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复习题(1)

复习题(1)
复习题(1)

一、名词解释

Reaction bonding

Materials science and engineering

Apparent porosity

Structure

Composition

Bulk density

Trans-granular

Ductile Fracture

Glass Intermediates

shot peening

Flexural modulus

tempering

conchoidal fracture

Stress

Strain

Young’s modulus

Synthesis

Processing

Weibull distribution

Aspect ratio

Delamination

Ductile to brittle transition temperature (DBTT) Creep rate

Rupture time

Fatigue life

Endurance limit

Tape casting

True stress

Fatigue strength

Notch sensitivity

Linear polymer

Brittle stress-rupture failures

Creep

Stress

Stress-corrosion

Rule of mixtures

True porosity

Cemented carbides

Electrical Contacts

Polymers

Tempering

Tensile toughness

Ductility

Creep

True strain

Structure

Glass-ceramics

Addition Polymerization Condensation Polymerization Deflection temperature Degree of Polymerization Injection molding Conchoidal fracture

Cross-linking

Poisson’s ratio

Bulk density

Powder metallurgy Reaction bonding Tempered glass

Tape casting

Injection molding

Glass temperature

Glass formers Intermediates

stiffness

Fracture mechanics Synthesis

Apparent porosity

True porosity

Bulk density

notch sensitivity Vulcanization Degradation temperature Thermoplastic elastomers Unsaturated bond Functionality

Glass formers

Branched polymer Crystallinity

Tacticity

Necking

Elastic limit

Tensile strength

Stress-corrosion

Chevron pattern

Climb

Impact energy

Impact toughness

Particulate composites Rule of mixtures

Relaxation time

Glass intermediates

Processing

Crack Growth Rate

Copolymer

Macrohardness

Microhardness

Nano-hardness

Reaction bonding

Processing

Shear modulus

Viscosity

Strain rate

Glass temperature

Load.

Thermoplastics

Engineering stress

Engineering strain

Geometric isomer

Cross-linking

The Rule of Mixtures in Fiber-Reinforced Composites

二、英译汉

1. Ceramic materials are generally composed of at least two elements: one (or more) a metallic element and one non-metallic. Metal oxides (Al2O3, ZrO2, FeO, etc.) are common examples of ceramics, but other compounds such as carbides and nitrides are also included.

The most common elements in the earth‘s crust(外壳) are silicon and oxygen, and silica (SiO2) is the most common component of ceramics and glasses even though for most purposes we would not consider Si a metallic element. The type of chemical bonds : covalent bond, ionic bond and van der waals bond.

2 The role of materials in the advance of civilization and culture is powerfully summarized by the fact that it is the name of each dominant new material that has been used to describe the culture - the Stone Age, the Bronze Age, the Iron Age, and so forth.

3. Metallic fibers, glass fibers, and polymer fibers can be formed by drawing processes, Boron, carbon, and ceramics are too brittle and reactive to be worked by conventional drawing processes. Boron fiber is produced by chemical vapor deposition (CVD).

Carbon fiber is made by carbonizing, or pyrolizing an organic filament, which is more easily drawn or spun into, continuous lengths. The organic filament, known as a precursor is often rayon, polyacrylonitrile, or a pitch.

4 Materials Science and Engineering forms the bedrock for the engineering disciplines because the structures, components, and devices that engineers design and use must be made out of something, and that is a material.

The properties of the materials that are available define and limit the capabilities that the device or structure can have, and the techniques that can be used to fabricate it.

5 The mechanical behavior of materials is described by their mechanical properties, which are measured with idealized, simple tests. These tests are designed to represent different types of loading conditions. The properties of a material reported in various handbooks are the results of these tests. Consequently, we should always remember that handbook values are average results obtained from idealized tests and, therefore, must be used with care.

6 Microstructure includes structure at dimensions ranging from the atoms in the material and the order (or lack of it) of their arrangement, up to the tiny grains of individual crystals that pack together to form most solids, and even up to the nearly macroscopic level of fibers in paper, sand in concrete, and the thin, multiple layers of plastic, metal, and paper in a microwave popcorn bag.

7 Toughness refers to the ability of materials to absorb energy before they fracture. Tensile toughness is equal to the area under the true stress-true strain curve. The impact toughness is measured using the impact test. This could be very different from the tensile toughness. Fracture toughness describes how easily a crack or flaw in a material propagates. The plane strain fracture toughness K IC is a common result of these tests.

8 Materials may be fabricated into objects in a variety of ways, including casting into a mold, machining to remove extra material, joining parts (e.g., by soldering or welding), forming (forging, rolling, bending, etc.), or compacting particles which are then fused together (sintering, used for both metal powders and most ceramics). These operations also modify the final microstructure and must be taken into account.

