Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
Lehigh UniversityLehigh Preserve
Theses and Dissertations
1994
Statistical failure analysis of copper beryllium stripmetal springs using a new fatigue test methodW. Drew PeregrimLehigh University
Follow this and additional works at: http://preserve.lehigh.edu/etd
This Thesis is brought to you for free and open access by Lehigh Preserve. It has been accepted for inclusion in Theses and Dissertations by anauthorized administrator of Lehigh Preserve. For more information, please contact [email protected].
Recommended CitationPeregrim, W. Drew, "Statistical failure analysis of copper beryllium strip metal springs using a new fatigue test method" (1994). Thesesand Dissertations. Paper 280.
·AUTHOR:
Peregrim, W. Drew
TITLE:i
Statistical Failure Analysis
of Copper Beryllium Strip
Metal Springs Using a New
Fatigue Test Method
DATE: May 29,1994
STATISTICAL FAaURE ANALYSIS OF COPPER
BERYLLIUM STRlP METAL SPRINGS USING A
NEW FATIGUE lEST METHOD
by
W. Drew Peregrim
A Thesis
Presented to the Graduate Committee
of Lehigh University
-I"in Candidacy for the Degree of
Master of Science
III
Materials Science and Engineering
This thesis dedicated to Professor John Wood
John became a friend when we worked on a pr<;>ject together and convinced me to
pursue my Masters Degree.
III
Vita
W. Drew Peregrim was born the 11th of March 1957 to Walter and Jeanne
Peregrim of Scranton, Pennsylvania. He graduated from Wilkes University with a
Bachelor of Science degree in Materials Engineering while working full time as a
Design Engineer for the Babcock and Wilcox Co. After graduation he held the
position of Managing Technical Editor for Applied Science with the Northeast
Educational Institute.
Drew presently works for Instrument Specialties Co. 'as Technical Projects
Manager and is the owner of WAP Consuiting which specializes in structural
analysis of machine components using Finite Element Analysis. At Instrument
Specialties Co. Drew is in charge of new product development. Drew holds one
patent on an electromagnetic shielding device, with a'second patent pending. Drew
is active in many professional societies including ASTM where he is the chairman
<of the Electromagnetic Shielding Committee, and ASMI where he sat on the local
chapters steering committee. He is also a member of SAE, NACE, and the
Electrochemical Society where he is active in presenting technical papers and writing
technical standards in corrosion control and electromagnetic shielding.
Drew resides in Bear Creek, Pennsylvania with his wife Kathyleen and two
children Christine and Adam.
IV
Table of Contents
Results and Discussion
Appendix A
Alloy 17200 1I4HT
Alloy 17200 XHM (190)
Alloy 17410
'AppendixE
Alloy 17200 (Failure Distributions)
Abstract
Introduction
Procedure
Conclusions
References
Alloy 17200 HT
Page 1
Page 3
Page 13
Page 18
Page 58
Page 63
Page 64
Page 65
Page 90
Page 100
Page 107
Page 116
Page 117
v
ABSTRACT
An industry developed method for testing cycle life of strip metal springs was
used to produce metal fatigue data in quantities large enough for detailed statistical
analysis. This cycle life test method is called Endurance Testing and is described in
detail. The fatigue data was analyzed using advanced statistical techniques and
computerized stress analysis. After the analysis was complete, the results were
compared to standard fatigue testing on the same lot of material using the ASTM
B593-85 test method.
The main advantages ofthe "Endurance Test method" are easily machine test
samples and the ability to simultaneously test up to 48 fatigue specimens at a time.\
Testing 48 specimens simultaneously w~s used to advant~~oducing enough test
data points to analyze statistically. Several statistical distribution functions were
tried, with a close match found between the fatigue test data and a three parameter+-
Weibulldistribution of the log of cycles to failure. Other commonly used statistical
distributions used for analyzing fatigue test results such as the two parameter
Weibull distribution are shown to provide a poor correlation to the metal fatigue
data.
Also discussed in this thesis is the ability of computerized Finite Element
Analysis to accurately analysis the complex stress distribution in a formed strip
Page 1
metal spring. This is verified by comparing the fatigue data from ASTM testing to
endurance test data. The maximum stress on the endurance test specimens were
predicted by Finite Element Analysis while the stress on the ASTM fatigue specimens
was extrapolated from strain gauge measurements.
Page 2
./
INTRODUCTION
1.0 BACKGROUND
About 30 :years ago Instrument Specialties Co. (I.S.) received several requests for
<::::metal fatigue data on Beryllium Copper strip springs. In response to this Instrument
Specialties Company invented and built a fatigue testing apparatus which Instrument
Specialties Company called the "Endurance Test Machine"l. The machine consisted of two
rows of 24 fatigue test specimen holders, allowing up to 48 fatigue specimens (Figure 1.0-1)
to be tested simultaneously. The machine is a constant deflection test machine with each
bank of 24 specimens tested to the same deflection.
The original "Endurance Test" specimen was a rectangular strip ofmetal.378 inches
wide, and 2 inches long. All the specimens in each bank of 24 were deflected the same
amount by a set of pins connected to a moving rail, one rail for each of the two rows of
specimen holders. These rails or contact pin holders are shown in Figures 1.0-2, and 1.0-3.
Each of the pins that contacts the specimens were connected electrically to an hour meter.
When each specimen broke, the connection was broken and the individual hour meter
stopped.
An electric motor with a speed control drives an adjustable crankshaft which moves
the rails with a back and forth movement The adjustable crankshaft is shown in Figure
1.0-4 and is labeled 1. This adjustable crankshaft produces the fine adjustment for setting
Page 3
the specimen deflection. Multiplying the time in minutes recorded on the hour meter, after
a fatigue specimen failed, by the RPM of the motor gave the cycles to failure.
In preliminary tests comparing commercially produced contact springs,· the
"Endurance Test" data proved to overestimate the fatigue life of the springs. It was
determined that the typical configuration of a contact spring induced a stress concentration
because of the sharp bend usually found in the high stress region. The "Endurance Test"
specimen configuration was changed from a straight specimen, to a specimen with a tight
45 degree bend at the high stress region. See Figure 1.0-1.
This specimen shape closely matched the shape of typical contact springs. These
springs typically have a flat portion which provides for mounting. The spring usually has
a tight bend and a straight portion which extends from this bend and forms the spring arm.
The electrical contact and source ofthe springs deflection is usually at the end of this spring
arm. The new specimen duplicated the stress concentrations of typical springs and
provided a superior correlation between actual spring life and metal fatigue testing.
After producing some promising data, the hour meters of the original machine began
to fail. Replacement parts were difficult to obtain, and the test program was abandoned
until 1986 when the test program was revived due to a renewed interest among Instrument
Specialties Company's customers. Several new contact alloys were coming on the market,
and comparison data on these alloys was needed.
Page 4
The "Endurance Test" machine was rebuilt using an electronic control system to
replace the ~nreliable hour meters. The control system determined if an endurance
specimen failed by measuring continuity across the specimen. Figure 1.0-2 shows the
arrangement of test specimens in the Endurance Tester including how the contact pin
deflects the specimen. The specimen holder or mounting' fIxture (item 3 -in Figures 1.0-2
and 1.0-3) anchors the specimen to the test machine. Figures 1.0-3 and 1.0-4 show the
endurance test machine.
The contact pin holder (item 2 in Figures 1.0-2 and 1.0-3) moves parallel to the block
holding the specimen mounting fIxtures. The movement is controlled by the adjustable
crankshaft, and linkage arms shown in Figures 1.0-3 and 1.0-4. The deflection can be
adjusted coarsely by attaching the lead control arm to different holes along the fIrst link
arm (item 2 of Figure 1.0-4). The fIne adjustment is made by sliding the end link in and
out in aT-slot on the crankshaft (Item 1 in Figure 1.0-4).
Each of the linkage rods has left and right hand threads so that their lengths can be
adjusted by rotating the linkage rod. This allows fIne adjustment of the contact pin holders
position. The ratio of deflection of the two contact pin holders can be varied by moving the
rod end to different holes in the linkage arm (Item 3 of Figure 1.0-4). This allows different
deflections to occur in the two contact pin holders, and so deflect the specimens different
amounts· in each bank of the "Endurance Test" machine. 1\\'0 different stress levels can
be tested simultaneously in the machine by adjusting this deflection ratio.
Page 5
When the specimen failed, electrical continuity was broken, and the control system
would indicate which specimen failed and shut the machine off. With the machine shut
down, each specimen that failed can be vismtlly verified before continuing the test. This
eliminated any. false alarms which would happen due to corrosion and abrasion of the
"Endurance Test Specimen" between the specimen and the contact pin.
To give credibility to the comparison of fatigue test data of different connector alloys
using the "Endurance Test" method, it was decided to first compare "Endurance Test"
results to ASTM B593-852 test results. To insure a good comparison, material from the
same coil of metal was used in both studies. Brush Wellman Incorporated3 provided the
test material, and performed the fatigue testing using the ASTM method at their facility.
This test data was used as a point of comparison to verifY the results of "Endurance Test"
results.
Four of the most common conductive strip metals based on Beryllium Copper were
chosen for this test program. These materials and some of their properties are described
in Table 1.0-1. The first three materials are variations of the same alloy C17200. Two of
these materials (C17200 1/4H and C17200 H) are differenqated by the amount of cold
rolling (temper) before ·ageing. The third material C17200 XHM (commercially known as
Alloy 190 XHM) is rolled and heat treated as received. No heat treatment is required after
forming with Alloy 190.
Page 6
Springs made from alloy 17200 1/4HT and 17200 HT are both formed in the solution
annealed condition and are later subjected to a ,solution ageing heat treatment. This final
heat 'treatment removes most of the residual forming stresses in these 'materials. These
three variations of alloy C17200 have different strengths, and in the case of alloy 190
include residual forming stresses not relieved by a final heat treatment. The last material
"Alloy 17410" is a relatively new alloy which is becoming increasingly popular in industry.
Alloy 17410 was chosen because it is also a Copper Beryllium alloy" and no metal fatigue
data is currently available on this alloy
Page 7
'S".cos.----- .ass 'e
.I(.,'C,
_.001
.0''0 DIP-..
t+---+--- .I '0'0..---l--*--:~:;,c.,*.oo't.
Endurance Test SpecimenFICURE 1.0-1
Page 8
-...:;n~
-a I I
~
-.7
~I~I
r-.-110
0'1 "0'1
1. Mounted Endurance Test Specimens2. Moving Contact pin Holder
3. Specimen Mounting fixture
Endurance Test Machine - Test SetupFIGURE 1.0-2
----
1. Mounted Endurance Test Specimens2. Moving contact Pin Holder
3. specimen Mounting fixture4. Adjustable Control Rod
...... In .... ".. Test ne
CURE 1 ..0 ..3
1. Fine Deflection Adjustment2. Coarse Deflection Adjustment
uI
3. Deflection Ratio Adjustment
..
Properties of Beryllium Copper Alloys
ppy
CI7200 1I4HT CI7200 HT C17200 XHM C17410
(190 XHM)
Heat Treatment 2 Hours@ 2 Hours@ Proprietary Proprietary
600'" 6OOF' from Supplier from Supplier,
Tensile Strength 175 to 205 KSf 190 to 220 KSf 155 to 175 KSf 110 to 130 KSf
Yield Strength .2% • 159.8 KSf 196 KSf 140 KSf 112.5 KSf-
Elongation %/
3 to 10 1 to 6 4 to 15 7 to 17
Hardness DPH 353 to 424 373 to 446 1317 to 378 210 to 278-- ~ ----
Electrical 22 to 28 22 to 28 17 to 28 45 to 55
Conductivity--
% lACS -
CHEMICAL
COMPOSITION - %
Beryllium 1.80 - 2.00 'i.80 - 2.00 1.80 - 2.00 0.15 - 0.50---- -- \ - ------ -----------
Cobalt - - - 0.35 - 0.60
Cobalt + Nickel 0.20 min 0.20 min 0.20 min -
Cobalt + Nickel + .06 max .06 max .06 max -Iron
Copper Balance Balance Balance Balance
Ph'sicaJ arameter --tal< enotrotLmaterial certification ~other arametersllFe f rom material -
suppliers catalog
Page 12
. Ii'
PROCEDURE
-;1.1 FATIGUE SPECIMEN PREPARATION
The I.S. '''Endurance Test" specimens were blanked in a stamping die with
tight clearances to produce a minimum burr size. A hole was then pierced in the,
center, of one end. This hole was precisely located and is used to align the specime_n
in the bending die. Details of the I.S. "Endurance Test" specimen are shown in-
Figure 1.0-1. This hole is also used later to align the specimens in the load gauge.
The 45 degree bend is then formed in a wiping die with the burr on the outside of
the bend (compression side of specimen as tested.) Specimens not requiring heat
treatment such as mill hard alloys are degreased, and are then ready for load
measurement.
Specimens requiring heat treatment (Alloys 17200 1I4H and 17200 II) were
placed in a heat treat fIxture. The fIxture clamps and holds the specimen so that it
retains its shape during the heat treat process. The fIxture used allows the heat
treatment of 12 specimens at a time. The specimens remain in the fIXture until the
heat treatment is completed and the fIxture is cooled to room temperature.
-
A liquid salt bath was preheated to the heat treat temperature recommended
by the manufacture of each alloy. The loaded fIXture was then immersed in the
liquid salt for the time period recommended by the manufacturer. Upon removal
Page 13
from the liquid salt the loaded fIxture is quenched in water. ~This quickly cools down
the fIxture and also helps dissolve the salt which entrusts the specimen. The
specimens were then removed from the heat treat fIxture.
The liquid salt heat treatment leaves a light layer of scale on the fatigue test
specimens. This scale was removed by dipping the parts in a series of caustic
chemical baths. For cleaning Beryllium Copper the commercial procedure is called
"Bright Oean" and consists of the following dips. The exact concentrations of these
chemicals are proprietary to Instrument Specialties COl.
1. Alkaline Oeaner - concentrated alkaline bath
2. Sulfuric Acid Pickle - Concentrated hot sulfuric acid mixture
3. Sulfuric/Peroxide Desmut - Concentrated mixture of sulfuric acid and
hydrogen peroxide
4. Copper Shield Anti-Tarnishing Solution - BTA solution
5. Vapor Drying - Hot Vapor Degrease with Trichloroethylene
Some Beryllium Copper alloy specimens were processed through a
proprietary cleaning process called' 'Endurance Finishingl". "Endurance Finishing"
is a tumbling operatioIiwhich fInely polishes the specimens while removing burrs.
The test results of "Endurance Finished" test specimens were treated separately in
this investigation so as to determine if the "Endurance Finish" process actually
Page 14
improves the fatigue life of contact springs.
1.2 LOAD DEFLECTION MEASUREMENTS
The width, thickness, and "A" dimension of the finished "Endurance Test"
specimens was then measured. The "A" dimension is shown in Figure 1.2-1. The
"A" dimension is a measurement of the "Endurance Test" specimen which
determines the distance from a fixed point on the "Endurance Test" specimen as
mountedin the "Endurance Test" machine to the point of contact at zero deflection
of the contact pin. This provides a reference point for setting up the test machine.
The mean of the "A" dimensions of a test group is then calculated. The
specimen with the "A" dimension closest to the mean "A" dimension is made the
master specimen and is used to set up the test machine.
Using the simple deflected beam formula, Equation 1.2-1, the load ,F, at the
contact pin necessary to produce the desired maximum stress "ef' is calculated.
a Wt 2F =
6L
EQUATION 1.2-1
Where: F = Load required to produce the desired maximum stress
Page 15
·w = Width of specimen
t = Thickness of specimen
L = Vertical distance from clamp to contact pin
The master specimen is then placed in a test jig which is a duplicate of a
specimen holder from the "Endurance Test" machine. The contact pin of the test
jig is connected to a load cell which measures the contact force of the deflected
"Endurance Test". specimen. A micrometer deflects the specimen until the
calculated force (F) of Equation 1.2-1 is reached.
The deflection is recorded, and each specimen in tum is placed in the test jig,
and deflected the same amount. The load on each specimen is recorded. Since the
"Endurance Test" machine deflects each specimen in a test group the same amount,
the stress on each specimen during the test can be calculated from the previously
measured values. The procedure for this is given in section 2.1.
Next the specimens are mounted in the "Endurance Test" machine and the
machine set to deflect the specimens the same amount as was measured above. The
"Endurance Test" machine is started, and the cycles to failure of each specimen is
recorded. The frequency of the "Endurance Test" machine is adjustable from 500
cycles per minute to about 2000 cycles per minute. A standard frequency of 1000
cycles per minute was used throughout the test program.
Page 16
A DiMension
0,9999/1
Endurance Test Specimen - "A" DimensionFIGURE 1.2-1
RESULTS AND DISCUSSION
2.1 ANALYSIS OF SPECIMEN STRESS
The stress on each specimen was determined by first measuring the load on
a fully deflected specimen. The length, width, and thickness of the specimen along
with the load on the specimen was used to calculate the load on each specimen
before the test start. The simple deflected beam relationship of Equation 2.1-1 was
at first used to calculate the stress on each "Endurance Test" specimen.
