Cover -- Title Page -- Copyright -- Contents -- Preface -- Chapter 1 Failure Analysis -- I. Introduction -- II. Examples of Case Studies Involving Structural Failures -- A. Problems with Loads and Design -- B. Problems with Design, Inspection, Maintenance, and Repair -- III. Summary -- References -- Problems -- Chapter 2 Elements of Elastic Deformation -- I. Introduction -- II. Stress -- A. Definitions -- B. Decomposition of a Stress Tensor -- C. Principal Stresses -- D. Mohr Circles -- III. Strain -- IV. Elastic Constitutive Relationships -- A. Assumptions -- B. The Elastic Constants -- C. Elastic Stress-Strain Relations -- D. Strain Energy Density -- E. Relationship between Elastic Constants -- V. State of Stress Ahead of a Notch -- VI. Summary -- References -- Appendix 2-1: Mohr Circle Equations for a Plane Problem -- Appendix 2-2: Three-Dimensional Stress Analysis -- I. Principal Stresses and Stress Invariants -- II. Maximum and Octahedral Shear Stresses -- III. Stress Deviator Tensor -- Appendix 2-3: Stress Formulas Under Simple Loading Conditions -- I. Bending of a Beam -- II. Torsion of a Circular Shaft -- III. Thin-Walled Cylinder -- Problems -- Chapter 3 Elements of Plastic Deformation -- I. Introduction -- II. Theoretical Shear Strength -- III. Dislocations -- IV. Yield Criteria for Multiaxial Stress -- A. Distortional (Shear) Energy Criterion -- B. Maximum Shear Stress Criterion -- V. State of Stress in the Plastic Zone Ahead of a Notch in Plane-Strain Deformation -- VI. Summary -- For Further Reading -- Appendix 3-1: The von Mises Yield Criterion -- Problems -- Chapter 4 Elements of Fracture Mechanics -- I. Introduction -- II. Griffith's Analysis of the Critical Stress for Brittle Fracture -- III. Alternative Derivation of the Griffith Equation.

IV. Orowan-Irwin Modification of the Griffith Equation -- V. Stress Intensity Factors -- VI. The Three Loading Modes -- VII. Determination of the Plastic Zone Size -- VIII. Effect of Thickness on Fracture Toughness -- IX. The R-Curve -- X. Short Crack Limitation -- XI. Case Studies -- A. Failure of Cannon Barrels -- B. Failure of a Post-tensioned Steel Bar -- XII. The Plane-Strain Crack Arrest Fracture Toughness, KIa, of Ferritic Steels -- XIII. Elastic-plastic Fracture Mechanics -- XIV. Failure Assessment Diagrams -- XV. Summary -- References -- Problems -- Chapter 5 Alloys and Coatings -- IIntroduction -- II. Alloying Elements -- III. Periodic Table -- IV. Phase Diagrams -- A. Steels -- B. Aluminum Alloys -- C. Titanium Alloys -- D. Nickel-Base Superalloys -- V. Coatings -- VI. Summary -- References -- Problems -- Chapter 6 Examination and Reporting Procedures -- I Introduction -- II. Tools for Examinations in the Field -- III. Preparation of Fracture Surfaces for Examination -- IV. Visual Examination -- V. Case Study: Failure of a Steering Column Component -- VI. Optical Examination -- VII. Case Study: Failure of a Helicopter Tail Rotor -- VIII. The Transmission Electron Microscope (TEM) -- IX. The Scanning Electron Microscope (SEM) -- X. Replicas -- XI. Spectrographic and Other Types of Chemical Analysis -- XII. Case Study: Failure of a Zinc Die Casting -- XIII. Specialized Analytical Techniques -- XIV. Stress Measurement by X-Rays -- XV. Case Study: Residual Stress in a Train Wheel -- XVI The Technical Report -- A. An Outline for Preparing the Technical Report -- XVII. Record Keeping and Testimony -- A. Maintain a "Chain of Custody" -- B. Photos and Other Records -- C. Examination in Your Laboratory (or Service Laboratory) -- D. Storage -- E. Depositions -- F. Pretrial Preparation -- H. Cross-Examination -- I. A Final Point.

XVIII. Summary -- References -- Problem -- Chapter 7 Brittle and Ductile Fractures -- I Introduction -- II. Brittle Fracture -- III. Some Examples of Brittle Fracture in Steel -- IV. Ductile-Brittle Behavior of Steel -- A. The Charpy Test -- V. Case Study: The Nuclear Pressure Vessel Design Code -- A. Prevention of Brittle Failure (4) -- VI. Case Study: Examination of Samples from the Royal Mail Ship (RMS) Titanic -- A. Chemistry -- B. Tensile Properties -- C. Microstructure -- D. Fractography -- E. Corrosion -- F. Rivets -- VII. Ductile Fracture -- VIII. Ductile Tensile Failure, Necking -- A. Condition for Necking of a Bar -- B. Strain Localization -- C. Axisymmetric Stress in Necking -- D. Necking in a Thin Strip Under Tension -- IX. Fractographic Features Associated with Ductile Rupture -- X. Failure in Torsion -- XI. Case Study: Failure of a Helicopter Bolt -- XII. Summary -- References -- Problems -- Chapter 8 Thermal and Residual Stresses -- I Introduction -- II. Thermal Stresses, Thermal Strain, and Thermal Shock -- A. Thermal Stresses -- B. Thermal-Mechanical Cyclic Strains -- C. Thermal Shock -- III. Residual Stresses Caused by Nonuniform Plastic Deformation -- A. An Example of Mechanically Induced Residual Stresses: Springback After Bending into the Plastic Range (2) -- B. Case Study: Shaft of a Golf Club -- IV. Residual Stresses Due to Quenching -- A. Quench Cracking -- V. Residual Stress Toughening -- VI. Residual Stresses Resulting from Carburizing, Nitriding, and Induction Hardening -- A. Carburizing -- B. Nitriding -- C. Induction Hardening -- VII. Residual Stresses Developed in Welding -- VIII. Measurement of Residual Stresses -- IX. Summary -- References -- Appendix 8-1: Case Study of a Fracture Due to Thermal Stress -- Problems -- Chapter 9 Creep -- I Introduction -- II. Background.