9 When a material is designed for a given application, a number of factors must be considered. The material must acquire the desired physical and mechanical properties, must be capable of being processed or manufactured into the desired shape, and must provide an economical solution to the design problem. Satisfying these requirements in a manner that protects the environment – perhaps by encouraging recycling of the materials – is also essential.

10 The properties of these various classes of materials are usually rather distinct. For instance, metals are required to light and reflective. They are (usually) ductile, meaning that they can be bent before they break. They are electrically and thermally conducting.

On the other hand, ceramics and glasses are usually brittle, can be transparent to light, and are good insulators. They are particularly useful at high temperatures or in corrosive environments, since they retain their properties. Most polymers, on the other hand, cannot withstand high temperatures. Most are insulators, and many are highly deformable (which is the real meaning of the word, "plastic"), and some have unique elastic properties (rubber bands).

Semiconductors, of course, are distinguished by their electrical behavior. All of these property characteristics, and the reasons they exist, are discussed in some detail in the chapters that follow.

11 Elastomers are thermoplastics or lightly cross-linked thermosets that exhibit greater than 200% elastic

deformation. Chains are eventually cross-linked using vulcanization. The cross-linking makes it possible to obtain very large elastic deformations without permanent plastic deformation. Increasing the number of cross-links increases the stiffness and reduces the amount of elastic deformation of the elastomers.

12 The factors that affect a material’s resistance to crack propagation(裂纹扩展) :

1. The size of a flaw Larger flaws reduce the permitted stress. Special manufacturing techniques, such as filtering impurities from liquid metals and hot pressing or hot iso-static pressing of powder particles to produce ceramic or superalloy components reduce flaw size and improve fracture toughness.

2. Deformation ability The ability of a material to deform is critical. In ductile metals, the material near the tip of the flaw can deform, causing the tip of any crack to become blunt(钝的), reducing the stress intensity factor, and preventing growth of the crack. Increasing the strength of a given metal usually decreases ductility and gives a lower fracture toughness. Brittle materials such as ceramics and many polymers have much lower fracture toughness than metals.

3Thickness or rigidity of a sample Thicker, more rigid pieces of a given material have a lower

fracture toughness than thin materials.

4. Strain rate (应变速率) Increasing the rate of application of the load, such as in an impact test, typically reduces the fracture toughness of the material.

5. Service temperature Increasing the temperature normally increases the fracture toughness, just as in the impact test.

6. Grain size and defect density(缺陷密度) A small grain size normally improves fracture toughness, whereas more point defects and dislocations reduce fracture toughness. Thus, a fine-grained ceramic material may provide improved resistance to crack growth.

7. Tensile or compressive stress In certain ceramic materials we can also take advantage of stress-induced transformations that lead to compressive stresses that cause increased fracture toughness.

13 . Alumina (A12O3) is used to contain molten metal or in applications where a material must operate at high temperatures, but where high strength is also required. Alumina is also used as a low dielectric constant substrate for electronic packaging that houses silicon chips. One classical application is for insulators in spark plugs. Some unique applications are also being found in dental and medical use

14 Many factors must be considered when designing a fiber-reinforced composite, including the length, diameter, orientation, amount, and properties of the fibers; the properties of the matrix; and the bonding between the fibers and the matrix.

Fiber can be short, long or even continuous. Their dimensions are often characterized by the aspect ratio I/d, where I is the fiber length and d is the diameter. Typical fibers have diameters varying from10 μm (10x10-4cm) to 150 μm (150x 10-4 cm).

15. The impact test describes the response of a material to a rapidly applied load. The Charpy and Izod tests are typical. The energy required to fracture the specimen is measured and can be used as the basis for comparison of various materials tested under the same conditions. In addition, a transition temperature above which the material fails in a ductile, rather than a brittle, manner can be determined.

16 Examination of the fracture surface at a high magnification-perhaps using a scanning electron microscope-reveals a dimpled surface. The dimples are traces of the microvoids produced during fracture.

Normally, these microvoids are round, or equiaxed (由等轴晶粒组成的), when a normally tensile stress produces the failure [Figure 3-8(a)] However, on the shear lip(边缘the dimples(窝) are oval- shaped(椭圆的), or elongated, with the ovals (椭圆形), pointing toward the origin of the fracture [Figure 3-8(b)].

17. The strength of ceramics and glass depends upon the probability of finding a flaw that exceeds a certain critical size. For large components or larger fibers this probability increases. As a result, the strength of larger components and fibers is likely to be lower than that of smaller components or shorter fibers.