F*L*6a=---W*t 2
EQUATION 2.1-1
Where: (j = the maximum stress
W = width of specimen
L = length of specimen
t = thickness of specimen
F = force
This simple relationship along with the shape of the "Endurance Test"
specimen correlated well to cycles to failure of contact springs whose stress was
Page 18
calculated in a similar manner. The ASTM specimen's2 stress was determined from
strain gauges mounted to the specimens. The ASTM fatigue test resulJ indicated'. ~
significantly longer fatigue life at the same stress level as the "End~e Test"
specimens. This indicated that the cantilever beam method of calculating the stress
on "Endurance Test" specimens was not accurate, and the actual stress was
significantly greater than that calculated.
Instrument Specialties Company started using Finite Element Analysis
software called NISA n4 to accurately predict stress in a deflected spring. Finite
Element Analysis (FEA), has been used for many years to design critical,components
for spacecraft, aircraft, automobiles, etc. An FEA model of the loaded "Endurance
Test" specimen was made, and analyzed on a computer. The stress pattern on the
"Endurance Test" specimen as analyzed using NISA n is shown in Figures 2.l-lA
and 2.l-lB. These figures show the right half of the specimen. A mirror image of
the stress distribution occurs on the left hand side. Figure 2.2-1A shows the stress
distribution on the bottom or tension side, while Figure 2.2-1B shows the stress
distribution on the top or compression side.
From this figure you can see that there are three significant stress
concentration areas on the bend area of the "Endurance Test" specimen, the center,
and a region near the edge on either side. In examining the failed "Endurance Test"
specimens, the fracture always started at one of these three stress concentrations,
Page 19
and then continued toward one of the other high stress regions. The difference
between calculated stress and FEA stress is shown in the raw test data iIi Appendix
A for each specimen. This difference averaged about 10 KSI (68.9 MPa) higher for
the stress levels tested. This proved to explain most of the difference between the
ASTM fatigue test results, and the beam formula calculated "Endurance Test"
results.
The stress value used in the final analysis of the fatigue data was the mean
FEA stress of a test group. Since each specimen in a test group experiences the
same deflection, and not the same stress, a narrow distribution of stresses occurs for
each test group. The mean and standard deviation stress of each test group is shown
in Figures 2.1-2 to 2.1-5.. The standard deviation of stress for a test group was...
usually under 4 KSI (27.6 MPa), except where the stress exceeded the 0.2% yield
strength for. individual specimens. The stress variability within each test group is
small enough that the entire group can be considered at the same stress for statistical
analysis of the cycles to failure data. This narrow range of stress distribution also
shows that the "Endurance Test Specimens" tested are very consistent in shape and
thickness.
2.2 WEffiULL STATISTICAL DISTRIBUTION
Initial examination of data from "Endurance Testing" showed that early in
a test the frequency of failures would increase very quickly to a peak value, and then
Page 20
<. decrease slowly until the end of the test The pattern of these failures resembled a
normal distribution which was not symmetrical, and was skewed toward the high
cycle life side. To analyze the "Endurance Test" data a two parameter Weibulld"
distribution function was chosen. The second parameter of the Weibull function is
a shape parameter, which alters the shape of the statistical distribution and controls
the amount of skew in the statistical model. The Weibull cumulative distribution
function is given in Equation 2.2-1 5,6.
F(n) = 1 - e -(~)P
EQUATION 2.2-1
Where: a = Weibull Scale Parameter
~ =Weibull Shape Parameter
n = Number of cycles to failure
F(n) = The probability of failure at a given n
The alpha and beta parameters are determined from each group of test data
using the following equations. The degree of fit equation is given in
Equation 2.2_25,6. When the alpha and beta parameters represent the best fit to the
data, D(J3) equals zero. The maximum likelihood estimate of alpha is given by
Equation 2.2-2.
Page 21
1 N [(X)P] 1D(p)=-Eln(xi) --.i -1 --N i=l a P
EQUATION 2.2-2
Where:
EQUATION 2.2-3
EQUATION 2.2-4
N = Number of Test Pieces in a Test Group
Xi = The Cycles to Failure of Each Test Specimen in a Test Group
e = Natural exponent
The technique to finding the scale and shape is an iterative technique. The
above equations were programmed into a Quattro Pro spreadsheee, and the Alpha
and Beta parameters for each test group were calculated to a tolerance of 10-8.
Page 22
The resulting Weibull distribution was plotted against the actual test points
for each test, and is shown in Figures 2.2-1 through 2.2-12. The cumulative
distribution 5, 6 is given by
-(X-Xe)'P (P-l).
(P) = - (X-Xo> eP .
cz
EQUATION 2.2-5
Where:
(P) = The probability of failure
x = Cycles to Failure
Xo = Threshold Value (0 for 2 Parameter Weibull)
(Xo is also commonly referred to by the symbol "y")
The Quattro Pro spreadsheet allowed preliminary analysis of the data, and
helped prove that the two parameter Weibull statistical distribution did not properly
characterize the fatigue data. The two parameter Weibull function predicts that a
significant number of failures will occur at low fatigue cycles. This is not indicated
by the test data especially at low stress levels.
The distribution of the test data is shown in the graphs in Appendix B. The
region between the first failure, and the last failure was segmented into 10
sub-regions. The number of failures that occurred in each sub-region is shown by
Page 23
the height of the bars in the graphs. This is the two parameter Weibull data that
is plotted in Figures 2.2-1 to 2.2-12 as the actual distribution from the test results.
A three parameter Weibull distribution was tried next. The three parameter
Weibull cumulative distribution function is given by Equation 2.2-5 5,6. The Weibull
threshold parameter is the number which is subtracted from each cycle to failure
value before the two parameter Weibull function is calculated. After the Weibull
distribution is found, the threshold value is then added to the distribution creating
an offset value for the zero probability of failure. Th~ probability of failure is
mathematically zero at the threshold value, and by dermition is zero below the
threshold value.
Like the a and ~ parameters, the Weibull thresholtvaIue (y) is determined
using an iterative technique. The threshold value is determined when a log plot of
percent failures vs cycles to failure best matches a straight line. The shape of this
plot is manipulated by offsetting the data by a trial threshold-;11ue. To determine~
the best fit to a straight line, the following equation is used.
EQUATION 2.2-6
Page 24
Where:
M=
ELog(Xi-yt) * ELn(N%)
N
[Log(Xi-y t)]2
N
- E [Log(Xi - Yt) * (Ln(N% )]
- E [Log(Xi- Yt)]2
EQUATION 2.2-7
N% = The number of failures which have occurred up to and including
the test point divided by the total number of test points.
Xi = The cycles to failure of a test point.
Yt = The Weibull trial threshold value.
N = The number of specimens in a test group
The trial threshold value equals the true threshold value when R of Equation
2.2-6 is maximized. Equation 2.2-6 is the least squares degree of fit equation
modified to work with the X and Y axis of a Weibull distribution plot. When the
Weibull threshold value Yis determined for a test group, each Xi point is then
reduced by the threshold value y. The Weibull a and ~ parameters are then
determined from the modified Xi data just as they were for the two parameter
Weibull distribution.
The three parameter Weibull distribution is also plotted in Figures 2.2-1
Page 25
through 2.2-12 using the same evenly distributed points. Although the three
parameter Weibull distribution shows a bettercorrelation to the actual test data
than the two parameter Weibull distribution, it was not a good match. This
indicated that either the data is random, or a different mathematical technique was
needed.
In examining the correlation of the three parameter Weibull distribution to ~
the actual failure distribution (Figures 2.2-1 to 2.2-12), it was noticed that the three
parameter distribution peaked earlier than the test data indicated, and that the three
parameter distribution was also wider than the actual data. The test data could not
be normalized by the three parameter Weibull distribution alone. Fatigue data is
commonly plotted on a log scale, and the crack growth rates predicted by fracture
mechanics are also logarithmic in nature. With this in mind, the three parameter
Weibull analysis on the log of the cycles to failure was the next distribution to be
evaluated.
The three parameter Weibull analysis procedure using the log of the cycles
to failure was used to determine the Weibull constants for each "Endurance Test"
of alloy 17200 1/4R The antilog of this probability distribution was then plotted in
Figures 2.2-1 through 2.2-12 and compared with the other statistical techniques. The
three parameter Weibull distribution of the log of the fatigue data provided the
closest match to the actual fatigue failure distribution of the three distributions tried.
Page 26
.,
All the "Endurance Test" data was finally analyzed using the three parameter
Weibull analysis on the log of cycles to failure.
2.3 COMPARISON TO ASTM TEST RESULTS
Researchers at Brush Wellman Inc.3 used material from the same coil of
metal and performed ASTM metal fatigue testing. The Brush Wellman produced
ASTM test results were compared to the 500AJ failure prediction of the "Endurance
Test" data. The 500/0 failure point was predicted using the three parameter Weibull
technique using the log of cycles to failure. The results of the comparison is shown
in Figures 2.3-1 to 2.3-4. The ASTM results plotted are individual specimen failures
because there was not enough test data to attempt a statistical analysis. The ASTM
tester tests only 1 specimen, and Brush Wellman had access to three testers. With
the ability to test only three specimens at a time, Brush Wellman could not produce
enough data to permit a detailed statistical analysis.
The "Endurance Test" machines ability to test many ,specimens
simultaneously was used to advantage to gain a significant statistical test group. At
high stresses, where the failure distribution is relatively tight, the test group size
usually consisted of 12 specimens. As the fatigue limit of the alloy was approached,
the scatter in the failures increased dramatically. The number of specimens in a test
group was increased to 48 when the fatigue limit was approached, or the scatter
increased. This was not possible with the ASTM test method, due to the limitation
Page 27
on the number of specimens which could be tested.
The "Endurance Test" results were broken down into two categories for each
alloy and temper. "Endurance Finished" fatigue results are identified separately
from the standard manufactured finish (bright clean for heat treated alloys, and the
mill finish for mill hard materials). Most of the "Endurance Test" results are
comparable to the ASTM test results with some "Endurance Finished" test groups,
showing a trend toward early failures. In general the "Endurance Finished"
specimens produced more repeatable data, and a better correlation to the ASTM test
results than standard finished parts. This indicates that there is a source of
variability in the contact spring manufacturing process (the same manufacturing
processes used to make the "Endurance Test" specimens is used to make precision
springs), and that this can result in reduced fatigue life. The "Endurance Finishing"
process lessens this variability, but does not eliminate it.
The "Endurance Test" specimen undergoes all the manufacturing operations
of a manufactured spring, and the variability in the results mimics the problems seen
in production springs. These problems were usually blamed on a bad lot of material.
The test results indicate that the variability is more likely due to a variability in the
manufacture of the springs. The test results varied batch to batch from the same
coil of material. During the test program, the specimens were blanked in a large
batch, with specimens randomly selected from the bulk for each test. The specimens
Page 28
were then formed into the "Endurance Test" specimen just before each test This
should have randomized any variability in the coil.
2.4 TREND OF THE WEffiULL PARAMETERS
The large quantity of test groups analyzed for Alloy 17200 1I4HT allowed
analysis of the trend of the Weibull parameters. The individual Weibull parameters
from each test group were plotted against the stress of the individual test groups.
These graphs are shown as Figures 2.4-1 to 2.4-3. A least squares line fit was
performed on this graph and the results presented. Several test points were
eliminated from each least squares line fit because they fell well outside the trend of
the majority of the data. These points were so far removed from the majority of the
test points that the line fit including these points fell outside of the bulk of the data.
Using the linear relationships developed from each ofthe Weibull parameters,
a relationship was developed which related the trend of the Weibull parameters to
cycles to failure. Multiple plots were developed using the Weibull probability density
function to predict the 1010, 10%, 50%, and 90% failure points at different stress
levels. These plots are shown in Figure 2.4-4. The predictions are not unreasonable
and results in a detailed description of the fatigue behavior of alloy 17200 1I4HT
between the 0.2% Yield' Strength, and the fatigue limit of the material.
Unfortunately this plot required the results of over a thousand individual test points.
Page 29
This is only possible because of the ability of the "Endurance Test" machine to test
so many specimen~ at a time.
2.5 HUMIDITY EFFECfS
Humidity was not controlled during the major portion of the "Endurance
Testing" program. This was thought to be a possible cause of variability in the test
results, and so was investigated. Ambient humidity was not measured during the
test program, and so to determine any humidity effects, the relative humidity as
recorded by the local U.S. weather service was obtained and compared to the test.;
results. No correlation to the variability of the test results was noted in this
comparison. To further confirm that the variability in test results was not due to
humidity, the last tests were performed in a sealed tester packed with activated .
desiccant There was no improvement in consistency with the dry environment.
2.6 FATIGUE TEST RESULTS ON ALWY 17200
The fatigue test results on alloys 17200 1/4HT and HT were similar in shape,
with the stronger HT material producing about the same fatigue life with a 20 KSI
increase in stress. This is shown in Figures 2.3-1 and 2.3-2. These alloys are
chemically identical, and are differentiated only by the amount of cold reduction
after the final solution annealing. The difference in the .2%, yield strength for these
alloys is 36 KSI, and the difference in the fatigue results represented about half of
the difference in the .2% yield strengths.
Page 30
The fatigue life of the mill hard version of alloy 17200, the XHM temper,
produced significantly lower fatigue life than the HT materials. The fatigue test
results are shown in Figure 2.3-3. The.20./0 yield strength of alloy 17200 XHM is
lower than that of the 1/4HT and HT versions of this alloy which partially explains
the difference in fatigue life. This can also be explained by the presence of residual
forming stresses in the mill hard material. The 1I4HT and HT materials are solution
aged after forming which removes most of the forming stresses. Specific material
properties for the materials tested are given in Table 1.0-1
2.7 FATIGUE LIFE OF ALWY 17410
Alloy 17410 is also a Copper Beryllium alloy, but has a different chemistry
and metallurgy than alloy 17200. This is a special alloy with lower strength than
conventional Copper Beryllium alloys, but with higher conductivity. It is also only
available as a mill hard alloy, and includes residual forming stresses in the finished
"Endurance Test" specimen. This data is shown in Figure 2.3-4. The specific
material properties for this alloy are given in Table 1.0-1
Page 31
FIGURE 2.1-1A
-:t'r.~
'.;;t ....
E.M.R.C. - DISPUl't-II POST-PROCESSOR IJER 2-.'30
I
EHOURAHCE TEST SPECIMEN - TENSIOH SIDERIGHT HAL, OF TEST SPECIMEN
Hay/HV1993 STRESS COHTOURSUOH-HI SES STRESS K S JUIE~ : 9.~3E.Q4
RAHCE : L 19EH~S
(Band * 1. QE3)~ 119.4..,
6 112. a
S lIi~6 . 3
4. 99.7Q
3 93.13
_2_ 86.57
Min 8Q.QQ
,'1 IX RX= 22\ RIf= 6Q\ RZ= 2:>'------.....2
Stress Distribution - Tension Side
:;,""'r.;':;
'.;0',M
E.M.R.C. - D!~PL~V-II POST-PROCESSOR VER 2.30
ENDURAHCE TEST SPECIMEH - (OMPRESSIQH SIDERIGHT H~Lf 0f TrST SPfCIMfN
Mily/llV1993 STRESS CONTOURSIJOH-HISES STRESS K S IIJJEY : 7.48E.Q4RilHGF.: : 1.12[.Q5
<Band * 1.~[3)
~~ 112.1
FIGURE 2.1-1B
Stress Distribution - Compression Side
,~e
en~
I
enen
~ (J):;1-n .....-:: en
'4-'<:(...wu..
ALLOY 17200 1/4HT
':~~-----~----~--~---"~----r--10.2% YIELD STRENGTH I[~~I"~~~--- . " ! "i" i 1
:~~= -=- -'. -.:_---~~~-" ----~: --..~.-; -----~=~- ... .~.l~==I= ~~=I! CB-l ! : \ I
.. 4 s-; .. - --:-.--.;----.....-.---. --..... ---- ..-..----- -.-- .-~- ...--,~--~-!--~~-!
~ 4!j-"---- . .-~--...-- ;--....--.--.. ---.... --..--..---.-~ .. --- .--.....~.-.~~-,~~~-
i : I ! I
,35"'---~;--- A:----~\~-----. ---- ...--..--.....~--.- ..-------.! F/J·1! , I
~ -'0-+-~-.. :.--+-..--.... -----;. -----.----..-----.~-~ ..~---~ ! • 40·2 • !
..2sL~-A:t~-·--72-1 ,----i 175% OF 0.2% YIELD STRENGTH~rf I, • I I
'<:cr; 58'1 •
< : s-i-rXY'lJj~.,.n-t; rr IB,.. Jt-----.---·-·----A2'1---·-- i----·-,----;-------_._--_.
.,..... . . ' , , .
<C5--~~2____--, .'---'--- ~~-..---'----..-:-.------.--" ~<' ! !
