After the bell was returned to Philadelphia in 1778, it continued to ring until 1835 when it cracked while tolling the funeral of Chief Justice Marshall. (The second whitechay bell was given to a church in 1828, before being destroyed in a fire. After grinding the mating surfaces of the crack to prevent them from rubbing together, the Liberty Bell was struck once again in 1846 to celebrate Washington,s birthday. After ringing
Vi ABOUT THE COVER for several hours, the original crack extended into the shoulder region. Since that time, the bell has effectively remained silent. After being sent on a series of national tours, beginning with a trip to New or 1885, the Liberty Bell has become a symbol independence. It is on permanent exhibition in the historical section of Philadelphia
To my wife Linda and my children michelle, Jason, and Nicholas
PREFACE TO THE FOURTH EDITION The addition of several new topics and the updating of numerous segments in both sections of the book enables the fourth edition of this text to continue to serve both as a textbook and as a reference volume. These changes reflect recent developments in our understanding of deformation and fracture processes in structural materials More than 130 additional references have been added to the text, raising the total to more than 1200. Twenty new example problems and 50 additional figures have been distributed throughout the manuscript to enable the reader to more readily understand the subject matter. Approximately 40 additional homework problems have been added at the end of most chapters; the solutions manual has been updated and is available to qualified users A new section on the isostress analysis, which characterizes the strength and stiffness of composites, has been added to complement the isostrain analysis that was introduced in the third edition. To establish the groundwork for expanded coverage of the fracture studies of ceramics, a new section on the modulus of rupture has been added. For students who possess a limited exposure to strength of materials concepts, the stress analysis of thin-walled cylinders has been included near the end of Chap ter 1. This discussion will help the reader in later chapters when dealing with fracture problems associated with thin-walled pressure vessels; these include circumstance surrounding leak-before-break criteria. In connection with crystallographic texture a new section on plastic anisotropy has been added to Chapter 3. A new section on creep fracture micromechanisms has been added at the conclusion of Chapter 5 Two new analytical sections have been added to Chapter 7 that deal with the Weibull analysis of the statistical nature of fracture and the generation of thermal stresses and thermal shock-induced fracture. Several new example problems have been added to the important discussions of fracture mechanics in Chapter 8. The discussions dealing with the fracture toughness of metals, ceramics, and polymers have been updated and compared with respect to the controlling crack tip shielding mechanisms. Recent observations regarding environmental threshold test procedures re included in Cl Discussion of‘ safe-life,"“fail-safe,"’and“ retirement-for- cause’ fatigue life design procedures have been added to Chapters 12 and 13. Also, a new section on procedures for the avoidance of fatigue damage, including the development of favor able residual compressive stresses and pretensioning of load-bearing members, com- pletes the discussion of Chapter 12. New topics added to Chapter 13 include:( 1) calculation and prediction of FCP data based on fundamental crystal properties;( 2) load interaction-induced macroscopic fracture surface appearance; an discussion dealing with the fatigue crack propagation response of polymers and
X PREFACE TO THE FOURTH EDITION ceramics.Finally, a new failure analysis has been added in Chapter 14 along with dditional discussions on the fracture surface appearance of metal alloys under block- loading and load-shedding conditions, respectively it the completion of the book. A number of individuals provided assistance Some contributed glossy prints of new figures, and others offered constructive criti- cism of new sections. To these individuals I express my sincere gratitude. Special thanks are extended to the authors son, J. L. hertzberg for drafting Section 5.8 and for providing several new figures. The author greatly appreciates the help of Drs.H. M. Chan, M. P. Harmer, and D. B williams for reviewing new sections of the book I appreciate the help of several of my former students, H. Azimi, T. Pecorini, C. Ragazzo, and T. Clark, for use of their recent research findings and for their usefu comments.I am grateful to the students in my recent graduate classes who reviewe several new sections of the book. Mr. Ken Marschall gratefully extended permissi of his artistic rendition of the sunken remains of the titanic. The also appreciates the editorial and production staffs at John wiley and to M.Mattie S. Siegler, and S. Coe from Lehigh University for their help with completion of the manuscript. book. To her, I extend my love and appreciation Qerstanding each time I revise this My wife Linda continues to be patient and ur Richard w. Hertzberg
PREFACE TO THE THIRD EDITION In recognition of rapidly changing developments in the field of mechanical behavior of solids, the third edition of this book covers many new topics with significantly broadened attention given to all structural materials, including metals, polymers, ceramics, and their respective composites. Most notably, a new chapter on the strengthening mechanisms in metals has been added along with extensive discussion of composites, which is treated and cross-referenced in eight chapters throughout the book. In addition, numerous topics introduced in earlier editions have been updated, with every chapter undergoing substantial change. A solutions manual for the chapter blems is available to qualified users. As before, special attention is given to providing the reader with many references for further study. A new supplementary reading list is also added to the end of several chapters. The current edition contains over 1100 references; of the more than 200 new listings, over 70%o represent citations published since the completion of the second edition in 1983. As such, this book should be viewed not only as a textbook for university study but also as a reference volume for professional use a major new section on composite materials was added to Chapter l and includes such topics as the isostrain analysis and the influence of fiber aspect ratio and orien tation on composite strength. Chapter 1 now also includes additional tables of me- chanical property data for ceramics and composites, an expanded discussion of strain rate effects on strength, and a section on classical failure theories (Tresca, Von Mises etc. ). The topic of partial dislocations has been moved from Chapter 3 to Chapter 2 and a new section on superlattice dislocations has been added to the discussion. Chapters 3 