18. In materials science, the emphasis is on the underlying relationships between the synthesis and processing, structure, and properties of materials. In materials engineering, the focus is on how to translate or transform materials into a useful device or structure.

19 Fracture in fiber-reinforced composite materials is more complex, Typically, these composites contain strong, brittle fibers surrounded by a soft, ductile matrix, as in boron - reinforced aluminum. When a tensile stress is applied along the fibers, the soft Aluminum deforms in a ductile manner, with void formation and coalescence(接合) eventually producing a dimpled fracture surface. As the aluminum deforms, the load is no longer transmitted effectively to tile fibers; the fibers break in a brittle manner until there are too few of them left intact to support the final load.

20 One way is to define ceramics based on their class of chemical compounds (e.g., oxides, carbides, nitride, sulfides, etc.). Another way which we will use here is to classify ceramics by their major function (Table4-1).Ceramics are used in a wide range of technologies such as refractories, spark plugs(火花塞), dielectrics in capacitors(电容器的电介质), sensors(传感器), abrasives(研磨剂), magnetic recording media, etc.

The space shuttle makes use of ~25,000 reusable(再使用的), light-weight, highly porous ceramic tiles that protect the aluminum frame from the heat generated during re-entry into the Earth’s atmosphere.

21 Fiber length and diameter

Fiber can be short, long or even continuous. Their dimensions are often characterized by the aspect ratio I/d, where I is the fiber length and d is the diameter.

Typical fibers have diameters varying from10 μm (10x10-4cm) to150μm (150x 10-4 cm).

The strength of a composite improves when the aspect ratio is large. Fibers often fracture because of surface imperfections. Making the diameter as small as possible gives the fiber less surface area, and consequently, fewer flaws might propagate.

Amount of Fiber

A greater volume fraction of fibers increases the strength and stiffness of the composite, as we would expect from the rule of mixtures. However, the maximum volume fraction is about 80%, beyond which fibers can no longer be ompletely surrounded by the matrix.

Orientation of Fibers The reinforcing fibers may be introduced into the matrix in a number of orientations. Short randomly oriented fiber, having a small aspect ratio such as glass fiber, are easily introduced into the matrix and give relatively isotropic(等方向的) behavior in the composite. Long, or even continuous, unidirectional arrangements of fibers produce anisotropic properties, with particularly good strength and stiffness parallel to the fibers.

Fiber properties In most fiber-reinforced composites, the fibers are strong, stiff, and lightweight. If the composite is to be used at elevated temperatures, the fiber should also have a high melting temperature. Thus the specific strength and specific modulus of the fiber are important characteristics

Matrix Properties The matrix supports the fiber and keeps them in the proper position and to transfer the load to the strong fibers, protects the fibers from damage during manufacture and use of the composite, and prevent cracks in the fiber from propagating throughout the entire composite.

The matrix usually provides the major control over electrical properties, chemical behavior, and elevated-temperature use of the composite. Bonding and Failure Particularly in polymer and metal-matrix composites, good bonding must be obtained between the various constituent.

The fibers must be firmly bonded to the matrix material if the load is to be properly transmitted from the matrix to the fibers. In addition, the fibers may pull out of the matrix during loading, reducing the strength and fracture resistance of the composite if bonding is poor.

22 In general, for a given type of thermoplastic (e.g., polyethylene) the tensile strength, creep resistance, impact toughness, wear resistance, and melting temperature all increase with increasing average molecular weight or degree of polymerization. The increases in these properties are not linear. As the average molecular weight increases, the melting temperature increases and this makes the processing more difficult.

23 The fracture mechanics approach allows us to design and select materials while taking into account the inevitable(不可避免的) presence of flaws. There are three variables to consider: the property of the material (KC or KIC), the stress that the material must withstand, and the size of the flaw a. If we know two of these variables, the third can be determined.

24. Silicon carbide (SiC) provides outstanding oxidation resistance at temperatures even above the melting point of steel. SiC often is used as a coating for metals, carbon-carbon composites, and other ceramics to provide protection at these extreme temperatures. SiC is also used as an abrasive in grinding wheels and as particulate and fibrous reinforcement in both metal matrix and ceramic matrix composites. It is also used to make heating elements for furnaces.

25 Compaction and sintering- one of the most cost-effectively ways to produce thousands of relatively small pieces (<6 inches) of simple shapes is compaction and sintering. The driving force of is the reduction in the surface area of a powder . Fine powders can be spray dried, forming soft agglomerates that flow and compact well .The different steps of uniaxial compaction(单轴压力), in which the compacting force is applied in one direction, are shown in Figure 4-3(a). The microstructure of a barium magnesium tantalate ceramic prepared using compaction and sintering is shown in Figure 4-3(b).