.. Cr,-----W-'-- -~--------~--~ ----~.----:-.._-------_._---7'4,- " '. 4 Q-i, !
j5------·-~LG1.L--.-----,-------,---T--- .._-----------1
"..... 75-1! ,j J- .-.....- .. -_.. " '-~-'- •.----..-------...---' .---,------.-.-._,
, !
;;S-'-·---·----- --' ---"---T-- 50% OF 1).2Ok YIELD STRENGTH I:;.r: i I I iIi I I
" 2 4 5 8 10 12 14 16
Standard Deviation - KSI
•Bright Clean....
Endurance Finish I
VARIABILITY OF STRESS IN ENDURANCE TESTING
FIGURE 2.1-2
ALLOY 17200 HT
11III
Bright Clean
•Endurance Finish
14-4.6..
---_._-_..-,_.-----_._-_._~ - -_._...._---'--.-.- ---- ,--------------------_._-----_.-11
12Q--'----~ ..------ ~ - -. - -- -- --
122 i 64-1 Ii 11III I
1--' !! 11 1. !
!115+11III---
~ i 4-~en~ 11
- ---_.__..
" _ ----')- , -,----- - ..- .-.1I);oJ ')~v : _
18- _'._,1061-
CIJ < • 0 iCIJ " --:~~- -~ .. -..;.-- 14-3
(1) --lo.....en<.(wu.
-...:;r~
'-,'.11
~ Drj-----------------. .=cc-=============; 0-.-0- • --••-.-
\ 50% OF 0.2% YIELD STRENGTH ! 63-1
98- 01-2 11III11III
9S i I Ii!1 2 3 4 5 6
Standard Deviation - KSI
VARIABILITY OF STRESS IN ENDURANCE TESTING
FIGURE 2.1-3
ALLOY 190 XHM
•Bright Clean
AEndurance Finish
65-1--..._._.- ..-----
... _.._.._---.~-----------102i--~.. -:··-·
i 20-4100+ -~ .•"--I -~- - ~ -----I -- .~---.---._- ---~-.-
1D8-:----
112 i 13-3 I'
I •
11 O~ .... -14::?J6.:~·~-----·- .-~~--- ..-~.~-- .. ; II -...-.-~.-,.-._-.- .. -~, .......-------, -""--"'-"~.-----.----, I, ., I
I10C ... -.~------.-.-..- ~OF 0.2% YIELD STRENGTH f J
1
18~A I104 .- "-'~'--'~-~~'~--""-""~---"--------en
::.c::I
(/)(/)
- Q)
.'Wl--
~en
~
..... «Cl' w
lJ..
32 ...J. ~__.~ .;".--.~- ..- --_ ....__.,., _."-'- ---------------.•--------- -~-----...-,---.
SOT-------(S~3--+- .. -·--t ._, I2.8 I ! i I
1 1.5 2 2.5 3.5 4 4.5
Standard Deviation - KSI
VARIABILITY OF STRESS IN ENDURANCE TESTING
FIGURE 2.1-4
ALLOY 17410
.------ .. ·----5~1·-·,I
I I120 . •
'~.. i. 10
.2
% YILJJ) STHENGTJI 1-- '.-~-' ---~- Bright Clean II
;::,~=-t --~2~~-_j~2~ ~.. ' __..-~ I •
105~82"'------- -0-- -0 ----i--o Endurance Finish I
70--- --....- ·--··----··---27-2-·--·~-----~-··! •
o~ 4_...•_-~.._._.._--~._.~-.----)
..._-_._-....•....~~~-.
'-[75% OF 0.2% YI ELf) STRENGTH [- .--~-.---.----~~!
2/J-; .-- ..
~o-~
85~----~
9S'-~(f)
~I
(/)(/)- Q)
::," lo.......:r: (f)-:.
'- <l---J UJu..
~s--. -~.-.--.--..,--..-.----~----------.-~--.'"---~----.--.-.-.- ..-..-.-----.~------------- ..,
OF 0.2% YIELD STRENGTH [~----....
__._..... . _.-!-__. ~ __"---- ~-J, i
':/)--- -.---.--.-..-~~-l-·---~--f~~-~--·-~~----i ~~2H-ii' • '
4,5 : i I I I I
I.S 2 2.5 3 3.5 4
Standard Deviation - KSI
,4.5
VARIABILITY OF STRESS IN ENDURANCE TESTING
FIGURE 2.1-5
;:,W~~
":'ole
Alloy 17200 1/4HT - Stress 89.7 KSITc:'>! Numbc:[ WAP75-1
1.1 ' , r' I , , ,
i I I H, 11,/":" I j II,,1 I I I ! , , ' ,,....J I i ".:/ \ I I I::: (! !! I ! 1:/ \ I I I
-::- 0.9:-r- ~i i '/" , l' Ii-, Iii' I: \ I-,' Iii' I I5 O.R! r----r I, i,/I I ! 'I ! I;.-- I I! III -I I ,I I I I r I:; 0.7l I i 1/,/ ;", I I I I I i= ! I',Ii ,I i I:; 0.6 ! I I , / / I I \ I I I I I.:,; I I i h I I I i \!\ i I J
5 0.5' ; i '7"/1/1' I"r' \'\' I' I' i:£' ! l 1/ ,I \\, i I i'- () 4 ; 'f::.",... • / / "I \ I Iq /-- I ! i \" 'S 0.3 I ./ 1/ .1 I ! 1'\\, I I I I~ (2 . i ' I \ i..; J. I ,,; / " I '. !,;, I I i I '; I
:::(1 -/, 1: 1 ," I~ J. ,..-,- ,- V i Iz 1---- ' I-- () ------,-~V I : I I I I I I
I I )
1.0£+04 1.0£+05 1.0£+06CYCLES TO FAILURE
• ACTUAL 2 PARAM WEIBULL -- 3 f'ARAM WEIIlVLL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONS
FIGURE 2.2-1
Alloy 17200 1/4HT - Stress 93.2 KSITest Number WAP59-01
1.0E+08"1.0E+071.0£+05 1.0E+06CYCLES TO FAILURE
1.0£+04
iI
i I II I I 1,1, I I I , I1 II '. I ,Ii I 1/> ~l IT
II I! I
.' /,i i A' I \ I, I \ ,
II ,,1/ I I / \ I I I I\ i I II i
I I'I
J" " I II 1/ 1\ I i I I I
II I
I J II I 1
I I,
Ii [
I I I I I I Ii\ II II-- i Ii I ! , !,
1
i I II ii', i~ i i I ,,
I I J, 'I II ! " I I I j i ! I
" I
+/'1 I I I 1/ I
Iil\
I I III
! I I 1\ I.. "/,,,-
I I I I II I I II ! I I I I i III
/ i I 1\ I i Ii i ; i! I I I Ii I I j i I I III I II,
!/ ii'I , ! 1 ! i I i\I I I
II I 1/ I Ii i 1\, i II
I iI I , \. j
I i I
k11 I Ii \,,1 II I ' I
I I " II I'--, , j
1.1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
(1.0£+03
...... ~.....~
-',.....-<;.;..'~-c;...-;....~
......-,..,.-<,..,.- -...c:;
~,.."~ -".~ --.0~-;.;J~-,-<-~~
cz
• AcrUAL -,- 21'ARAM WEIBULL -- 3 PARAM WEIBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-2
'7
~~
!lO~.
....~
Alloy 17200 1/4HT - Stress 93.2 KSI) TEST NUMBER WAPOl-l
1.1
~ III;:;, I I
~ 0.88 ~LL t-'I <,,~,' 1/;tT~"~ I·r _..... ~I I 1.1
~ i 1 12.o ! ' ,\;;.. ill"'f-' I i >1f ~\- 0 66 ! L /;.fj..J • Ii I I....' I "- . I ,\~ I 1 I I'- r .," Z
..-:: I I I I I : ....~ , I I '1Il'\o I i I I' ! 1'1 '7J I S\
I I I.ill' II I \
1--
I • ACTUAL --IIc- 2 PARAM WEIBULL0 3 PARAM WEIBULL z LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-3
Alloy 17200 1/4HT - Stress 94.9 KSITest Number WAP74-1
5 0
w=z::;:,....J~ 0;...
;...f-'-~
~
~....~ i
!rQ~
0
... ~- 0WN-.....-t.-£=z::0z
1
ooooooo
I 0<- ... --:. _ - -'
1' '
......
L..
.9--, 1\
!7 ......."
"
1\
.8 I \-"
,,
.7'" ., r
; \
6 'L, 1/ \I
"'" -,.,.15
I\
4 /I
.f·.>,3Ii I
.2i / -.:.I
J 1/ '-.VI •
0I r...
,~jr
1.0E+02 1.0E+03 1.0E+04 1.0E+05CYCLES TO FAILURE
1.0E+06 1.0E+07
• ACTUAL ,......". 2 PAHAM WEIBULL - 3 PARAM WEIBULL - LOG 3 PARAM
(:QM~AR1~iQ~_OLSTArISTICAL PREDICTIONS
FIGURE 2.2-4
Alloy 17200 1/4HT - Stress 95.9 KSI/TestNumberWAP4D-l '
_ ....... 2 J>ARAM WEIBULL - 3 PARAM WEIBULL - LOG 3 PARAM
..;",..:..,-.:~-:
1.0E+OS 1.0E+06CYCLES TO FAILURES
l-
il.OE+08
~
(..
I···--···_·-t--~······I--H+III·------------
1\
1.0E+07
1\
\ ...
1\
\ ,\',"'......
\\\ "
\r\
",
l/l\r-~
I
"'"
I..LI,.
II
,--..l<:::-·r·"
7
r
I
l-
--1--, ......
1.0E+04
1.1~ 1;:;;...J=1. 0.9:...b 0.8~'-"
~ 0.7-..J~
~ 0.6~ ~!10 o 0.5~
Cl::~
~ 0.4N
\oJt: 0.3..J
:$ 0.2~
~o 0.1z
0l.OE+03
• ACTUAL
COMPARISON OF STATISTICAL PREDICTIONS
FIGURE 2.2-5
l.OE+08 ..1.0E+071.0E+OS l.OE+06CYCLES TO FAlLURE
Alloy 17200 1/4HT - Stress 99.4 KSI-Test Number WAP23-1
"-~",::..,,,,,,,,,,,,,: ..".
1.0E+04
llrTmnnrTTTITmr-rrm~~~-rrnT~--,--r-~~r_1lmtttti-Mttttttr--t-fj1f~1;.y:;~.t-1\-+--H--W-U-U--LWlillJ7 " 1\
8 I \, \7 j \\
6 // I~\ \I \\
5 . \\
4 I I 1/ ':~3 \\
2 / / \":. \
1 __ I J "
----- V \.\o ~~-
1.
o.O.
O.
O.
O.
oooo
1.0E+03
~:;..:l...~~
~
0("t-'.....:l...~I:Q=-~'JQI:QI'll
0.£;.
=z::~
~
Q~N.....:l~...~0Z
• ACTUAl, _ 2 PARAM WEIUULL - 3 PARAM WElBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-6
:;;'"r":l
'. t
Alloy 17200 l/4HT - Stress 102.7 KSITlO\! ~umhl:r WAP23-2
, ' • I '! I[! -'----1 J 111.] '" Iii '\ \ I, i I ! I i I I I I I ,
! [il I j I , Iv' '1~ ]T- i ! ! Iii I I I Ii! J \ I I JJJ-' i; I I lUl--l
'I I I i I I:; O.9-;-----rnTlll~'I I I I i YI! Ii _1 'u~ iii I I I , ,'I I i II I I:::- O.8~,-rr- I ~ I i II I I/! Ii I I " I I I! y.'" I I! I I", ~ !! 'I ! I !II I' I IC 0.7/ i I Ii, I j' I! II i 'I Ii I U. I I , I I " I'I'I-: i I I ! i [' I I I , I, ,- '\' I,i . I 'I~ 0.6 i ! i' i I (I I III. 1 II I~), I, ' IIJ~ - i I \ 'i I -I 1\ I I T I "[,:; 0.,:, Ii! I Ii I I Iii I i \ : I I lJill:.t. I r , I I, I I I i I \ I~, , , I I , I i I II::: 0.4 '. I I I i [I I I :1111 iii i! , II Illi:.; I I I i j ) I , I I '! ,. II I i II \\~ 0.3 i [ '[ Iii I! II I il i ~, ,I) ',I 1\ ,IIIJ' i II I" I 11 I !.,. , i i ill it II'!' i ! I I
~ 0.2 i i II iIi I! I, /' _. iii <i i I III
Z 0.1 i • Iiii til I I UV , --,._-,j~I=:Lt _+1o 'Ii,
1.0£+03 1.0E+04 1.0E+05 1.0E+06 1.0£+07 1.0£+08CYCLES TO FAILURE
1.0E+09
• ACTUAL ...... 2 I'ARAM WEIHULL ---. 3 I'ARAM WErBULL - LOG 31'ARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-7
Alloy 17200 1/4HT - Stress 107.4 KSITest Number WAPA2-1
1.0E+091.0E+05 1.0E+06 1.0E+07 ·1.0E+08CYCLES TO FAlLURE
1.0E+04
1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
C1.0£+03
:.oJ:z::;:J..J
~;...;...0...~::::c~:c0~:z:::;;~'n
::J~
r_·'-~
~'.II --~-~
:z::0z
• ACTUAL .......... 2 P'ARAM WEI BULL .- 3 PARAM WEIBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-8
Alloy 17200 1/4HT - Stress 111.9 KSITEST WAP13-01
'-
1.1 ! I J , I I l) I' I I I I J ) I) I 'j j I I I j j r r J , ) I , j , j I J) j j j I j J I
/. - i1i 11 I I II! III' I I I1I1I1I I I I"!.ill I I I 1I1111 I I I Ill/Ii;:;,,.J (( ''''::: d..7 i :III
" , ;
~ i.: r~
~ 0.8 I I •
-' I~,~ !t: 0.7, '! 1\1 1 '
~ O.~ / 't II1I1111 I Io 0.;, , 7 \=' f \\::., {\ t
~ 0.4 I ;,11 ,~ \~ 0.3 1/ I \\ ''; 0.2, : \\,::; ! ./ \5 () 1 I / / i\ 1 I I I J 111
Z ., I . / / 1/ .... 111111111o J ...._. - ...... ../- \0 1III1.0E+03 l.OE+04 l.OE+05 . l.OE+06 l.OE+07 l.OE+08
CYCLES TO FAILURE
;tr.;~
~
• ACTUAL .......... 21'ARAM wmBULL - 3 PARAM WEIBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-9
Alloy 17200 1/4HT - Stress 112.4 KSITEST number WAP20-1
1.0E+08,.1.0E+07I
1.1 I11I II _ - - -1
1 I I I / I II111 I I / I I11II I {1"/[>1O.~ , I~ 1/ '.... I' I
f,' \;', \10.8 I/,; 'f
0.7 I I I I I I I / I \\1'
O 61 I II I I / I I /1/ .f,
• I I I I IIIII1 I I 11111/1 > I
0.5 I / I I I I I I I I IIlf, "I'
004 I / : { ;' \~O.~ I /" I ~.•
02' / / / .
. I 'I // . / • I \0.1 . /' /' \1:\
I ~--- - / ~() ....-'-- .._- \~
1.0E+03 1.0E+04 1.0E+05 1.0E+06CYCLES TO FAJLURE
W0::~-=2~
~
0>-;...:-...;-::Q~~::Q
:;
0r-0::
~
c..""' 0--.l
WSI--~-~0::0z
• ACTUAL .......... 21'ARAM WElHULL - 3 I'ARAM WEIBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-10~._------_..__._------_.
Alloy 17200 1/4HT - Stress 112.8 KSITest Number WAP73-1
------,,-- 21'ARAM WEIBULL - J I'ARAM WEIBULL - LOG 3 PARAM
~",.,:::,~*" .. :,''''
l~ I 1\
£)1 I 1\\
l.OE+06
\,"t{\,
\\1t
\'1\
~\
£t:1
-
/1 1/// /
jII!
#1 I r~
f!I\([ff/ I \~// \1,
/7
1//,1.0E+04 l.OE+05
CYCLES TO FAILURE
.~-_ ..,.,
1.1
~ 1;:J,.J=1. 0.9:...~ 0.8'..I
>-t-< 0.7-,.J~ 0.6
"'tl • ~~::. o 0.5110
~ ~
~~
Cl 0.4w~ 0.3,.J...r:;; 0.2
"~ 0.1
01.0E+03
• ACTUAL
COMPARISON OF STATISTICAL PREDICTIONSFIGURE 2.2-11
Alloy 17200 1/4HT - Stress 122.6 KSITest Mumber WAPAl-l
1.0E+05 l.OE+06CYCLES TO FAILURE
\
"\"
1\
1.0E+08l.OE+07
!~I".......1"....
-•• J-'""'''-.~:t...
• ........1
--7
".1.11..........
1.1~
~ 1;:; 1"d 09 ri
,\- --1. •..... .......~ 0.8 i,..,;
1"\. I \;;...r-- 0.7 ! \ II-..J:.; 0.6- --1.