III. Characteristics of Creep -- IV. Creep Parameters -- V. Creep Fracture Mechanisms -- VI. Fracture Mechanism Maps -- VII. Case Studies -- A. Failure at Longitudinally Welded Pipe (8) -- B. Failure of a Heat Exchanger Tube -- C. An Ovalized Tube (9) -- D. Failures in Fossil-Fired Boilers (2) -- VIII. Residual Life Assessment -- A. Microstructurally Based Approach -- B. Accelerated Creep Testing -- IX. Stress Relaxation -- X. Elastic Follow-up -- XI. Summary -- References -- Problems -- Chapter 10 Fatigue -- I Introduction -- II. Background -- III. Design Considerations -- IV. Mechanisms of Fatigue -- A. The Initiation of Fatigue Cracks -- B. Fatigue Crack Closure -- C. The Propagation of Fatigue Cracks -- V. Factors Affecting Fatigue Crack Initiation -- A. Surface Roughness -- B. Carburization -- C. Shot Peening -- D. Environments -- VI. Factors Affecting Fatigue Crack Growth -- VII. Analysis of the Rate of Fatigue Crack Propagation -- A. Crack Tip Stress Approach -- B. A Fatigue Crack Growth Relationship -- VIII. Fatigue Failure Analysis -- A. Macroscopic -- B. Microscopic -- IX. Case Studies -- A. Hydroelectric Generator Power Failure (62) -- B. Fatigue of a B747 Fuse Pin (63) -- C. Aircraft Gas Turbines -- D. Coil Springs (69) -- X. Thermal-Mechanical Fatigue -- XI. Cavitation -- XII. Composite Materials -- XIII. Summary -- References -- For Further Reading -- Problems -- Chapter 11 Statistical Distributions -- I. Introduction -- II. Distribution Functions -- III. The Normal Distribution -- IV. Statistics of Fatigue -- Statistical Distributions -- V. The Weibull Distribution -- A. Application to Yield Strength -- B. Application to Fatigue Life -- VI. The Gumbel Distribution -- A. Maximum Size of the Inclusion -- B. Influence of Inclusion Size on Fatigue Strength -- C. Maximum Depth of the Corrosion Pit.

VII. The Staircase Method -- VIII. Summary -- References -- Appendix 11-1: Method of Linear Least Squares (C. F. Gauss, 1794) -- Problems -- Chapter 12 Defects -- I. Introduction -- II. Weld Defects -- A. General Characteristics -- B. Effect of the Cooling Rate -- C. Laminar Tearing -- III. Case Study: Welding Defect -- A. The Alexander Kielland Accident, March 27,1980 (4) -- B. Accident Investigation -- C. Fracture in Bracing Member D-6 -- D. Conclusions -- IV. Casting Defects -- V. Case Study: Corner Cracking during Continuous Casting -- VI. Forming Defects -- VII. Case Studies: Forging Defects -- A. F-111 (7) -- B. Jet Engine Components -- VIII. Case Study: Counterfeit Part -- IX. The Use of the Wrong Alloys -- Errors in Heat Treatment, etc. -- X. Summary -- References -- Problems -- Chapter 13 Environmental Effects -- I. Introduction -- II. Definitions -- III. Fundamentals of Corrosion Processes -- IV. Environmentally Assisted Cracking Processes -- V. Case Studies -- A. Spring Failures -- B. Failure of a Ladder Rung -- VI. Cracking in Oil and Gas Pipelines -- VII. Crack Arrestors and Pipeline Reinforcement -- VIII. Plating Problems -- IX. Case Studies -- A. Welding Electrodes (10) -- B. Stack Corrosion (11) -- C. Backing Rings -- X. Pitting Corrosion of Household Copper Tubing -- XI. Problems with Hydrogen at Elevated Temperatures -- XII. Hot Corrosion (Sulfidation) -- XIII. Summary -- References -- Problems -- Chapter 14 Flaw Detection -- I. Introduction -- II. Inspectability -- III. Visual Examination (VE) -- IV. Penetrant Testing (PT) -- V. Case Study: Sioux City DC-10 Aircraft -- A. Summary -- B. Factual Information -- C. Stage 1 Fan Disk Historical Data -- D. Examination of the No. 2 Engine Stage 1 Fan Disk -- E. Fan Disk Manufacturing Process and Hard Alpha Material -- F. Initiation and Propagation of the Fatigue Crack.

VI. Case Study: MD-88 Engine Failure.