26 .We also discussed the concepts of short-versus long-range order in terms of atomic or ionic

arrangements in non-crystalline materials. The most important of the non-crystalline materials are glasses, especially those based on silica. Of course, there are glasses based on other compounds (eg. Sulfides, fluorides).

A glass is a meta-stable material, in some ways resemblesan undercooled liquid. Below the glass temperature (Tg). The rate of volume contraction on cooling is reduced and the material can be considered a ‘glass’ rather than an ‘under-cooled liquid’.

27. In ductile metallic materials, the engineering stress-strain curve typically goes through a maximum; this maximum stress is the tensile strength of the material. Failure occurs at a lower stress after necking has reduced the cross-sectional area supporting the load. In more brittle materials, failure occurs at the maximum load, where the tensile strength and breaking strength are the same. In brittle materials, including many ceramics, yield strength, tensile strength and breaking strength are all the same.

28 Sintering involves different mass transport mechanisms [Figure 4-3(c)]. With sintering the grain boundary and bulk (volume) diffusion contribute to densification (increase in density) , Surface diffusion and evaporation condensation(浓缩) can cause grain growth, but they do not cause densification The compaction process can be completed within one minute for smaller parts; thus, uniaxial compaction is well suited for making a large number of smaller and simple shapes. Compaction is used to create what we call ‘green ceramics’; these have respectable strengths and can be handled(可以手拿的) and machined.

29 . In a simple tensile test, ductile fracture begins with the nucleation, growth, and coalescence of microvoids at the center of the test bar. Microvoids form when a high stress causes separation of the metal at grain boundaries or interfaces between the metal and small impurity particles (inclusions). As the local stress increases, the microvoids grow and coalesce into larger cavities. Eventually, the metal- to metal contact area is too small to support the load and fracture occurs.

30 Glasses are manufactured into useful articles at a high temperature with viscosity(粘性) controlled so that the glass can be shaped without breaking Figure 4-9 helps us understand the processing in terms of the viscosity ranges.

1 Liquid range Sheet and plate glass are produced when the glass is in the molten state. Techniques include rolling the molten glass through water-cooled rolls or floating the molten glass over a pool of liquid tin(锡) (Figure 4-10). The liquid-tin process produces an exceptionally(异常光滑的) smooth surface on the glass. The

development of the float-glass(浮法玻璃) process was a genuine(真正的) breakthrough in the are of glass Processing. Basic float-glass composition has been essentially unchanged for many years (Table 4-6).

2. Working range Shapes such as those of containers or light bulbs(球状物) can be formed by pressing, drawing, or blowing glass into molds (Figure 4-14). A hot gab(凹节) of liquid glass may be preformed into a crude shape (parison 玻璃半成品), then pressed or blown into a heated die(模型) to produce the final shape. The glass is heated to the working range so that the glass is formable, but not ‘runny(易流动的).’

3 . Annealing range Some ceramic parts may be annealed to reduce residual stresses introduced during foxing. Large glass castings, for example, are often annealed and slowly cooled to prevent cracking. Some glasses may be beat treated to cause devitrification (除去玻璃光泽) or the precipitation of a crystalline phase from the glass.

31. Metals and alloys have good strength, good ductility, and good formability. Metals have good electrical and thermal conductivity. Metals and alloys play an indispensable role in many applications such as automotives, buildings, bridges, aerospace, and the like.

Polymers are classified in several ways: by how the molecules are synthesized, by their molecular structure, or by their chemical family. One way to classify polymers is to state if the polymer is a linear polymer or a branched

32 polymer.

Linear polymer - Any polymer in which molecules are in the form of spaghetti-like chains(类似与意

大利细面条).

Branched polymer – In a branched polymer, there are primary polymer chains and secondary offshoots(分支) of smaller chains that stem from these main chains.

Thermoplastics - Linear or branched polymers in which chains of molecules are not interconnected to one another.

Elastomers - These are polymers (thermoplastics or lightly cross-linked thermosets) that have an elastic(弹性形变) deformation > 200%.

Thermosetting polymers - Polymers that are heavily cross-linked to produce a strong three dimensional network structure.

33.The techniques used to form the polymers depend to a large extent on the nature of the polymer – in particular, whether it is thermoplastic or thermosetting. The greatest variety of techniques are used to form the thermoplastics. The polymer is heated to near or above the melting temperature so that it becomes rubbery or liquid. The polymer is then formed in a mold or die to produce the required shape.