V.Y- ~!1Ct o 0.5r)
='"'"' ::: 0.4 / h"0
'-'0, j....~
~ O.3r
-I 11~
:;; 0.2I='o 0.1 ...---,/ Iz ..-
0 -1.0E+03 1.0E+04
• ACTUAL ..-...... 2]'ARAM WElnULL - 3 PARAM WEIBULL - LOG 3 PARAM
COMPARISON OF STATISTICAL PREDICTIONS
FIGURE 2.2-12
'iData .Paints for Endurance TestingRepresent the 50% Failure Pre·d·iction
r Using the 3 Parameter Weibull Distributionof the Log of Cycles to· Failure
.....
.•.•.J
,, .r-
r I [J I" J .JIA>< i~
c: ,pI
,r-1
~ .~
L
l
"':i~
:r.;'.11o
170165
_ 160'(l 155~ 150CJ'J 145~ 140~ 135E-CJ'J 130_ 125~ 120= 115~
~ 110...; 105~ 100-< 95~. 90~ 85
80751E+04 lE+05
ALLOY 17200 1/4HT
lE+06 lE+07 IE+08CYCLES TO FAlLURE
IE+09 IE+IO
T~ BRIGHT CLEAN ..... ENDURANCE FINISH "'" ASTM R=O
COMPARISON OF TEST RESULTSFIGURE 2.3-1
I IData ~<?LI1s( for En9urance Testing
,,I
'"Represent the 50% Failure PredictionUsing the 3 Parameter Weibull
! '" Distribution of the Log of Cycles toIi Failure
~V
II i/ II I
"-" "'"I I
c- /I I
I
I....
I ! ..I i I
"-, I
I
17;)1701f;;)
- 1(;0'f, ISS~
I Sf),'l: 11 ;)':fj
1,10~
=t: 1~~:);;...J ~~ [)z'- 12;)c.
:;; 120- 1J:.,"";
c.:;;. - 11 ()~
~"~
]rJ:"'.J1 --
~
100<r .... "' %-;;;;.
~JfJfJ~(J .J
(\0'r)
11-:-,,01 J E+O;)
ALLOY 17200 HT
1E+0(; IE+07CYCLES TO FAILURE
1E+OB 1E+09
BRIGHT CLEAN .. ENDURANCE FINISH ;+' ASTM R=()
COMPARISON OF TEST RESULTSFIGURE 2.3-2
Data Points for Endurance Te~ting --Represent the 50% Failure PredictionUsing the 3 Parameter Weibull Distributionof the Log of Cycles to Failure -
~ - '"- ..,-"
~
I
"'"'--.
"
I
-'Jj
~I
'JJ'Jj
~~
CrJ-~;:J-~
~~
~
(J'Q~
~'JI~.."
~
~~~
175170165160155150145140135130125120115110105100
95908580751E+04 1E+05
ALLOY 190XHM
1E+06 1E+07CYCLES TO FAILURE
1E+08 1E+09
[] MILL FINISH .. ENDURANCE FINISH "'" ASTM R=O
COMPARISON OF TEST RESULTS
FIGURE 2.3-3
1E+081E+071E+06CYCLES TO FAILURE
1E+05
! i I i j I,
I I Data Points fercEndurance Testing, ,I
\
I
Represent the 50% Failure PredictionI I\ I " , Using the 3 Parameter Weibull DistributionI • );.LV
I I"
of the log of Cycles to Failure
;r II L I
I
I_i? i- -i?I I I I
,I I I /' j
i I iI ,
,~ ,
I i II ,
! II I I
! I ~
, I I
-~"'.
~
~'-'l:,-~~-~-~"'.
120" ALLOY 17410 I115
::;: 110~ 105'Jj 100'Jj
9590858075706560
, ~ ~-I ;-. ::J::J
50451£+04
'JI.~
"'=~on':>
MILL fINISH .. ENDURANCE FINISH ;¥ ASTM R=O
COMPARISON OF TEST RESULTSFIGURE 2.3-4
ALtOY 172(] 0 1/4 HT:3 PAPA\1. WEfFJULL OP IDG CYCLES TO PAIL
150 155 160 165 170
""
4,Ol,----r--,--~-r__,-_____r-__r---,-___r-_,_-_r_-_,_-__r_-_,__-,_-r_-r__-
3,8 7' <, "
. 3,6+---\--t------t--t---t--+--+--+---+--+--+---+---+--i----i--+--1~ 3.4 ;,c
~ 3.2 ,~;:: 3.0~~ 2.8 " :: 2.6 "~ I....- 2.4 ~
:-; 2.2 1----" • ..... !,..- 20 -...... " ~ ~ ,--;. 7. ~ ....... ~ ,
::: 1,8 -..... ~"./ 1,6 ,........ . , I1 4 X ------ ........ ~'.
....- 1,21
~" ,
~ 1,0; ", ~. "'--I---. .... "'!'-. ,~
~ 0.8, x X r----.. ........;:. 0.6 i x' k... '/.- ' ,I~.... 'i 7r
0.4 i /- r------..... ~' Ivg:~i I ~"'"
85 90 95 100 105 110 115 120 125 130 135 140 145STEES'S - KSl
'J!"-
~
=~":>
X Hl~rr;)1T r;Lr:r.rl
-- nr; Llrlr~ F'll
jV f)f([)PPf:D por~lE A. ElWUR/dICE FINlSH
........... EF I.lf'" Fit Z DHOPPED PDJPTS ITREND OF WEIBULL ALPHA PARAMETER
FIGURE 2.4-1
ALLOY 17200 1/4HT3 PARA..\f;, WEIBULL OF LOG CYClES TO FAIL
)~
~-+-FFI I:>_l-- -I-
/1
.- I
I I
~
o •
I I
J ~_ e----+-- f--'-- ~ I I,'- . -t---+-+--=~ 1 I_ _,- I - ~--='if--_~ IT······ x -. I 1.....- - -
'" f--:=t+ fe-.-'+--~ I >~ --c=.r~ J.----J---.. I --r ~ 0 ~a '-- ~ '~"'1 t ---I _~ f--'1- 1 *'. r- f--f-- -
'-- _~.,.'_ ~ I - X f--_f--
..' ~. I 1k-""A ... -+-f-- y r 0 I II -I ~ J 1---1 ' ' ---1--1 x "0 I I I
[.f-- 1-'-'-. f-- I 1 -
~ I r-- 1=+=~ I _ -- f----i -,.{--~ ->--I' 1'-!r-~f--f-- 1 ~---;;rf-- l---+--f-- . I, -r-r-~f--+-----+- I -=
J I II f--
J 1----'-1
7.67.4
. 7.2S 7.0-S 6.8~ 6.62 6.4~ 6.2::: 6.0("' 5.8~ 5.6~ 5.4
5.2I 5.0
:::: 4.8;:) 4.6,[j..... 4.4:.,
>- 4.2.- 4.0
3.83.6
85 90 95 100 105 11 0 115 120 125 130 135 140 145 150 155 160 165 170STEES'S - KSl
'"0~
TQ-:;
'Jl'Jl
X @JGIlT eLSAH
-- m; Lin', fil
* DROPPED POllJTS A ENDURANCE FINISH
.......--.. Ef LIflI' fit Z DROPPED POINTS
'-
~
TREND OF WEIBULL BETA PARAMETER
FIGURE 2.4-2
ALlDY 17200 1/4HT3 PARillJ. WEffiULL OF LDG CYCLES TO FAIL
5.0 I I I I I I I i I I I I I i I I i
4.8 I I .
~. 46m1J=..... 1 I,'".:, 4.4 A· 1 I I L;c..
G~ 4.2 '....
~ :~E8 I IEEEEl I n=EE-Ec 3.6~ 3.4 I I I I I I I II I I ! I I I I I I
I
J~~~ I §iE§2.41 I I I I I x I ! I I I ! i I I I I I
2.21 I I I I I I I j I I i I I I I I I85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170
STRESS - KSl
~:w'1Q~
~Q\
X rmlGHT CLEfl.lJ
-- Be !.iw: Flt
*' Be DROPPED POJ!JTS ..... ENDURANCE FINISH
........... EF' Line Fit L EF DROPPED POINTS
/
TREND OF WEIBULL XO PARAMETER
FIGURE 2.4-3
-==~til-..J
ALlDY 17200 1/4HT - BRIGHT CLEAN3 PARAM WEIBDlL OF LOG CYCLES TO FAIL
150iii I I I I i j I I) iii iii iii i I I I i I I i
145 "'"\"'j,140 ,,_ .135 . ".~.. ,.
\ ~ '.130 . .:.. .
~ 125 \ .;.. .
~ 120 \."" '. ......
~115 - 11111
2 110 '\.~ '. '.r;. 105 \ - -'.....
j ~'~••
100 ., - ", ".95 \ .
\ a ..
90 \ _ .
85 \ -'"\' l80
... '. '._ "'1'
1E+04 1E+05 1E+06 1E+07
Cycles to Failure-- J % F'ailurE:s "'" 10% F'ailUfE:S .. 50% Failures ...._..... 90% fAILURES
STATISTICAL FAILURE PREDICTION
FIGURE 2.4-4
CONCLUSIONS
3.1 ENDURANCE TEST METHOD
The "Endurance Test" method is an ideal method of determining the fatigue
life of strip spring alloys. The "Endurance Test" specimen is a manufactured
spring, and must pass through all the necessary manufacturing operations that a
typical strip metal spring would require. This subjects the "Endurance Test"
specimen to all the same side effects and variability of these processes. The
"Endurance Test" specimen is a realistic simulation of an electrical contact spring.
A special fatigue tester was designed to test the "Endurance Test" specimen
called the "Endurance Test" machine. A major feature of the "Endurance Test"
machine is the ability to test up to 48 specimens at a time. This was a significant
advantage because enough test data to analyze the fatigue life statistically was made
practical only because of the specimen capacity of the "Endurance Test" machine.
3.2 ROGUE TEST RESULTS
The test results show that the fatigue life of a few test groups deviate
significantly from the majority of the test groups measured in this program. oThe
cause of these deviations could not be determined, and the rogue test groups could
be identified only by the trend of the majority of the test data. Fortunately the
rogue groups stood out from the majority of the test data and could be separated.
Rogues (batches ofmanufactured springs which lack consistent properties) have been
Page 58
common in precision metal stamping of Copper Beryllium alloys. The cause of
rogues still remains a mystery. The rogues must be due to some variable in the
manufacturing process which has a serious detrimental effect on the fatigue life of
the formed spring. In comparing the "Endurance Finished" data to the general
production "Endurance Test" specimens, it was noticed that in general the
"Endurance Finishing" process produced higher fatigue life and better consistency
than the standard manufacturing process alone. This reduced the frequency of
rogues, but they also happened in "Endurance Finish" tests.
3.3 FINITE ELEMENT ANALYSIS
Finite Element Analysis (FEA) proved to be accurate in predicting the stress
levefin formed parts. This can be seen in comparing the fatigue test data produced
using the ASTM fatigue test method data to the "Endurance Test" data which used
FEA to analyze the "Endurance Test" specimen stress. The Stress on the ASTM
specimens was measured using strain gauges and the elastic modulus from tensile
test data. The stress distribution on the ASTM fatigue specimens is very uniform,
and can be predicted accurately using a strain gauge. The complicated stress
distribution present on the endurance test specimen is to complicated to measure
using strain gauges. Also standard beam equations are not suitable for highly
deflected structures due to edge curl of the structure.
F'imte element analysis, specifically-geometrically ··non-Iinear analysis can
Page 59
accurately predict the value and distribution of stresses in thin metal springs.
3.4 FATIGUE TEST RESULTS ON ALLOY 17200
The fatigue test results on alloys 17200 1I4HT and HT were similar in shape,
with the stronger HT material producing about the same fatigue life with a 20 KSI.increase in stress. This is_~hown in Figures 2.3-1 and 2.3-2. These alloys are
chemically identical, and are differentiated only by the amount of cold reduction
after the final solution annealing. The difference in the .2% yield strength for these
alloys is 36 KSI, and the difference in the fatigue results represented about half of
the difference in the .2% yield strengths.
The fatigue life of the mill hard version of alloy 17200, the XHM temper,
produced significantly lower fatigue life than the HT materials. The fatigue test
results are shown in Figure 2.3-3. The .2%) yield strength of alloy 17200 XHM is
lower than that of the 1I4HT and HT versions of this alloy which partially explains
the difference in fatigue life. This can also be explained by the presence of residual
forming stresses in the mill hard material. The 1I4HT and HT materials are solution
aged after forming which removes most of the forming stresses. Specific material
properties for the materials tested are given in Table 1.0-1
3.5 FATIGUE LIFE OF ALLOY 17410
Alloy 17410 is also a Copper Beryllium alloy, but has a different chemistry
Page 60
and metallurgy. This is a special alloy with lower strength than conventional Copper
Beryllium alloys, but with higher conductivity. It is also a mill hard alloy, and
includes residual forming stresses in the finished "Endurance Test specimen. This
data is shown in Figure 2.3-4. The specific material properties for this alloy are
given in Table 1.0-1
3.6 STATISTICAL DISTRIBUTIONS
The most important outcome of this thesis is the determination of proper
statistical methods to characterize metal fatigue test results. The commonly
recommended two and three parameter Weibull distributions did not accurately
portray the fatigue test data. When the logarithms of the cycles to failure is used,
the three parameter Weibull distribution produces a reasonable match to the data
that is being characterized. After the statistical analysis, the probabilities of failure
are determined. The antilog of the cycles to failure predicted by the probability
distribution give the true cycles to failure information.
Like all statistical techniques, the match is an empirical match, and is not
directly based on a physical model. One reason that the three parameter Weibull
function was chosen is because it predicts that there is a threshold value before
which there is an infinitely small probability of failure. The fatigue data produced
in this program strongly indicated that this is true. Another reason for choosing the
Weibull distribution is that the pattern of failures that were observed produced a
Page 61
r
non-symmetrical probability distribution. The Weibull distribution accounts for the
non-symmetrical data. The mathematics used to calculate the three parameter
Weibull distributions three parameters are complicated, but the iterative technique
used in this thesis is straight forward and well suited to computer analysis.
Page 62
REFERENCES
1. Endurance Finishing, Endurance Testing, & Bright OeanInstrument Specialties Co., Inc.Delaware Water Gap, PA - 1938
2. AS1J\i-B593-85AS1J\i (American Society for Testing Materials)Philadelphia, Pa - 1985
3. AS1J\i fatigue test data and test material courtesy ofSharon Shriver and John RatkaBrush Wellman Inc. - Oeveland, Ohio - 1987
4. NISA IT - Structural Finite Element Analysis ProgramEngineering Mechanics Research CorporationTroy, Michigan - 1987
5. Materials Handbook 9th EditionVolume 8 - Mechanical TestingASMI Press 1986Metals Park, OhioPages 632 to 635, 714 to 717
6. Engineering Statistics - Macmillan Publishing Company 1987by Robert V. Hogg and Johannes LedolterPages 116 to 123
7. Quattro Pro 3Borland International. Inc.Scotts Valley, CA - 1991
Page 63
.....