and 4 from the second edition have been combined into one chapter dealing with the slip and twinning response of crystalline solids; the topics of crys- allographic texturing and twinning have been condensed Chapter 4 represents a new addition to the book and is concerned with the strength- ening mechanisms in metals. Topics in this chapter include strain(work)hardening, grain-boundary strengthening, solid solution, precipitation, dispersion and martensitic strengthening, and metal-matrix composite strengthening. The section in Chapter 5 on materials for elevated temperature use has been expanded significantly to include a discussion of recent developments in cast and powder-produced conventional alloys, oxide-dispersion-strengthened mechanically alloyed systems, composites, and high- temperature coatings. Chapter 6 has been updated and includes new discussions designing with plastics (i.e, isochronous and isometric stress-strain curves), polymer composites, and expanded coverage of the strengthening of polymers Numerous changes and additions were also made to the second half of the book which examines the fracture mechanics of engineering materials. New sections on
PREFACE TO THE THIRD EDITION fracture mechanisms in composites and quantitative fractography have been added to Chapter 7 and the section on microvoid coalescence was updated. Chapter 8 contains new discussion of fracture toughness measurements in ceramics based on microhard- ness indentation test methods. JIc test procedures are updated. a discussion of impact esting in polymers has been added to Chapter 9 Chapter 10 now begins with expanded coverage of generic toughening mechanisms found in metals, plastics, and ceramics, and their respective composites. The section on mechanical fibering has been moved from Chapter 4 to Chapter 10 and is included with consideration of fracture toughness anisotropy. Sections on toughness in various material groups have been streamlined and updated and now include treatment of the toughness of composites. New sections on liquid metal embrittlement and EAC of polymeric solids have been added to Chapter 1l and recent Keac test methods are presented. The subject of fatigue has been updated and expanded in Chapters 12 and 13 and sections on the fatigue of composites have been added to both chapters. Other new sections in Chapter 12 include discussions of the Bauschinger effect, rainflow- counting methods to account for damage during random cyclic loading, and expanded coverage of the macrofractography of fatigue fracture surfaces. Parts of Chapter 13 have been condensed to achieve a better balance of topic coverage and other sections have been updated(especially the topics concerming the growth of short cracks and the infuence of load interactions on FCP); a new section on the fatigue of ceramics has been added. Finally, additional failure analysis case histories are briefly discussed a The many changes and additions made in the third edition of this book benefited nd other topics are updated in Chapter 14 greatly from the considerable support of many individuals who critically evaluated he strengths and weaknesses of the previous edition, reviewed sections of new ma terial, and provided advanced copies of their manuscripts and original photograp These individuals include R. Queeney, N. S. Stoloff, C. E. Price, L. L. Clements, D B. williams, G. A. Miller, R. Landgraf, R Jaccard, J. A. Manson, E. E. Underwood, w.A. Herman, T. Pecorini, T. Clark, R Marissen, S.Suresh, R.Arsenault, A.Yee R. Benn, J. Weber, E. Thompson, A. G. Evans, R. O Ritchie, B. Smith, A Benscoter R. Bucci, T Crooker W. Hoffelner, and J. Mecholsky. My apologies to those whom I may have inadvertently failed to mention The manuscript was typed with great care and dedication by betty Zdinak.Addi tional production assistance was rendered by Andrea Weiss, william Herman, Sharon Siegler and Kenneth Vecchio--I thank them all My wife Linda and children, Michelle and Jason, persevered once again. Their patience and understanding was exceptional and greatly appreciated Richard w. Hertzberg
PREFACE TO THE SECOND EDITION Since the completion of the first edition of this book, several subject areas have witnessed significant growth and maturation. These topics include fracture analysis utilizing J integral procedures, metallurgical and short crack aspects of fatigue crack propagation, and fracture processes associated with polymeric solids and ceramics Since these topics are of major interest to working engineers and academicians,a modification to the first edition was both timely and necessary. This second edition also incorporates numerous suggestions contributed by teaching colleagues, based on their considerable classroom experiences Chapters 1 to 4 contain modest changes designed to enhance the reader's under- standing of selected topics. For example, Chapter 1 contains a discussion of the relationship between the modulus of elasticity and atomic bonding forces. The differ- ent origins of annealing and deformation twins are described in Chapter 4. The topics of superplasticity and deformation maps are updated, and there is an expanded dis- cussion of materials for elevated temperature use. More recent findings pertaining to crazing in polymers are considered in Chapter 6. The section in this chapter on polymer toughness has been expanded and moved to Chapter 10 e discussion on fracture mechanics of engineering materials has undergone the most extensive revision. Chapter 7 now includes a section on macroscopic features of fracture surfaces(chevron markings), which had appeared in Chapter 14 of the fi edition. Chapter 7 also contains new sections on the fracture mechanisms in polymers and ceramics. Chapter 8 has undergone significant change. There is expanded coverage of stress intensity factors (including material originally found in Chapter 14 of the first edition), leak-before-break failure criterion, and updated discussion of Kic test procedures. Appendix B has been added to provide the reader with stress intensity factor formulas for common Krc test specimens. The chapter concludes with a con- siderable discussion of the J integral and its applicability in the elastic-plastic analysis of fracture toughnes Chapter 9 has been streamlined with the deletion of some material and the addition of updated correlations between fracture toughness and Charpy energy values. Chapter 10 contains new sections on optimizing fracture toughness in ceramics and polymers Metallurgical embrittlement phenomena, formerly considered in Chapter 11 of the discussion of hydrogen embrittlement and stress corrosion cracking model panded first edition, are now examined in Chapter 10. Chapter 11 contains an e Several new sections have been added to Chapter 12, including more detailed discussions of fatigue crack initiation and fatigue life estimations for notched com- ponents. a table of fatigue data for representative metal alloys has been added. Certain topics about the fatigue life of engineering plastics have been moved from Chapter