Silica (SiO2) is probably the most widely used ceramic material. silica is an essential ingredient(成分) in glasses and many glass ceramics. silica-based materials are used in thermal insulation, refractories, abrasives, fiber-reinforced composites, laboratory glassware etc. In the form of long continuous fibers, silica is used to make optical fibers for communications. Powders made using fine particles of silica are used in tires(轮胎), paints, and many other applications.

34. The steps of converting a ceramic powder (or mixture of powders) into a useful shape are known as powder processing. We begin with a ceramic powder and gel it ready for shaping by crushing, grinding, separating impurities, blending different powders, and spray drying, to form soil agglomerates. Different techniques such as compaction, tape casting, extrusion, and slip casting are then used to convert properly processed powders into a desired shape to form what is known as a green ceramic.

35 A special group of dispersion-strengthened nano-composite materials containing particles l0 to 250 nm in diameter is classified as particulate composites. These dispersoids(弥散体), usually a metallic oxide, are introduced into the matrix by means other than traditional phase transformations . Even though the small particles are not coherent (粘在一起)with the matrix, they block (阻塞) the movement of dislocations and produce a pronounced strengthening effect.

36 We also discussed the concepts of short-versus long-range order in terms of atomic or ionic arrangements in non-crystalline materials. The most important of the non-crystalline materials are glasses, especially those based on silica. Of course, there are glasses based on other compounds (eg. Sulfides, fluorides).

A glass is a meta-stable material, in some ways resemblesan undercooled liquid. Below the glass temperature (Tg). The rate of volume contraction on cooling is reduced and the material can be considered a ‘glass’ rather than an ‘under-cooled liquid’.

37 Titanium Dioxide (TiO2) is used to make electronic ceramics such as BaTiO3. The largest use, though, is as a white pigment to make paints. Titania is used in certain glass-ceramics as a nucleating (成核的) agent. Fine particles of TiO2 are used to make suntan (防晒) lotions that provide protection against ultraviolet (紫外

线的)rays.

38. These two aspects of ductile fracture give the failed surface characteristic features. In thick metal sections, we expect to find evidence of necking, with a significant portion of the fracture surface having a flat face where microvoids first nucleated and coalesced, and a small shear lip, where the fracture surface is at a 450 angle to the applied stress. The shear lip, indicating that slip occurred, gives the fracture a cup and cone appearance. Simple macroscopic observation of this fracture may be sufficient to identify the ductile fracture mode.

39. Fatigue is the lowering of strength or failure of a material due to repetitive stress which may be above or below the yield strength. The possibility of a fatigue failure is the main reason why aircraft components have a finite life. Fatigue is an interesting phenomenon in that load-bearing components can fail while the overall stress applied may not exceed the yield stress. Fatigue can occur even if the components are subjected to stress above the yield strength. A component is often subjected to the repeated application of stress below the yield strength of the material.

40. One of the most important functions of materials scientists and engineers is to establish the relationships between a material or a device’s properties and performance and the microstructure of that material, its composition, and the way the material or the device was synthesized and processed.

41 The properties for which ceramics are most often selected include:

high melting temperatures (the ability to be used at elevated temperatures)

high electrical resistivity(系数) (although some ceramics are super conductors);

a broad range of thermal conductivity(热传导) (some ceramics are excellent insulators);

high hardness (although many ceramics are brittle);

good resistance to chemical attack and other environmental conditions;

42 .In general, for a given type of thermoplastic (e.g., polyethylene) the tensile strength, creep resistance, impact toughness, wear resistance, and melting temperature all increase with increasing average molecular weight or degree of polymerization. The increases in these properties are not linear. As the average molecular weight increases, the melting temperature increases and this makes the processing more difficult.

43. Sintering involves different mass transport mechanisms. With sintering the grain boundary and bulk

(volume) diffusion contribute to densification (increase in density), Surface diffusion and evaporation condensation can cause grain growth, but they do not cause densification

44 Most fiber-reinforced composites provide improved strength, fatigue resistance, Young's modulus, and strength-to-weight ratio by incorporating strong, stiff, but brittle fibers into a softer, more ductile matrix. The matrix material transmits the force to the fibers, which carry most of the applied force. The matrix also provides protection for the fiber surface and minimizes diffusion of species such as oxygen or moisture that can degrade the mechanical properties of fibers. The strength of the composite may be high at both room temperature and elevated temperatures.

45 We begin with a ceramic powder and get it ready for shaping by crushing(挤压), grinding, separating impurities, blending different powders, and spray drying (喷雾干燥) to form soil agglomerates (造粒). Different techniques such as compaction (压缩), tape casting (流延成型), extrusion (挤出), and slip casting (流铸法) are then used to convert properly processed powders into a desired shape to form what is known as a green ceramic.