.APPENDIX - A
Page 64
ALLOY 17200 1/4HT
Page 65
F I L E = WAP3-1.WQl
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES = ENDURANCE FINISHED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 24,680 91.725 269,536
10 774722 STDDEV50 12278897 2.48595422
IALPHA = 21019757.752895,IBETA = 0.68178212633819
AVERAGE AVERAGE83:03 91.72
81.4 90.0 1 10000000089.3 98.5 1 350580082.2 90.8 1 10000000082.1 90.8 1 7,486,50083.9 92.7 1 4,280,90083.8 92.6 1 100,00000082.1 90.7 1 729140079.6 88.0 1 6,13670082.6 91.3 1 4,374,00081.7 90.2 I 3858,40085.0 93.8 1 3,070,40082.7 91.3 1 4,302,200
SPECIMEN THICKNESS# INCHES
1 0.00992 0.00993 0.009854 0.00995 0.009856 0.009857 0.009958 0.00989 0.00985
10 0.009911 0.0112 0.00985
LOAD STRESS FEALBS K S I STRESS
0.50030.54880.49990.50480.51060.50980.50950.47920.50250.50180.533
0.5028
Page 66
cyclesto fail
FILE= WAP59-1
OFFSET = 0.9995
WIDTH = 0.,376
MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 58,170 93.225 235,187
10 435.865 STDDEV50 2.190.653 3.30043375
IALPHA = 2999159.8~1BETA = 1.16674636
3.5064E-Q7
AVERAGE AVERAGE0.0022 84.35 93.22
cyclesf1'1
STRESS FEAS I STRESS
SPECIMEN THICKNESS LOAD# INCHES ,grams K to at
1 0.0096 235.40 89.8 99.2 1 3,5607002 0.0096 223.46 85.3 94.2 1 26899003 0.0096 216.53 82.6 91.3 1 6,132,5004 0.0096 213.51 81.5 90.1 1 832,4005 0.0096 221.34 84.4 93.3 1 545,800
6 0.0096 235.36 89.8 99.2 1 600,6007 0.0096 219.35 83.7 92.5 1 872.2008 0.0096 217.67 83.0 91.8 1 1963,600
9 0.0096 214.91 82.0 90.7 1 2330.70010 0.0096 216.48 82.6 91.3 1 9609.20011 0.0096 209.89 80.1 88.5 1 3846.20012 0.0096 228.93 87.3 96.5 1 946,500
Page 67
.FILE= WAPl-l
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES mean
1 52,874 93.245 155,015
10 249,271 STDDEV50 864,113 4.26281017
IALPHA = 1100551.5~1BETA = 1.51537126
AVERAGE AVERAGE84.42 93.24
77.6 85.8 1 288260082.6 91.3 1 77060082.6 91.3 1 44870083.1 91.8 1 102610083.7 92.5 1 53760091.9 101.4 1 79590081.6 90.2 1 79730090.1 99.3 1 221120089.3 98.5 1 44420081.8 90.5 1 57580085.7 94.7 1 43790082.9 91.6 1 821700
,,"
SPECIMEN THICKNESS# INCHES
1 0.00982 0.00973 0.00974 0.00985 0.00976 0.00977 0.00988 0.00989 0.0099
10 0.009711 0.009912 0.0099
LOAD STRESSLBS KS I
0.46740.48720.48720.50040.49380.54230.49160.54230.549
0.48280.52690.5093
; Page 68
FEASTRESS
cyclesto fail
FILE= WAP74-1
DATE = 3/22/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = BURR OUTSIDE
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 1,422 94.865 8,304
10 18,106 STDDEV50 139,232 3.17908289
\ALPHA = 207061.251;1BETA = 0.92349846
6.3428E-1O
AVERAGE AVERAGE0.0022 85.86 94.86
cyclesf: '1
STRESS FEAK S I STRESS
SPECIMEN THICKNESS LOAD# INCHES grams to at
1 0.0097 240.05 89.7 99.0 1 791002 0.0097 232.37· 86.8 95.9 1 818003 0.0096 232.93 88.9 98.2 1 14180004 0.0097 239.90 89.7 99.0 1 1144005 0.0097 227.03 84.8 93.8 1 112,3006 0.0097 225.30 84.2 93.0 1 1204007 0.0097 226.05 84.5 93.4 1 853008 0.0097 223.60 83.6 92.4 1 1119009 0.0097 231.28 86.4 95.5 1 96600
10 0.0098 222.12 81.3 89.9 1 92 10011 0.0096 233.58 89.1 98.4 1 16060012 0.0097 217.67 81.3 89.9 1 148,400
Page 69
F IL E = WAP40-1
a DATE = 11/17/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES = (DREW'S CONTROL) BURR OUT - # 10 DENTED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 33,556 95.875 154,981
10 304607 STDDEV50 1 785 470 6.03182452
!ALPHA= 2518680.52 1
BETA = 1.065278152.408E-09
AVERAGE AVERAGE0.0022 86.74 95.87
cyclesf1"l
STRESS FEAK S I STRESS
SPECIMEN TIllCKNESS LOAD# INCHES ~ to aI
1 0.0093 230.64 93.8 103.6 1 2339002 0.0093 221.02 89.9 99.3 1 45062003 0.0092 222.50 92.4 102.2 1 3,197,3004 0.0092 228.64 95.0 104.9 1 1349,7005 0.0093 222.44, 90.4 100.0 1 1,708,4006 0.0093 216.15 87.9 97.2 1 5986007 0.0094 202.91 80.7 89.3 1 351 5008 0.0094 212.82 84.7 93.6 1 257,0009 0.0093 201.28 81.8 90.5 1 5870800
10 0.0093 212.04 86.2 95.3 1 128470011 0.0094 197.31 78.5 86.8 1 4,95610012 0.0093 195.53 79.5 87.9 1 5,193,800
Page 70
FILE= WAP23-1
~
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = BURR ON OUTSIDE OF BEND
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 61,438 99.425 562582
10 1,495,950 STDDEV.I50 19340,976 1.83580644
IALPHA = 31822768'~1BETA = 0.73603467
2.4277E-I0
AVERAGE AVERAGE0.0012 90.11 99.42
90.0 99.3 1 13,633,60087.6 96.7 1 1212470092.3 101.8 1 13,775,10091.3 100.7 1 1,532,00087.5 96.6 1 6,536,90090.8 100.2 1 10000000090.5 99.8 1 1 135,20088.9 98.1 1 6,005,40089.7 99.0 1 745000092.8 102.4 .~ 'i 10000000088.4 97.6 )1 10000000091.7 101.1 1 100,000,000
SPECIMEN THICKNESS# INCHES
1 0.00982 0.00983 0.00964 0.00985 0.00986 0.00977 0.00988 0.00989 0.0097
10 0.009711 0.009812 0.0097
LOAD STRESSLBS K S I
0.54190.52760.53310.54970.52680.53550.54490.53530.52890.54770.53230.5407
Page 71
FEASTRESS
cyclesto fail
FILE = WAP23-2
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = BURR ON INSIDE OF BEND
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 23,543 102.725 291,116
10 883916 STDDEV50 16171533 1.51541827
I:ALPHA= 28467249'~1BETA = 0.64811979
1.9282E..Q8
AVERAGE AVERAGE0.0012 93.24 102.72
94.2 103.7 1 6,509,70093.7 103.2 1 1533,00094.0 103.5 1 100000,00091.2 100.7 1 1436,90093.9 103.5 1 100,000,00091.8 101.2 1 18411.10094.7 104.1 1 3412 10093.6 103.1 1 100,000,00090.6 100.0 1 19372 70092.6 102.1 1 506,60096.0 105.6 1 7765,20092.5 101.9 1 100,000,000
SPECIMEN THICKNESS# INCHES
13 0.009814 0.009815 0.009816 0.009717 0.009718 0.009819 0.009920 0.009821 0.009722 0.009823 0.009924 0.0098
LOAD STRESSLBS K S I
0.56710.56410.56610.53830.55390.55300.58160.56380.53480.55760.59010.5569
Page 72
FEASTRESS
cyclesto fail
FILE= WAP23-4
OFFSET = 0.9995
VVUD1lI = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = ENDURANCE FINSHED - BURR ON OUTSIDE OF BEND
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 32,238 102.755 268.662
10 685,286 STDDEV50 7,946,045 1.60598217
IALPHA = '12800050.;IBETA = 0.76873379
9.l336E-1O
AVERAGE AVERAGE0.0013 93.35 102.75
94.8 104.2 1 8,930800
93.3 102.8 1 100,00000091.7 101.1 1 18,873,20091.4 100.7 1 72250092.9 102.3 1 6,500,70091.9 101.2 1 8,076,90092.6 101.9 1 7.31680092.5 101.9 1 21,63520096.2 105.7 1 2,65160095.6 105.1 1 7.992 80094.9 104.2 1 2,35960092.4 101.8 1 1,756,700
SPECIMEN 1lIICKNESS# INCHES
37 0.009938 0.009939 0.009940 0.009941 0.009942 0.009843 0.010044 0.009945 0.009946 0.009947 0.010048 0.0099
LOAD STRESSLBS K S I
0.58230.57360.56380.56160.57080.55310.58090.56860.59110.58740.59470.5679
Page 73
FEASTRESS
cyclesto fail
FILE= WAP23-3
OFFSET = 0.9995
WIDTH = 0,376
MATL. = ALLOY 17200 1I4HT
NOTES = ENDURANCE FINSHED - BURR ON INSIDE OF BEND
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 1l,074 105.955 116789
10 330,537 STDDEV50 5031152 1.44522256
IALPHA = 8545119'~1BETA = 0.69191072
6.9506E-10
AVERAG AVERAGE0.0013 96.39 105.95
94.5 103.9 1 100,00000096.8 106.3 1 1,821,70095.4 104.9 1 6,28940097.8 107.5 1 595,30097.4 107.0 1 6,584,20098.2 107.9 1 835030096.8 , 106.4 1 264260093.7 103.1 1 606150096.9 106.4 1 472740098.0 107.6 1 384900095.6 105.2 1 469680095.6 105.2 1 1,169,000
SPECIMEN THICKNESS# INCHES
25 0.009926 0.010027 0.009928 0.009929 0.0099 ""30 0.009931 0.009932 0.009933 0.009934 0.009935 0.009836 0.0099
LOAD STRESSLBS K S I
0.58050.60710.58620.60120.59870.60360.59500.57550.59520.60210.57540.5877
FEASTRESS
cyclesto fail
Page 74
FILE= WAPA2-I
DATE = 10/19/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT?
NOTES = 800 CPM - TERMINATED@ 51,081,500
% FAILURES ESTIMATEDACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 289 107.45 10,901
IO 54,139 STDDEV50 3590,214 5.79714014
!ALPHA= 811937~1BETA = 0.44913514
3.9769E-10
AVERAGE AVERAGE1.0000 97.55 107.4
cyclestofl'l
STRESS FEAKS I STRESS
SPECIMEN THICKNESS LOAD# INCHES grams al
1 0.00945 0.5344 95.4 105.3 1 100,000,0002 0.00970 0.5657 95.9 I05.6 1 49,8753003 0.00970 0.5752 97.5 I07.3 1 2473004 0.00960 0.5573 96.4 106.3 1 5323005 0.00980 0.5428 90.1 99.4 1 3IO 0006 0.00985 0.5741 94.4 103.9 1 1977007 0.00925 0.6173 115.1 126.2 1 7669008 0.00960 0.5734 99.2 109.2 1 161,6009 0.00985 0.6263 103.0 112.8 1 247300
10 0.00955 0.5199 90.9 I00.4 1 36120011 0.00960 0.5997 103.8 114.0 1 27800012 0.00965 0.5271 90.3 99.7 1 17860013 0.00965 0.5670 97.1 106.9 1 1836590014 0.00970 0.6065 102.8 112.9 1 872540015 0.00975 0.6096 102.3 112.3 1 754520016 0.00970 0.5721 97.0 106.8 1 2,261,70017 0.00975 0.6023 lOLl 111.0 1 10000000018 0.00975 0.6012 100.9 110.8 1 97800019 0.00935 0.4905 89.5 98.9 1 10000000020 0.00960 0.5542 95.9 105.7 1 155200021 0.00955 0.5516 96.5 106.3 1 10000000022 0.00930 0.5287 97.5 107.6 1 111620023 0.00935 0.5084 92.8 102.5 1 6,532,80024 0.00975 0.5721 96.0 105.7 1 6484,400
. Page 15
F I L E = WAP13-1.WQl
OFFSET = 0.9995
WIDTH = 0,376
....MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 154,603 111.895 288.833
10 380641 STDDEV50 783.836 1.28977672
IALPHA = 902108.80~1BETA = 2.60797815
-4,363E-Q9
AVERAGE AVERAGE102.1 111.89
103.9 113.7 1 909"500
101.6 111.4 1 1405,900100.7 110.5 1 533 100100.2 109.9 1 1.326.500101.5 111.3 1 513,200102.7 112.5 1 1064600104.1 114.1 1 421.900100.7 110.5 1 902,600103.2 113.0 1 379.100102.9 112.8 1 546.600101.2 111.0 1 954.500102.4 112.2 1 614,800
SPECIMEN THICKNESS# INCHES
1 0.00992 0.00993 0.00994 0.00995 0.00996 0.00997 0.00988 0.00999 0.0099
10 0.009911 0.009912 0.0099
LOAD STRESSLBS K S I
0.63830.62450.61890.61580.62380.63100.62670.61890.63420.63260.62190.6292
Page 76
FEASTRESS
cyclesto fail
F I L E = WAP20-1.WQl
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 43,743 112.395 102,433
10 149,154 STDDEV50 398,778 1.26078502
IALPHA = 482864.56;IBETA = 1.91560459
2.4636E-08
AVERAGE AVERAGE102.4 112.39
102.3 112.2 1 306,800102.6 112.6 1 1,070,100101.0 111.0 1 456,900101.7 . 111.6 1 326,000102.9 112.9 1 375,100102.1 112.0 1 156,700
102.8 112.9 1 276,700
102.3 112.2 1 306,800103.2 113.3 1 572,100104.9 115.1 1 237,700
101.0 110.8 1 780,700100.6 110.4 1 360600104.0 114.1 1 298800
SPECIMEN THICKNESS# INCHES
1 0.00982 0.00973 0.00974 0.00985 0.00986 0.00987 0.00978 0.00989 0.0097
10 0.009711 0.009812 0.009813 0.0097
LOAD STRESSLBS KSI
0.61580.60510.59580.61220.61990.6146
0.60650.61610.60880.61890.60790.60550.6135
FEASTRESS
cyclesto fail
Page 77
FILE= WAP73-1
DATE = 3/10/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = BURR OUTSIDE
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 11,683 112.755 18906
10 23,384 SIDDEV50 40,790 3.63532579
IALPHA = 45452.9804 1
BETA = 3.38602084-7.434E-08
AVERAGE AVERAGE0.0022 102.56 112.75
cyclesi1'1
STRESS FEAK S I STRESS
SPECIMEN THICKNESS LOAD# INCHES In'ams to at
1 0.0097 280.23 104.7 114.9 1 34.5002 0.0094 244.29 97.2 107.2 1 451003 0.0095 259.45 lOLl 111.3 1 44.1004 0.0094 252.96 100.7 110.9 1 658005 0.0095 262.88 102.4 112.7 1 26,3006 0.0096 269.52 102.8 113.0 1 46.9007 0.0094 244.78 97.4 107.5 1 49,2008 0.0097 268.50 100.3 110.3 1 23,5009 0.0096 267.22 102.0 112.1 1 31,100
10 0.0096 280.83 107.1 117.5 1 6120011 0.0096 275.93 105.3 115.6 .<t 31,80012 0.0096 287.28 109.6 120.0 1 29,600
Page 78
F I L E = WAP18-l.WQ1
OFFSET = 0.9995
WIDTII = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES = ENDURANCE FINISHED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 67,298 113.785 220249
10 371.80250 1463641
IALPHA = 1910814.43:1BETA = 1.37475522
8.6467E-Q8
AVERAGE AVERAGE103.68 113.78
SPECIMEN TIIICKNESS LOAD# INCHES LBS
STRESSKSI
FEASTRESS
cyclesto fail