46 The impact test describes the response of a material to a rapidly applied load. The Charpy and Izod tests are typical. The energy required to fracture the specimen is measured and can be used as the basis for comparison of various materials tested under the same conditions. In addition, a transition temperature above which the material fails in a ductile, rather than a brittle, manner can be determined.

47 In ductile metallic materials, the engineering stress-strain curve typically goes through a maximum; this maximum stress is the tensile strength of the material. Failure occurs at a lower stress after necking has reduced the cross-sectional area supporting the load. In more brittle materials, failure occurs at the maximum load, where the tensile strength and breaking strength are the same. In brittle materials, including many ceramics, yield strength, tensile strength and breaking strength are all the same.

48. When a material is designed for a given application, a number of factors must be considered. The material must acquire the desired physical and mechanical properties, must be capable of being processed or manufactured into the desired shape, and must provide an economical solution to the design problem. Satisfying these requirements in a manner that protects the environment – perhaps by encouraging recycling of the materials – is also essential.

For sintered ceramics, the average grain size, grain size distribution, and the level and type of porosity are

important. Similarly, depending upon the application, second phases in the microstructure auld (旧的) occur as separate grains of components dissolved(溶解) in solid solutions of the matrix, so second phases at grain boundaries also become important, In the rose of extruded ceramics(挤出的陶瓷), orientation effects(倾向性) also can be important.

49 Grains and Grain Boundaries the average grain size is often closely related to the primary particle size(基本尺寸). An exception (例外) to this is if there is grain growth due to long sintering times or exaggerated (过分的) or abnormal grain growth (Chapter 5). Typically, ceramics with a small grain size are stronger than coarse-grained (晶粒粗糙的) ceramics. Finer grain sizes help reduce stresses that develop at grain boundaries due to anisotropic(各向异性的)expansion and contraction(膨胀和收缩).

50 Thermosetting polymers often begin as linear chains. Depending on the type of repeat units and the degree of polymerization, the initial polymer may be either a solid or a liquid resin; in some cases, a two- or three-part liquid resin is used. Heat, pressure, mixing of the various resin, or other methods initiate the cross-linking process. Cross-linking is not reversible; once formed, the thermosets cannot be reused or recycled conveniently.

51 Composites are produced when two or more materials or phases are used together to give a combination of properties that cannot be attained otherwise(另外的方法).

Composite materials may be selected to give unusual combinations of strength, weight, high-temperature performance, corrosion resistance, hardness, or conductivity. Composites highlight(突出) how different materials can work in synergy. Abalone shell(鲍鱼壳), wood, bone, and teeth are examples of naturally occuring composites.

52 Most fiber-reinforced composites provide improved strength, fatigue resistance, Young's modulus, and strength-to-weight ratio by incorporating(合并) strong, stiff, but brittle fibers into a softer, more ductile matrix.

The matrix material transmits the force to the fibers, which carry most of the applied force. The matrix also provides protection for the fiber surface and minimizes diffusion of species such as oxygen or moisture that candegrade the mechanical properties of fibers.

三、分析或计算

1. Silicon carbide particles are compacted and fired at a high temperature to produce a strong ceramic shape. The specific gravity of SiC is 3.2 g/cm3. The ceramic shape subsequently is weighed when dry (360g), after soaking in water (385 g), and while suspended in water (224 g). Calculate the apparent porosity, the true porosity, and the fraction of the pore volume that is closed.

2 The flexural strength (弯曲强度) of a composite material reinforced with glass fibers is 45,000 psi and the flexural modulus is 18 106 psi. A sample, which is 0.5 in. wide, 0.375 in. high, and 8 in. long, is supported between two rods 5 in. apart. Determine the force required to fracture the material and the deflection of the sample at fracture, assuming that no plastic deformation(塑性变形) occurs.

3. Assume that an advanced ceramic, Sialon (acronym for silicon aluminum oxy-nitride), has a tensile strength of 60,000 psi. Let us assume that this value is for a flaw-free ceramic. (in practice, it is almost impossible to produce flaw-free ceramics.) A thin crack 0.01 in. deep is observed before a Sialon part is tested. The part unexpectedly fails at a stress of 500 psi by propagation of the crack. Estimate the radius of the crack tip.

4 A chain used to hoist heavy loads fails (提升重物的链断裂失效). Examination of the failed link indicates considerable deformation and necking prior to failure. List some of the possible reasons for failure.

5. A titanium pipe used to transport a corrosive material at 400℃ is found to fail after several months. How would you determine the cause for the failure?

6 An aluminum rod is to withstand(经受)an applied force of 45,000 pounds. To assure a sufficient safety(足够的安全), the maximum allowable stress on the rod is limited to 25,000 psi. The rod must be at least 150 in. long but must deform elastically no more than 0.25 in. when the force is applied. Design an appropriate rod.

7 We produce good chemical resistance in a glass when we introduce B2O3 into silica. To assure that we have good glass-forming tendencies, we wish the O:Si ratio to be no more than 2.5, but we also want the glassware to have a low-melting temperature to make the glass-forming process easier and more economical. Design such a glass.

8 Design a supporting 3-in.-wide plate made of sialon, which has a fracture toughness of 9,000 psi , that will withstand a tensile load of 40,000 lb. The part is to be nondestructively tested (非破坏性的实验)to assure that no flaws are present that might cause failure.

in

9 An engineer investigating the cause of an automobile accident finds that the right rear wheel has broken off at the axle. The axle is bent. The fracture surface reveals a Chevron pattern pointing toward the surface of the axle. Suggest a possible cause for the failure.

10 The flexural strength of a composite material reinforced with glass fibers is 45,000 psi and the flexural modulus is 18 106 psi. A sample, which is 0.5 in. wide, 0.375 in. high, and 8 in. long, is supported between two rods 5 in. apart. Determine the force required to fracture the material and the deflection of the sample at fracture, assuming that no plastic deformation occurs.

11 A large steel plate used in a nuclear reactor has a plane strain fracture tough ness of 80,000 psi.in and is exposed to a stress of 45,000 psi during service. Design a testing or inspection procedure capable of detecting a crack at the edge of the plate before the crack is likely to grow a t a catastrophic rate (Assuming f = 1.12).

12 A large steel plate(盘子) used in a nuclear reactor has a plane strain fracture toughness of 80,000 psi and is exposed to a stress of 45,000 psi during service. Design a testing or inspection procedure capable of detecting a crack at the edge of the plate before the crack is likely to grow at a catastrophic rate(灾难的速率).

13 Suppose 2 wt% ThO2 is added to nickel. Each ThO2 particle has a diameter of 1000 ?. How many particles are present in each cubic centimeter?( The densities of ThO2 and nickel are 9.69 and 8.9 g/cm3, respectively)

14 Design a unidirectional fiber-reinforced epoxy-matrix strut having a round cross-section. The strut is 10 ft long and, when a force of 500 pounds is applied, it should stretch no more than 0.10 in. We want to assure that the stress acting on the strut is less than the yield strength of the epoxy matrix, 12,000 psi. If the fibers should happen to break, the strut will stretch an extra amount but may not catastrophically fracture. Epoxy costs about $0.80/lb and has a modulus of elasticity of 500,000 psi.

15 A chain used to hoist heavy loads fails. Examination of the failed link indicates considerable deformation and necking prior to failure. List some of the possible reasons for failure.

16 A high-strength steel plate (Figure 7-19), which has a plane strain fracture toughness of 80 MPa , is alternately loaded in tension to 500 MPa and in compression to 60 MPa. The plate is to survive for 10 years, with

the stress being applied at a frequency of once every 5 minutes. Design a manufacturing and testing procedure that assures that the component will serve as intended.

17 Assume that an advanced ceramic, Sialon (acronym for silicon aluminum oxy-nitride), has a tensile strength of 60,000 psi. Let us assume that this value is for a flaw-free ceramic. (in practice, it is almost impossible to produce flaw-free ceramics.) A thin crack 0.01 in. deep is observed before a Sialon part is tested. The part unexpectedly fails at a stress of 500 psi by propagation of the crack. Estimate the radius of the crack tip.

18 An engineer investigating the cause of an automobile accident finds that the right rear wheel has broken of at the axle. The axle is bent. The fracture surface reveals a Chevron pattern pointing toward the surface of the axle. Suggest a possible cause for the fracture.

19 A cemented carbide cutting tool used for machining contains 75 wt% WC, 15 wt% TiC, 5 wt% TaC, and 5 wt% Co. Estimate the density of the composite

20 Derive the rule of mixtures (Equation 6.5) for the modulus of elasticity of a fiber-reinforced composite when a stress ( ) is applied along the axis of the fibers. We use the symbol ‘‘ ’’ for stress to distinguish it from the symbol used for conductivity.

21. A silver-tungsten composite for an electrical contact is produced by first making a porous tungsten powder metallurgy compact, then infiltrating pure silver into the pores. The density of the tungsten compact before infiltration is 14.5 g/cm3. Calculate the volume fraction of porosity and the final weight percent of silver in the compact after infiltration.