1 0.0097 0.6158 104.4 114.5 1 1742002 0.0097 0.6022 102.1 112.1 1 45061003 0.0097 0.6223 105.5 115.7 1 1,3273004 0.0097 0.6186 104.9 115.0 1 1,989,3005 0.0097 0.6059 102.7 112.8 1 1,912,2006 0.0097 0.6167 104.5 114.7 1 1433,0007 0.0097 0.6073 102.9 113.0 1 2940008 0.0097 0.6162 104.5 114.6 1 2,3879009 0.0097 0.6131 103.9 114.0 1 610 100
10 0.0097 0.5901 100.0 110.0 1 332120011 0.0097 0.6142 104.1 114.2 1 2,39370012 0.0097 0.6174 104.7 114.8 1 654000
Page 79
FILE= WAPI4-1.WQl
OFFSET = - 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4lIT
NOTES = ENDURANCE FINIS¥
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 92,228 115.285 176,753
10 235,573 STDDEV50 499,615 2.19038026
\ALPHA = 578308.23~IBETA = 2.50574006
5.0269E-08
AVERAGE AVERAGE105.26 115.28
SPECIMEN THICKNESS LOAD# INCHES LBS -
STRESS FEAKS I STRESS
cyclesto fail
1 0.0098 0.6255 103.9 113.9 1 8556002 0.0098 0.6342 105.3 115.3 1 371 6003 0.0098 0.6482 107.6 117.7 1 250,7004 0.0098 0.6378 105.9 116.0 1 2667005 0.0099 0.6542 106.5 116.4 1 464,4006 0.0098 0.6115 101.6 111.4 1 337,6007 0.0098 0.6083 101.0 110.9 1 5823008 0.0097 0.6322 107.2 117.4 1 957,1009 0.0098 0.6467 107.4 117.5 1 284700
10 0.0097 0.6236 105.7 115.9 1 582,30011 0.0099 0.6402 104.2 114.0 1 51450012 0.0098 0.6435 106.9 116.9 1 664,000
Page 80
F I L E = WAP58-1
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 111,697 116.455 151331
10 173049 SIDDEV50 245809 1.86212829
IALPHA = 263180.303,1BETA = 5.36743839 i
-9.862E-08
AVERAGE AVERAGE0.0022 106.13 116.45
cyclesf1 '1
STRESS FEAK S I STRESS
SPECIMEN THICKNESS LOAD# INCHES ~ams to at
1 0.0096 276.23 105.4 115.7 1 2477002 0.0096 283.66 108.2 118.6 1 2188003 0.0096 275.76 105.2 115.5 1 2760004 0.0096 278.38 106.2 116.5 1 2856005 0.0096 277.55 105.9 116.2 1 198,2006 0.0096 282.14 107.6 118.0 1 186,1007 0.0096 281.44 107.4 117.7 1 2143008 0.0096 270.05 103.0 113.2 1 246,0009 0.0096 284.43 108.5 118.9 1 334400
10 0.0096 283.40 108.1 118.5 1 31490011 0.0096 273.55 104.4 114.6 1 20080012 0.0096 271.50 103.6 113.8 1 193,700
Page 81
FILE = WAP72-1
DATE = 3/9/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES = BURR OUTSIDE
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO ~SS
OBTAIN KSI% FAILURES
1 13,158 121.015 21,134
10 26,054 STDDEV50 45,055 5.4380233
IALPHA = 50121.251~1BETA = 3.43952036
-2.431E-07
AVERAGE AVERAGE0.0022 110.57 121.01
cycles£; '1
STRESS FEAK S I STRESS
SPECIMEN THICKNESS LOAD# INCHES ,grams to at
1 0.0094 301.72 120.1 131.1 1 34,5002 0.0095 293.30 114.3 125.0 1 47,6003 0.0097 290.76 108.7 118.9 1 38,0004 0.0097 290.26 108.5 118.7 1 417005 0.0096 286.02 109.1 119.6 1 30,6006 0.0095 295.96 115.3 126.1 1 26,3007 0.0097 266.12 99.5 109.4 1 59,1008 0.0097 294.36 110.0 120.3 1 44,5009 0.0097 293.70 109.8 120.1 1 76100
10 0.0097 297.51 111.2 121.5 1 4130011 0.0096 303.45 115.8 126.4 1 39,20012 0.0095 268.96 104.8 115.2 1 62,200
Page 82
FILE= WAPAl-l
DATE = 10/6/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES =
% FAILURES ESTIMATEDACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 377 122.565 4293
10 12564 STODEV50 208709 1.88402277
IALPHA = 360562.30~IBETA = 0.6703826
7.9614E-Q9
AVERAGE AVERAGE1.0000 112.4 122.56
cyclest f:'1
STRESS FEAKS I STRESS
SPECIMEN THICKNESS LOAD# INCHES grams o at
1 0.00950 0.6292 111.2 121.8 1 2983,5002 0.00990 0.6971 113.4 123.5 1 22775003 0.01000 0.7141 113.9 123.7 1 97,3004 0.00980 0.6826 113.4 123.6 1 106,1005 0.00980 0.6964 115.7 125.9 1 127,0006 0.00950 0.6199 109.6 120.1 1 133 1007 0.00980 0.6909 114.7 125.0 1 973008 0.01000 0.7154 114.1 123.9 1 100,8009 0.01000 0.7026 112.1 121.9 1 97,300
10 0.00990 0.6792 110.5 120.5 1 10240011 0.00990 0.6759 110,0 120.0 1 102,80012 0.00950 0.6237 110.2 120.8 1 110,600
Page 83
FILE= WAP40-2
DATE = 11/17/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES = (DREW'S CONTROL) - BURR OUT
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 34,718 124.775 40918
10 43,99750 53 198
IALPHA = 55200.457~IBETA = 9.92015694
'-
-2.264E-Q7
AVERAGE AVERAGE0.0022 114.4 124.77
cyclesf'
STRESS FEAS S SS
SPECIMEN THICKNESS LOAD# INC SHE JmUlls K I TRE to ad
13 0.0093 264.41 107.5 118.2 1 6380014 0.0093 275.22 113.1 124.2 1 5770015 0.0096 298.06 113.7 124.3 1 5090016 0.0098 309.73 113.4 123.6 1 5230017 0.0097 331.74 124.0 134.4 1 43,70018 0.0098 308.05 112.8 123.0 1 5090019 0.0098 327.35 119.9 130.1 1 4370020 0.0098 302.38 110.7 120.9 1 5800021 0.0099 320.07 114.8 124.9 1 4660022 0.0098 312.50 114.4 124.6 1 5510023 0.0098 314.27 115.1 125.3 1 5590024 0.0097 303.47 113.4 , 123.8 1 52,700
Page 84
FILE= WAP60-1
DATE = 10/5/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 89,817 129.365 106,969
10 11555250 141418
IALPHA = 147085.85~1BETA = 9.32627928
-7.666E-Q8
AVERAGE AVERAGE0.0022 118.29 129.360
cyclesfail
FEASTRESS
STRESSKSI
SPECIMEN TIllCKNESS LOAD# INCHES grams to
1 0.0093 295.23 120.0 131.2 1 1613002 0.00'93 288.60 117.3 128.5 1 1606003 0.0093 285.38 116.0 127.1 1 1257004 0.0094 304.20 121.1 132.1 1 1299005 0.0094 294.46 117.2 128.1 1 1521006 0.0094 297.96 118.6 129.6 1 1541007 0.0093 296.86 120.7 131.9 1 1456008 0.0093 297.78 121.1 132.3 1 1036009 0.0093 297.86 121.1 132.3 1 158100
10 0.0094 290.24 115.5 126.4 1 10730011 0.0094 291.72 116.1 127.0 1 13060012 0.0094 288.48 114.8 125.7 1 139700
Page 85
FILE= WAP9-l.WQl
OFFSET = 1.1500
WIDTH = 0.376
MATL. = ALLOY 17200 1/4IIT
NOTES = ENDURANCE FINISH
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 23901 135.345 48753
10 66,79250 152,240IALPHA = 178706.67~I
BETA = 2.28657279
AVERAGE AVERAGE123.71 135.34
SPECIMEN THICKNESS LOAD# INCHES LBS
STRESSKSI
FEASTRESS
cyclesto fail
1 0.0098 0.6504 124.3 135.9 1 3095002 0.0098 0.6669 127.4 139.1 1 3537003 0.0098 0.6642 126.9 138.6 1 1871004 0.0098 0.6238 119.2 130.7 1 861005 0.0098 0.6807 130.1 141.8 1 119,0006 0.0097 0.6271 122.3 134.0 1 1807007 0.0098 0.6477 123.8 135.4 1 1480008 0.0098 0.6543 125.0 136.7 1 1407009 0.0098 0.6855 131.0 142.7 1 183600
10 0.0098 0.6486 123.9 135.5 1 14360037 0.0098 0.6220 118.9 130.3 1 11400038 0.0098 0.6496 124.1 135.7 1 9550039 0.0098 0.6518 124.5 136.2 1 9450040 0.0097 0.6244 121.8 133.5 1 10450041 0.0097 0.6052 118.0 129.6 1 13410042 0.0097 0.6056 118.1 129.7 1 128000
Page 86
FILE= WAP8-1.WQl
OFFSET = 1.15
WIDTH = 0.376
MATL. = ALLOY 17200 1I4HT
NOTES =
% FAILURES ESTIMATED PEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 37,752 145.265 47,174
10 52.05250 67,339IALPHA = 70799.057~1
BETA = 7.31572949
AVERAGE AVERAGE133.47 145.26
SPECIMEN THICKNESS LOAD# INCHES LBS
STRESSKSI
PEASTRESS
cyclesto fail
1 0.0098 0.6855 131.0 142.7 1 835002 0.0097 0.6785 132.3 144.3 1 814003 0.0098 0.7184 137.3 149.1 1 593004 0.0098 0.6854 131.0 142.7 1 698005 0.0098 0.6922 132.3 144.0 1 611006 0.0099 0.6987 130.8 142.4 1 595007 0.0098 0.6939 132.6 144.3 1 630008 0.0098 0.7005 133.8 145.6 1 67600
9 0.0099 0.7103 133.0 144.5 1 5970010 0.0097 0.6751 131.7 143.6 1 7890011 0.0098 0.7211 137.8 149.6 1 5900012 0.0097 0.7084 138.2 150.2 1 56300
Page 87
FILE= WAP61-1
DATE = 10/7/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 51,292 151.395 59367
10 6332750 74984
IALPHA = 77490.3117 1BETA = 11.1488924
-4.74E-Q9
AVERAGE AVERAGE0.0022 140.96 151.39
cyclesf1 '1
FEASTRESS
STRESSKSI
SPECIMEN THICKNESS LOAD# INCHES grams to at
1 0.0098 409.64 150.0 160.5 1 871002 0.0098 382.86 140.2 150.5 1 830003 0.0098 383.62 140.5 150.8 1 765004 0.0098 417.74 152.9 163.6 1 704005 0.0097 397.65 148.6 159.2 1 720006 0.0098 255.37 93.5 103.0 1 638007 0.0098 425.50 155.8 166.5 1 731008 0.0097 404.71 151.2 161.9 1 685009 0.0097 379.50 141.8 152.3 1 72600
10 0.0097 377.61 141.1 151.6 1 6850011 0.0097 383.93 143.5 154.0 1 7190012 0.0097 354.41 132.4 142.9 1 84000
Page 88
FILE= WAP71-1
DATE = 2/15/88
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 1/4HT
NOTES = EQUIP PROB - FAILURE CYCLES APPROXIMATE
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 7,454 166.465 9700
10 10 89750 14776
IALPHA = 15677.3399 1
BETA = 6.18720801-1.193E-Q8 FEA
STRESS STRESSAVERAGE AVERAGE
0.0022 155.23 166.46
cyclesf: '1
STRESS FEAK S I STRESS
SPECIMEN THICKNESS LOAD# INCHES grams to aI
1 0.0094 440.12 175.1 187.3 1 192002 0.0097 437.25 163.4 174.7 1 192003 0.0095 342.69 133.5 144.4 1 13 3004 0.0096 357.71 136.5 147.2 1 14,9005 0.0096 351.81 134.2 144.9 1 13,300
6 0.0094 436.58 173.7 185.7 1 13 3007 0.0096 469.84 179.3 192.3 1 133008 0.0096 430.22 164.1 175.5 1 13,300
9 0.0097 368.92 137.9 148.4 1 13 30010 0.0097 446.15 166.7 178.3 1 13,30011 0.0096 410.49 156.6 0.0 012 0.0096 371.24 141.6 152.3 1 14,900
Page 89
ALLOY 17200 HT
Page 90
FILE= WAPOI-2
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 HT
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 4,888 97.155 41949
10 108,401 STDDEV50 1,300398 2.16661526
ALPHA = 2108674.09BETA = 0.75821538
Calculated FEAStress Stress
AVERAGE AVERAGE88.04 97.15
SPECIMEN THICKNESS LOAD STRESS FEA cycles# INCHES LBS KSI STRESS to fail
13 0.0098 0.5137 85.3 94.2 1 58050014 0.0099 0.5401 87.9 97.0 1 1044660015 0.0099 0.5445 88.6 97.7 1 64100016 0.0099 0.5357 87.2 96.2 1 36620017 0.0096 0.5335 92.3 101.9 1 32980018 0.0099 0.5467 89.0 98.1 1 280570031 0.0099 0.5534 90.1 99.3 1 1025180032 0.0099 0.5181 84.3 93.1 1 160550033 0.0098 0.5357 89.0 98.2 1 23950034 0.0099 0.5379 87.5 96.6 1 212310035 0.0098 0.5313 88.2 97.4 1 18350036 0.0098 0.5247 87.1 96.2 1 1116500
Page 91
FILE= WAP63-1
DATE = 10/9-10/19/87
OFFSET = 0.9995
WIDTI-I = 0.376
MAIL. = ALLOY 17200 HI
NOTES = TEST TERMINATED 11,303,500
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 100000000 98.215 100000000
10 100000000 STDDEV50 100000000 4.79117576
IALPHA = 100,000,000 IBETA = 9.2100498684846E+161
-1.0857704510611E-17
AVERAGE AVERAGE0.0022 88.93 98.21
SPECIMEN nnCKNESS LOAD STRESS FEA cycles# INCHES grams KSI STRESS to fail
1 0.0095 230.76 89.9070564 99.3202425 1 1000000002 0.0093 222.09 90.2908135 99.7991269 1 1000000003 0.0094 229.35 91.2690429 100.835612 1 1000000004 0.0094 236.46 94.0984429 103.89874 1 1000000005 0.0096 233.46 89.0739013 98.377927 1 1000000006 0.0097 224.57 83.9244936 92.7502311 1 1000000007 0.0098 223.04 81.6603175 90.2554759 1 1000000008 0.01 239.27 84.133452 92.8696617 1 1000000009 0.0096 238.63 91.0464536 100.507169 1 100000000
10 0.0096 230.69 88.0170406 97.2328751 1 10000000011 0.0096 224.97 85.8346422 94.8590591 1 10000000012 0.0096 256.71 97.9446638 107.872277 1 100000000
Page 92
F I L E = WAP20-3
OFFSET = 0.9995
"WIDTH = 0.376
MATL. = ALLOY 17200 HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 9,553 106.85 137442
10 446173 STDDEV50 9,723929 1.76599099IALPHA = 17710139'~1
BETA = 0.61131585l.3527E-09
AVERAGE AVERAGE97.09 106.8
SPECIMEN TIllCKNESS LOAD# INCHES LBS
STRESS FEAK S I STRESS
cyclesto fail
25 0.0098 0.5814 96.6 106.2 1 10000000026 0.0097 0.5850 99.2 1P9.1 1 217860027 0.0098 0.5799 96.3 106.0 1 2,30920028 0.0099 0.5829 94.9 104.3 1 10000000029 0.0098 0.5803 96.4 106.0 1 4,735,70030 0.0098 0.5708 94.8 104.4 1 486960031 0.0098 0.5902 98.0 107.8 1 3,383,20032 0.0098 0.5971 99.2 109.0 1 10000000033 0.0099 0.5862 95.4 104.9 1 122770034 0.0097 0.5684 96.4 106.1 1 5925,80035 -0.0097 0.5840 99.0 108.9 1 429140036 0.0098 0.5972 99.2 109.0 1 3,932,300
Page 93
FILE= WAP18-3.WQ1
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 HT
NOTES = ENDURANCE FINISHED
% FAILURES ESTIMATED FEA -ACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 132,759 107.15 1006582
10 2,462,544 STDDEV50 25,598,529 1.68309988
IALPHA = 40368663 .1fI
BETA = 0.804605241.0731E-D8
STRESS FEAAVERAGEAVERAGE
97.38 107.1
SPECIMEN THICKNESS LOAD# INCHES LBS
STRESS FEAK S I STRESS
cyclesto fail ...