22 Describe the difference in fracture mechanism between a boron-reinforced aluminum composite and a glass fiber-reinforced epoxy composite.

23 Silicon carbide particles are compacted and fired at a high temperature to produce a strong ceramic shape. The specific gravity of SiC is 3.2 g/cm3. The ceramic shape subsequently is weighed when dry (360 g), after soaking in water (385 g), and while suspended in water (224 g). Calculate the apparent porosity, the true porosity, and the fraction of the pore volume that is closed.

24 A large steel plate used in a nuclear reactor has a plane strain fracture tough ness of 80,000 psi.in and is exposed to a stress of 45,000 psi during service. Design a testing or inspection procedure capable of detecting a crack at the edge of the plate before the crack is likely to grow a t a catastrophic rate(Assuming f = 1.12).

25 . A titanium pipe used to transport a corrosive material at 400℃ is found to fail after several months. How would you determine the cause for the failure?

26 Compare engineering stress and strain with true stress and strain for the aluminum alloy in Example 6.1 at

(a) the maximum load and (b) fracture. The diameter at maximum load is 0.497 in. and at fracture is 0.398 in.

27 We produce good chemical resistance in a glass when we introduce B2O3 into silica. To assure that we have good glass-forming tendencies, we wish the O:Si ratio to be no more than 2.5, but we also want the glassware to have a low-melting temperature to make the glass-forming process easier and more economical. Design such a glass.

28 A silver-tungsten composite for an electrical contact is produced by first making a porous tungsten powder metallurgy compact, then infiltrating pure silver into the pores. The density of the tungsten compact before infiltration is 14.5 g/cm3. Calculate the volume fraction of porosity and the final weight percent of silver in the compact after infiltration.

29 A chain used to hoist heavy loads fails. Examination of the failed link indicates considerable deformation and necking prior to failure. List some of the possible reasons for failure.

30 A cemented carbide cutting tool used for machining contains 75 wt% WC, 15 wt% TiC, 5 wt% TaC, and 5 wt% Co. Estimate the density of the composite.

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77

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31An advanced engineered ceramic has a Weibull modulus m = 9. The flexural strength is 250 MPa at a probability of failure F = 0.4. What is the level of flexural strength if the probability of failure has to be 0.1?

32 Seven silicon carbide specimens were tested and the following fracture strengths were obtained: 23, 49, 34, 30, 55, 43, and 40 MPa. Estimate the Weibull modulus for the data by fitting the data to Equation 7-11. Discuss the reliability of the ceramic.

33 A crankshaft in a diesel engine fails. Examination of the crankshaft reveals no plastic deformation. The fracture surface is smooth. In addition, several other cracks appear at other locations in the crankshaft. What type of failure mechanism would you expect?

34 A solid shaft for a cement kiln produced from the tool steel in Figure 6.50 must be 96 in. long and must survive continuous operation for one year with an applied load of 12,500 lb. The shaft makes one revolution per

minute during operation. Design a shaft that will satisfy these requirements.

35 We want to make 1000 kilograms of BaTiO3 ceramic from BaCO3 and TiO2. How much barium carbonate and titanium dioxide should be ball milled and calcined?

36 A manufacturer of barium zinc tantalate (Ba(Zn1/3Ta2/3)O3 or BZT ceramics) produces cylindrical, puck-shaped devices known as dielectric resonators. The particular pucks made in this case are 2 inches in diameter and 1/2 inch tall and they have a 1/2 inch hole at the center. The sintering of these pieces is conducted at 1500oC, using additives. The manufacturing process used to make these pieces is well established. Suddenly, one day, a batch of the dielectric resonators comes out of the furnace with cracks and must be rejected. The plant manager determines that the material has reached 98% of the theoretical target level of densification. What could be the reason for the cracks?

37 We produce good chemical resistance in a glass when we introduce B2O3 into silica. To assure that we have good glass-forming tendencies, we wish the O:Si ratio to be no more than 2.5, but we also want the glassware to have a low-melting temperature to make the glass-forming process easier and more economical. Design such a glass.

38 Suppose 2 wt% ThO2 is added to nickel. Each ThO2 particle has a diameter of 1000 ?. How many particles are present in each cubic centimeter(立方厘米)?

Solution

39 The densities of ThO2 and nickel are 9.69 and 8.9 g/cm3, respectively. The volume fraction is:

A titanium pipe used to transport a corrosive material at 400oC is found to fail after several months. How would you determine the cause for the failure?

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