25 0.0098 0.5830 96.8 106.5 1 5039,70026 0.0098 0.5799 96.3 106.0 1 10000000027 0.0098 0.5828 96.8 106.5 1 100.00000028 0.0098 0.6022 100.0 109.8 1 100.000.00029 0.0098 0.5832 96.9 106.5 1 7,102,90030 0.0098 0.5916 98.2 108.0 1 671700031 0.0098 0.5989 99.5 109.3 1 10000000032 0.0098 0.5799 96.3 106.0 1 5,50320033 0.0099 0.5930 96.5 106.1 1 543000034 0.0097 0.5708 96.8 106.5 1 10000000035 0.0097 0.5893 99.9 109.8 1 1157490036 0.0098 0.5698 94.6 104.2 I 5,087,200
Page 94
FILE= WAP13-4
OFFSET = 0.9995
WIDTH = . 0.376
MATL. = ALLOY 17200 HT
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 30,787 115.865 287292
10 770333 STDDEV50 10,179403 1.23083569
IALPHA = 16820029. ~IBETA = 0.72980884
1. 1551E-09STRESS FEA
AVERAGE AVERAGE105.82 115.86
SPECIMEN THICKNESS LOAD# INCHES LBS
STRESS FEAK S I STRESS
cyclesto fail
37 0.0098 0.6344 105.4 115.4 1 3464,00038 0.0097 0.6286 106.6 116.8 1 287480039 0.0098 0.6403 106.3 116.4 1 9,90720040 0.0098 0.6302 104.7 114.7 1 4403--,90041 0.0099 0.6421 104.5 114.4 1 10,598,70042 0.0099 0.6468 105.3 115.1 1 3831 10043 0.0097 0.6405 108.6 118.8 1 279570044 0.0098 0.6302 104.7 114.7 1 552450045 0.0098 0.6377 105.9 115.9 1 7915,90046 0.0098 0.6324 105.0 115.0 1 10000000047 0.0098 0.6447 107.1 117.1 1 958800048 0.0098 0.6379 105.9 116.0 1 100,000,000
Page 95
FILE= WAP14-4
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 HT
NOTES = ENDURANCE FINISH
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 1,192 116.915 28,363
10 114,991 STDDEV50 4,483,647 2.33931439
IALPHA = 9144538.0~1BETA = 0.51424535
2.5317E-08
AVERAGE AVERAGE106.74 116.91
SPECIMEN THICKNESS LOAD STRESS FEA# INCHES LBS KSI STRESS.. 37 0.0098 0.6712 111.5 121.6
38 0.0097 0.6265 106.2 116.439 0.0098 0.6248 103.8 113.740 0.0098 0.6191 102.8 112.841 0.0096 0.6241 108.0 118.442 0.0097 0.6207 105.2 115.443 0.0097 0.6422 108.9 119.144 0.0097 0.6338 107.4 117.745 0.0097 0.6408 108.6 118.946 0.0097 0.6278 106.4 116.647 0.0098 0.6359 105.6 115.648 0.0097 0.6283 106.5 116.7
Page 96
FILE= WAP64-1
DATE = 10/19/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 HT
NOTES =
% FAILURES ESTIMATED PEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 57,146 120.825 98390
10 125,072 STDDEV50 234,361 5.3505737
IALPHA = 264816.89~1BETA = 2.99989947
-3.518E-Q8
STRESS PEAAVERAGE AVERAGE
0.0022 110.26 120.82
cyclesf: '1
STRESS PEAKS I STRESS
SPECIMEN THICKNESS LOAD# INCHES .l!;Tams to aI
1 0.0095 264.41 103.0 113.3 1 2458002 0.0094 303.79 120.9 131.9 1 150,5003 0.0096 298.94 114.1 124.6 1 205,8004 0.0096 268.53 102.5 112.6 1 222,6005 0.0093 270.88 110.1 121.0 1 137,9006 0.0096 297.54 113.5 124.1 1 435,6007 0.0096 277.35 105.8 116.1 1 216,2008 0.0094 289.61 115.2 126.2 1 354,6009 0.0096 282.69 107.9 118.2 1 204,700
10 0.0094 283.26 112.7 123.6 1 19880011 0.0096 283.32 108.1 118.5 1 279,90012 0.0096 286.36 109.3 119.7 1 186,800
Page 97
FILE= WAP28-2
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 H
NOTES = UNHEAT TREATED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 40675 92.825 47307
10 50571 STDDEV50 60217 7.961641
I:U-PHA= 62297.281 ~I
BETA = 10.7907705-1.926E-08
STRESS KSIAVERAGI AVERAGE
0.0022 84.21 92.82
SPECIMEN THICKNESS LOAD STRESS FEA cycles# INCHES e.rams KS I STRESS tofatl
25 0.0101 246.55 85.0 93.7 1 6610026 0.0102 266.66 90.1 99.1 1 5260027 0.0102 177.97 60.1 66.4 1 52,60028 0.0102 248.25 83.9 92.5 1 5880029 0.0101 256.98 88.6 97.6 1 5810030 0.0101 243.85 84.1 92.7 1 6100031 0.0101 239.12 82.4 -91.0 1 6480032 0.0101 277.65 95.7 105.0 1 46,80033 0.0104 238.61 77.6 85.6 1 6100034 0.0102 262.78 88.8 97.7 1 5430035 0.0104 248.20 80.7 89.0 1 6410036 0.0102 255.40 86.3 95.1 1 56,70037 0.0103 256.39 85.0 93.6 1 58,80038 0.0099 237.72 85.3 94.2 1 56,20039 0.0101 237.36 81.8 90.3 1 56,20040 0.0103 229.62 76.1 84.1 1 5260041 0.0099 268.73 96.4 106.0 1 6960042 0.0103 224.73 74.5 82.3 1 5880043 0.0099 252.81 90.7 99.9 1 6610044 0.0099 239.87 86.1 95.0 1 4880045 0.0101 261.94 90.3 99.4 1 61 10046 0.0101 252.42 87.0 95.9 1 6960047 0.0102 233.56 78.9 87.2 1 6410048 0.0101 248.47 85.6 94.4 1 69000
Page 98
F I L E = WAP28-1
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 H
NOTES = UNHEAT TREATED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 10,173 125.595 12.228
10 13.262 STDDEV50 16,404 4.38354888
IALPHA = 17096.737~1BETA = 8.86101904
-1.883E-09STRESS FEA
AVERAGE AVERAGE0.0022 116.06 125.59
cyclesf: '1
STRESS FEAKS I STRESS
"'-SPECIMEN THICKNESS LOAD
# INCHES grams to aI
13 0.0099 320.47 115.0 125.0 1 1450014 0.0101 333.13 114.8 124.5 1 1450015 0.0104 366.73 119.2 128.3 1 1450016 0.0101 321.98 111.0 120.6 1 16,50017 0.0101 328.85 113.4 123.0 1 16,50018 0.0102 364.67 123.2 132.7 1 14,50019 0.0102 356.40 120.5 129.9 1 1870020 0.0105 357.17 113.9 122.9 1 1650021 0.0105 357.87 114.1 123.1 1 1870022 0.0099 304.87 109.4 119.3 1 1870023 0.0102 367.45 124.2 133.7 1 1150024 0.0099 317.76 114.0 124.0 1 18,700
Page 99
ALLOY 17200 XHM (190)
Page 100
FILE= WAPOI-3
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 (l90)XHM
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN:1 KSI% FAILURES
1 80,584 88.9250 469,976
STDDEV1.73746366
ALPHA =BETA =
547488.2292.4008691
AVERAGE AVERAGE80.49 88.92
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail19 0.01 0.5093 81.2 89.7 1 42620020 0.01 0.5027 80.2 88.6 1 47450021 0.01 0.5049 80.5 89.0 1 41590022 0.01 0.5137 81.9 90.5 1 67520023 0.01 0.5093 81.2 89.7 1 57580024 0.01 0.496 79.1 87.4 1 42680025 0.0099 0.5049 82.2 90.8 1 33190026 0.01 0.5181 82.6 91.3 1 27790027 0.01 0.5049 80.5 89.0 1 39090028 0.01 0.4806 76.7 84.7 1 108700029 0.01 0.4938 78.8 87.0 1 35880030 0.01 0.5071 80.9 89.4 1 373200
Page 101
FILE= WAP65-1
DATE = 10/20/87
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 (190)XHM
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KS1% FAILURES
1 121294 95.945 178,282
10 211 338 STDDEV50 329,838 4.01956582
IALPHA = 359676.83~IBETA = 4.23202606
-1.925E-08
AVERAGE AVERAGE0.0022 86.84 95.94
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES grams KS I KSI to fail1 0.0096 222.76 85.0 93.9 1 353,9002 0.0096 231.97 88.5 97.8 1 285,7003 0.0096 224.72 85.7 94.8 1 309,9004 0.0095 226.23 88.1 97.4 1 287,7005 0.0095 223.67 87.1 96.3 1 225,8006 0.0096 237.88 90.8 100.2 1 258,6007 0.0096 188.57 71.9 79.5 1 550,3008 0.0096 238.93 91.2 100.6 1 417,8009 0.0096 234.81 89.6 98.9 1 255,800
10 0.0096 227.74 86.9 96.0 1 32070011 0.0096 230.96 88.1 97.3 1 234,40012 0.0096 230.86 88.1 97.3 1 220,00013 0.0096 218.66 83.4 92.2 I 285,70014 0.0096 229.36 87.5 96.7 1 351,50015 0.0096 220.38 84.1 92.9 1 385,80016 0.0096 228.85 87.3 96.5 1 339,40017 0.0096 224.42 85.6 94.6 I 432,20018 0.0096 232.74 88.8 98.1 1 326,70019 0.0096 233.70 89.2 98.5 1 396,80020 0.0096 222.56 84.9 93.9 1 417,80021 0.0096 234.87 89.6 99.0 1 319,90022 0.0096 231.26 88.2 97.5 1 396,00023 0.0096 227.50 86.8 95.9 1 296,20024 0.0096 229.36 87.5 96.7 I 210,000
Page 102
FILE= WAP20-4.WQl
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 XHM (l90)
NOTES =
% FAILURES ESTIMATED FEA
ACCEPTABLE CYCLES TO STRESSOBTAIN KSI% FAILURES
1 45,719 100.225 158,475
10 274,394 STDDEV50 1,154324 1.43148652
IALPHA = 1526583.8~IBETA = 1.31123249
2.7456E-I0
AVERAGE AVERAGE91.03 100.22
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail37 0.0099 0.5789 94.2 103.7 1 522,60038 0.0100 0.5652 90.1 99.3 1 601600
. 39 0.0100 0.5752 91.7 101.0 1 58010040 0.0100 0.5734 91.5 100.7 1 3,60270041 0.0100 0.5736 91.5 100.7 1 582,70042 0.0100 0.5632 89.8 99.0 1 561,90043 0.0100 0.5641 90.0 99.1 1 1,133,40044 0.0100 0.5583 89.0 98.1 1 642,60045 0.0100 0.5615 89.6 98.7 1 55550046 0.0100 0.5745 91.6 100.9 1 2,406,10047 0.0100 0.5749 91.7 100.9 1 3,694,90048 0.0100 0.5740 91.5 100.8 1 1,839,000
Page 103
F IL E = WAP18-4
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 XHM (190)
NOTES = ENDURANCE FINISHED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 52,399 104.455 156,328
10 253328 STDDEV50 896072 2.09718519
!ALPHA= 1145743.9~IBETA = 1.49117315
4.3502E-09
AVERAGE AVERAGE94.97 104.45 -"
CALCULATED FEASPECIMEN TIllCKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail37 0.0099 0.5765 93.8 103.2 1 1,960,60038 0.0099 0.5743 93.5 102.9 1 69960039 0.0099 0.6051 98.5 108.1 1 568,60040 0.0099 0.5839 95.0 104.5 1 2,064,30041 0.0099 0.5853 95.2 104.8 1 2,737,50042 0.0099 0.5784 94.1 103.6 1 601,00043 0.0099 0.5701 92.8 102.1 1 1,190,20044 0.0099 0.5750 93.6 103.0 1 518,00045 0.0099 0.5755 93.7 103.1 1 46220046 0.0099 0.5931 96.5 106.1 1 46600047 0.0099 0.6102 99.3 109.0 1 381,90048 0.0100 0.5877 93.7 103.1 1 629,800
Page 104
a
FILE= WAP14-3
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 HM
NOTES = ENDURANCE FINISH
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI, % FAILURES1 144,376 109.85 194,855
10 222,443 STDDEV50 314,573 2.48111896
IALPHA = 336512.999\BETA = 5.43613431
-2.231E-Q9
AVERAGE AVERAGE100.18 109.8
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail25 0.0100 0.6465 103.1 112.8 1 328,70026 0.0100 0.6134 97.8 107.3 1 282,30027 0.0099 0.6052 98.5 108.1 1 397,90028 0.0100 0.6541 104.3 114.0 1 307,60029 0.0100 0.6094 97.2 106.7 1 309,10030 0.0099 0.6098 99.2 108.9 1 300.40031 0.0100 0.6016 96.0 105.4 032 0.0100 0.6342 101.2 110.8 1 265,50033 0.0100 0.6338 101.1 110.7 1 207,50034 0.0100 0.6411 102.3 111.9 1 282,30035 0.0099 0.6234 101.4 111.2 1 435.60036 0.0100 0.6274 100.1 109.7 1 312,200
Page 105
FILE= WAP13-3
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17200 XHM (190)
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN - KSI
% FAILURES1 156,289 110.845 224,827
10 263,991 STDDEV I50 401891 2.92912641
\ALPHA = 436132.2~1BETA = 4.48252894
-2.808E-Q8
AVERAGE AVERAGE101.22 110.84
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail25 0.0100 0.6210 99.0 108.6 1 347,20026 0.0100 0.6372 101.6 111.3 1 377,50027 0.0100 0.6272 100.0 109.6 1 522,10028 0.0100 0.6260 99.8 109.4 1 354,90029 0.0100 0.6276 100.1 109.7 1 513,20030 0.0100 0.6921 110.4 120.2 1 195,60031 0.0100 0.6243 99.6 109.1 1 421,90032 0.0100 0.6354 101.3 111.0 1 522,10033 0.0100 0.6293 100.4 110.0 1 401,50034 0.0100 0.6281 100.2 109.8 1 316,20035 0.0100 0.6368 101.6 111.2 1 522,10036 0.0100 0.6302 100.5 110.1 1 266,500
Page 106
ALLOY 17410
Page 107
FILE= WAP27-1
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
I 1065979 47.815 4880,531
10 9,555571 STDDEV50 55449,305 4.30862927
!ALPHA= 78066702.~IBETA = 1.07137935
-4.028E-07
AVERAGE AVERAGE0.0006 44.05 47.81
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KS I KSI tofaHI 0.0099 0.3072 50.0 54.6 1 100,000,0002 0.0099 0.2926 47.6 51.9 1 1,471,0003 0.0100 0.2435 38.8 41.8 1 100,000,0004 0.0099 0.2698 43.9 47.6 1 100,000,0005 0.0100 0.2833 45.2 49.1 1 100,000,0006 0.0100 0.2656 42.4 45.9 1 1000000007 0.0100 0.1978 31.5 33.5 I 100,000,0008 0.0100 0.2787 44.5 48.3 1 14,631,9009 0.0100 0.2512 40.1 43.2 1 713,400
10 0.0100 0.2721 43.4 47.1 1 100,000,00011 0.0099 0.2729 44.4 48.2 1 10000000012 0.0100 0.2736 43.6 47.4 1 100000,00013 0.0100 0.2474 39.5 42.6 1 10000000014 0.0099 0.2842 46.3 50.3 1 100,00000015 0.0099 0.2848 46.3 50.4 1 1 115,80016 0.0100 0.2716 43.3 47.0 1 100,00000017 0.0099 0.2661 43.3 46.9 1 100,000,00018 0.0100 0.3003 47.9 52.3 1 1778,40019 0.0100 0.2793 44.6 48.4 1 10000000020 0.0099 0.2794 45.5 49.4 1 100,00000021 0.0099 0.2695 43.9 47.5 1 1,343,200
22 0.0100 0.2792 44.5 48.4 1 100000,00023 0.0100 0.3032 48.4 52.8 1 10000000024 0.0100 0.3032 48.4 52.8 1 100000000
Page 108
FILE= WAP27-2
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 2 68.055 220
10 1948 STDDEV50 584091 2.76225904
IALPHA = 1771646.491BETA = 0.33030832
-7.185E-I0
AVERAGE AVERAGE0.0008 61.72 68.05
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail37 0.0099 0.3994 65.0 71.7 1 13510038 0.0100 0.3765 60.1 66.2 1 122,90039 0.0099 0.3730 60.7 66.9 1 174,50040 0.0100 0.3810 60.8 67.0 1 100,000,00041 0.0100 0.3721 59.4 65.4 1 143,90042 0.0100 0.3881 61.9 68.3 1 14390043 0.0100 0.3631 57.9 63.7 1 138,80044 0.0099 0.3906 63.6 70.1 1 100,00000045 0.0100 0.3946 62.9 69.4 1 135,10046 0.0100 0.3728 59.5 65.5 1 185,60047 -0.0099 0.4107 66.8 73.8 1 182,50048 0.0100 0.3893 62.1 68.5 1 144,000
Page 109
FILE= WAPI-4
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410HM
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 26,998 80.3450 95,621-
STDDEV4.17638599
ALPHA =BETA =
106684.0193.34772404
AVERAGE AVERAGE72.68 80.34
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail37 0.0099 0.4211 68.5 75.7 1 8710038 0.0099 0.4674 76.1 84.1 1 8030039 0.01 0.4431 70.7 78.1 1 8660040 0.0099 0.4167 67.8 74.9 1 10480041 0.0098 0.4343 72.1 79.7 1 9180042 0.0099 0.4123 67.1 74.1 1 9250043 0.01 0.4718 75.2 83.2 1 8030044 0.0099 0.4564 74.3 82.1 1 87900
45 0.01 0.4872 77.7 85.9 1 18050046 0.01 0.474 75.6 83.6 1 8030047 0.0099 0.4255 69.2 76.5 1 10140048 0.0099 0.4784 77.9 86.1 I 86100
Page 110
FILE= WAP57-1
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSIQ % FAILURES
I 11,341 97.885 31182
10 48742 STDDEV50 156,891 3.9636523
\ALPHA = 196957.5~1BETA = 1.61148642
2.8511E-09
AVERAGE AVERAGE0.0022 85.01 97.88
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES l!J'llIllS KSI KSI to fail25 . 0.0099 223.30 80.1 88.5 1 6540026 0.0099 240.99 86.5 95.4 1 95,30027 0.0099 245.69 88.1 97.2 1 144 20028 0.0099 228.32 81.9 90.5 1 11250029 0.0099 241.67 86.7 95.7 I 78,40030 0.0099 237.03 85.0 93.9 1 112,50031 0.0099 243.48 87.4 %.4 I 11250032 0.0099 259.30 93.0 102.4 I 82,40033 0.0099 255.95 91.8 101.1 1 10450034 0.0099 244.54 87.7 %.8 1 65,50035 0.0099 255.29 91.6 100.9 1 109,60036 0.0099 244.86 87.8 96.9 1 7910037 0.0099 256.37 92.0 101.3 1 9920038 0.0099 241.37 95.6 1 311,40039 0.0099 239.89 86.1 95.0 1 311,40040 0.0099 250.93 90.0 99.2 1 127,50041 0.0099 246.27 88.4 97.4 1 311,40042 0.0099 243.80 87.5 %.5 1 311 40043 0.0099 247.90 88.9 98.1 1 311 40044 0.0099 259.80 93.2 102.6 1 112,50045 0.0099 265.90 95.4 104.9 1 123,80046 0.0099 254.49 91.3 100.6 1 311,40047 0.0099 263.90 94.7 104.2 1 522,600
Page 111
F I L E = WAP20-2
OFFSET 0.9995
WIDTH 0.376
MATL. =ALLOY 17410
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 76,252 107.35 94,978
10 104.651 STDDEV50 134,888 2.87540989
IALPHA = 141715.94 1BETA = 7.42215861
-1.1 17E-08
AVERAGE AVERAGE97.78 107.3
CALCULATED FEASPECIMI THICKN LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail14 0.0099 0.6201 ,. 100.9 110.7 1 117,90015 0.0100 0.6141 97.9 107.5 1 113,90016 0.0100 0.6241 99.5 109.1 1 133,40017 0.0100 0.5918 94.4 103.8 1 151,60018 0.0100 0.5941 94.8 104.1 1 136,20019 0.0100 0.6119 97.6 107.1 1 117,90020 0.0100 0.5869 93.6 102.9 1 169,90021 0.0100 0.6399 102.1 111.7 1 133,40022 0.0100 0.6280 100.2 109.8 1 107,50023 0.0100 0.6073 96.9 106.3 1 151,600
Page 112
FILE= WAPI8-2.
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410
NOTES = ENDURANCE FINISHED
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 84,069 105.55 104,314
10 114743 STDDEV50 147241 1.67137797
\ALPHA = 154561.013.1BETA = 7.5542714
-1.092E-Q8
AVERAGE AVERAGE96.04 105.5
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KS I KSI to fail13 0.0100 0.6078 96.9 106.4 1 106,50014 \ 0.0100 0.5972 95.3 104.7 1 17570015 0.0099 0.6070 98.8 108.4 1 12380016 0.0100 0.5894 94.0 103.4 1 135,100 I
17 0.0099 0.5919 96.3 105.9 1 144,50018 0.0100 0.6033 96.2 105.7 1 151,30019 0.0100 0.6031 96.2 105.6 1 ..14450020 0.0100 0.5831 93.0 102.3 1 17900021 0.0100 0.6012 95.9 105.3 1 15130022 0.0100 0.5954 95.0 104.4 1 172,30023 0.0100 0.6043 96.4 105.8 1 135 10024 0.0100 0.6180 98.6 108.1 1 123,800
Page 113
FILE= WAP13-2
OFFSET = 0.9995
, WIDTH = 0.376
'MATL. = ALLOY 17410
NOTES =
% FAILURES ESTIMATED FEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 41,080.."
109.45 61,921
10 74,223 STDDEV50 119262 3.51117452
IALPHA = 130789.766 1BETA = 3.97224835
-1.071E-Q8
AVERAGE AVERAGE99.8 109.4
CALCULATED FEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail13 0.0100 0.6226 99.3 108.9 1 89,20014 0.0099 0.6207 101.0 110.8 1 89,20015 0.0100 0.6247 99.6 109.2 1 103,20016 0.0100 0.6315 100.7 110.3 1 99,10017 0.0099 t· 0.6232 101.4 111.2 1 115,90018 0.0100 0.6378 101.7 111.4 1 99,10019 0.0100 0.5947 94.9 104.2 1 142,50020 0.0100 0.6448 102.8 112.5 1 9910021 0.0100 0.5693 90.8 100.0 1 195,60022 0.0100 0.6400 102.1 JI1.7 1 138,30023 0.0099 0.6227 101.3 111.1 1 13830024 0.0100 0.6387 101.9 111.5 1 119,900
Page 114
FILE = WAP14-2
OFFSET = 0.9995
WIDTH = 0.376
MATL. = ALLOY 17410
NOTES = ENDURANCE FINISH
% FAILURES ESTIMATED PEAACCEPTABLE CYCLES TO STRESS
OBTAIN KSI% FAILURES
1 42,285 112.745 55.514
10 62,606 STDDEV50 85,753 3.20060885
!ALPHA= 91166.16411
1
BETA = 5.9878139-9.08E-09
AVERAGE AVERAGE102.99 112.74
CALCULATED PEASPECIMEN THICKNESS LOAD STRESS STRESS cycles
# INCHES LBS KSI KSI to fail13 0.0100 0.6208 99.0 108.6 1 99,10014 0.0099 0.6193 100.8 110.5 1 70,50015 0.0098 0.6256 103.9 113.9 1 70,50016 0.0099 0.6045 98.4 108.0 1 110,60017 0.0100 0.6617 105.5 115.3 1 72,30018 0.0099 0.6682 108.7 118.7 1 65,50019 0.0100 0.6384 101.8 111.5 1 72 30020 0.0100 0.6688 106.7 116.4 1 70,50021 0.0100 0.6254 99.7 109.3 I 106,20022 0.0098 0.6185 102.7 112.7 1 9030023 0.0100 0.6638 105.9 115.6 1 87,90024 0.0100 0.6442 102.7 112.4 I 99,100
Page 115
APPENDIX - B
Page 116
ALLOY 17200 1/4HT
FAILURE DISTRffiUTIONS
(CYCLES TO FAILURE vs PERCENT FAILED WITHIN EACH RANGE)
Page 117
ALLOY 17200 1/4HT [3 RUN OUTS]
TEST 03-1 91.7 KSI AVERJ\G!,j: STRESS
,.265,6955,9.tO,865 6,382,475 6,824,085
4,616,0355,057,645
5,499,255CYCLES TO FAILURE
-----r--·--- ------r-------r----- -r--------r---- r------------,
1j
J--I-~ -I -/----f ~
J
II
2~1-1 I 1---1 I f 1--------1!i
o -. (1,.205
3,29 3 732,lS 15 74 425' 4,1,
3(j '," ----·-r --.--.
Z 25
0-'fj-- 2:: 20
.,'¥ 0
r-~
~
;:::;
- '.i) 15-~ Z-,....-~...;J 10-~~.c.t...' 5
ALLOY 17200 1I4HTTEST 01-1 93.2 KSI AVERAGE STRESS
50
Z0 40-'fJ->-- -
..wP
To:
:tl 30
~~- 'fJ
--.c Z-P 20W,..J-~~
10•.ct..'
o
J
:1
682,370 1,415,780 2,149,190' 2,882,600926,840 1,660,250 2,393,660
1,171,310 1,904,720 2,638,130CYCLES TO FAILURE
ALLOY 17200 1I4HTTEST 59-1 93.2 KSI AVERAGE STRESS
4,171,1605,077,500
5,983,840CYCLES TO FAILURE
II I + I I + I I +-~-!
1,452,140 2,358,48°3
,264,820
o -
-------r----~-r I I I
45 -j I I-~----I----I----! I I I I I
•
50 -,------r------r--------r ------r
5
Cl 20W.....l.-< 15-<u..l": 10
Z 40o......;2 35>0 30~
::JC/) 25Z......
'":.-~~-.~o
~
1
./if~ '.;;"-"~
~
)
ALLOY 17200 1/4HTTEST 74-1 94.8 KSI AVERAGE STRESS
~,,::,:-~,*",:.•-,. •
.:r'-'~
547,715 . 949,385681,605 1,083,275
815,495 1,217,165CYCLES TO FAILURE
.~
] I I I -I 1·1·1 -=1,351,055
"
~-..;;<~~:,'-;
r-
"I...l••..•~'~.
. ~"""'.'"
)
ALLOYI7200 1I4HTTEST 40-1 95.9 KSI AVERAGESTRESS
..-=~:.:.~--;;- "!\
SO I i I Iii " Iii
I I I I I I45 I I I I,.-,~
~
,.
~~c.~'_ .
o
5
~ 40 I I I I I 11· I I I
"""' I I I I~ 35 I I I I I Ie;.~ 30
rn 25
~~ 20
=::lIS~~.
~ 10
1~
~
~
797,590 . 2,488,660' 4,179,7~0' .1,361,280 3,052,350 ~,420
'·1,924,970. 3,616,040 . 5,307,110CYCLES TO FAILURE
)
•.,
5,870,800
~ .._..~
• J
,..
')
'"
ALLOY 17200 1/4 HT [4 RUN OUTS]TEST·23-1 99.4 KSI AVERAGKSTRESS
~,-,.:;,:r_-<;;-ioi._."._ "=- .\
30 I iii I I I Iii
..
'"
:,.,--~
~".'~~=...:-' .. "
.... '~ -~... ·.P •
"
- - ----
'351'13510'615'12~1,879,1l55,559,165
6,823,155. 8,087,145
CYCLES·TO FAILURE
)
1,767,1953,031,185 295 1754, , .
o
Z 25O.....crn....c •.•e; 20
~rn 15
~Cl
..~ 10
~I:l' 5'~
~~~
~w
.,..."., ..
:\
/'
,
';ALLOY 17200 l/4HT
TEST 23-2 102.7 KSI AVERAGESTRESS..o::-;_~,;;;-->;;.-, ~.-.",
-,,_c"_,' -'".........
J-j
'. ~c,;::.:~.,:"""
;;=~~
N...
10095
90
00 85~
Z 809 75
~ 70e; 65
~ 60
~ 5500 50
~ 45~ 40~ 35
~ 30~ 25~ 20~ 15
105o
'..
, .
I
8 ' ..
0.455.940 0,303.960 0,151.980 100,000,0020,405,280 50,25~,300 80,101,320
30,354,620 60,202,640 90,050,660CYCLES TO FAILURE -
J
"
t'
"...'-~
'\'
- ,e 'II
-------
[....l' --..e---'::-
..
,':,::: ,~
ALLOY 17200 1/4 HT [1 RUN OUT]TEST 23-4 102.7 KSI AVERAGE STRESS
~'~",:;.o~..:;.,.~ ':-"' . \
40 • Iii iii "I ..
~~
Ntil
35 I I I I I I I I I I I
zo~ 30 I~ I I~ I
.~ 25 Ip::l I I;:J I
rF1 20Z I I~ I
~ 15
~
.~ 10
~
5""""'0.,-
o
-...-:~
> •
~ .C5
t'
~~.~.~:C~""
)
. 0,553,4404,062,88016,226,400
18,389,920'\
- I
,,', I ....:.-...._.'
~
-~~ :i.:: -,,,,,
.L
)ALLOY 172~0 1I4-HT [IRUNOU'F]
TEST 23-3 105.9 KSI AVERAGESTRESS..:::-",-~c";_-:_·~
30 I , i I I i • iiiI..
..,.-:~
'I'
.~ .
~:'.~'~;"~.
3,309,5504,085,050
4,860,550CYCLES TO FAILuRE
1,758,550 2,534,050
o
+ " ~+ + ·..·..+..·..·..·..·····..·:.. ·1·..·······..·..·..····:1·'·'···..·..··..·..·'·I·.:.:·:·::~:·~·=.:::~t- ..·.._~ ..·······+ ·..····· ..
Z 25 I Io I I~ I I~ I I..... .
~ 20 I IQ 1 I 1!§ I I I
~ 15
~Q~ ....d 10
~
* 5
?....NQ\
J
l'
l ' "';;' ..--'~--.., .
,:",_: ')
)
-r'-'~
I..
'"
"'.~.
"
~~.'<:~~';'_:', . .- .'
. \
'.,0-.\
ALLOY 17200 1I4HTTEST A2-1 107.4 KSI AVERAGES'tRESS
. ~:'::"f~~~- '/- ,~£
20,129,280 _ 50,080,800 . 80,032,320 .30,113,120 60,064,640 90,016,160
CYCLES TO FAILURE
"
.... .
, '
.....
j
•-.
~~ ~~ ..
0.145.440 0.096.960 0.048.480 .100.000.00
100959085
Z 809 75
~ 70
~65Q 60
E§.55rrJ 50
~ 45Q 40~ 35=30~ 25
Q 20~ 15
10
'5o
~10-0"N~
J
45
.)TEST 20-1
TEST 20-1 112.4 KSI AVERAGE STRESS
<~~::.~"""~- :. \
_....-...•.......•~....,
~......NQO
Z 40'9~ 35
~§30
Cf.) 25
~~ 20~
~ 15
~~ 10
5
. 0248,040
339,380430,720
613,400704,740
.CYCLES TO FAILURE
L
887,420978,760
1,070,100
~-.' - ~
"
Yf~
~c,~~~c:,.;
.\ .
.. ,"
,",,,,;, _:--.~
)
, ....:\-". )
ALLOY 17200 1I4HT'._TEST 13-1 111.9 KSI AVERAGE STRESS
. .c:-~:.~':*- ~.._'~r
30 I I I I i I I I I i
,
:=(JQ~
~
NIC
25 I IZ9~> 20 I ,I~
~r..n 15
~~ •...
~ 10
~~ 5
o, .. 481,780
584,460687,140
,· .. ···....·..·..·······..·1·,·".. ··········..·..·.. ·1
789,820 .. 1,097,860" 1,405,900892,500 1,200,540 .. ,
, 995,180 1,303,220CYCLES TO FAILURE
......~
.,
.~ ....... 1 .-,. . .' .~><-::_~">
)
---'\__ 1
_~c-,-,:.~ __ .-",_
65,80053,110
-,-
40,420
)
\ '~'::';::O'."",*.:
ALLOY 17200 1I4HTTEST 73-1 112.7 KSI AVERAGKSTRESS
31,960 44,650 57,34027,730
o
30 I I I I I I I I I I
~ 25 l ~ I I I I I I I I I ...-•. "
1-01VJ1-01
> 201-01
;p Q(JQ ~I'D~ VJ 15~
~Q
Q~
d 10 I~'I~I I I --I~'<fl I I I I I ~
-<~
~ 5
:""' ....
k
I
.[i
I
_r. . -------,------y.li
)
-,
.:" ,. .)
ALLOY 17200 1I4HTTEST18-1 113.8 KSI AVERAGE-STRESS
~"'::'-~-'.'. \
C:--:0<'~~~""
~:
cfg~....~....
..
20Iii i I I Iii I I
z9 15Cf)
5=)000(
~Cf) 10
~
S~~ 5
~
o390,795 . "1,690,365' '. 2,989,935' 4,289;505
823,985 2,123,555 3,423,1251,257,175 2,556,745 3,856,315
CYCLES TO FAILURE
"
'"C-',,_
..
Of'
·1
.. I·....,l< • __.... :
') t.;I,
lA
ALLOY 17200 1I4HTTEST.14-1 115.3 KSI AVERAGE~STRESS
..-=-"'~~_~~_. _:_ '~r
30 I • I I I iii I i I
i·_._._ _ _ ·1..·· ·1 _._._.- ·1···· ·· ..·..· ·····..1 · ··: 1·..·..· ·..·..·· 1· _ 1 _.- ..I..· · ·..· j1· - 1 _ _ -..I..· ·1 _ J 1 ·..· I· _. _. - · 1· _.1_ ""'''''''-' ·1 ..· _.. _· j
·_·_·_·_· ·..·.._··..· · ·..·_·-..1 ·..·.._·_· ·+· J ..· · ·+ _· ··..· ·+..·..· · 1·_ ·..·..·1- ·_..·..· •..·..· ·..·..·..· ..
~
.-,.-.~ ..
..
~.~~o,'c;:.._~ .. ,>...
·1- · ·..·..· 1..·..·..· · 1..· ·_· · ·..1·..· · + ·' ·1 · ·..· ·_·_..1 _ _ + , j·1 _ ·1·..·..· I ·..·..·_ ·1 ·..1.._· ·..· 1 · · · ·..·..·1 ·..·..· 1..· _·_·..·_..·..1
o
Z25o~ ..
~e; 20
~;:JrJ.) 15
~Q~ ..._..
d 10
~~ 5
1ttl....~
639,220 851,140CYCLES TO FAILURE
286,020356,660
427,300
497,940 709,860568,580 780,500 .
921,780
J
..Jo'-"_."
l""'"~~
i
)ALLOY 172001l4HT
TEST 58-1 116.4 KSI AVERAGE STRESS..\
";;:,""':~~-:c'."'" ~.-, -.~--
.. - ." .
50
45
Z040~
r:J:J;;: 35~
~ 30
r:J:J 25~.
~ 20~
d 15-<~ 10~ ..
5
0200,930 -245,420 - -289,910 - . 334,400
215,760 260,250 304,740230,590 . 275,080 319,570
CYCLES TO FAILURE\
_:,..-~
"
I
._ ....~,'-.
)i -' ,-T
ALLOY 17200 1I4HTTEST 72-1 121.0 KSI AVERAGE STRESS
,,::;'"~'-"O_""'-ry;_ ',C·_""
30 I Iii Iii I iii~·······"·"···········:"·I..·..···············C"C"·IC" ···..·,·'·..··I·;·..;·;;··,,,,,·..·..··{···;·..·..·..·,·,,,,'Oc.lo"='o"=o=I='=~·~"7.·,"",I,",",,,··,···,,,··,~'"·~·t~""'''·''·····''·''''I''''''''''·''-·''·-''''i··· I _ ..~ 1 ·1 ..· ·..· 1..· { "'''''' ·1· ·1·..·..·..·· ·..· ·1 · ·..·..·1 ·..·..· I· ·..·..· ·.. j
;p~~
W~
I I25 I IZ9en I' I~ 20 I I
~en 15
~Q , ..
~ 10
~~ 5
o31,280
36,26046,220
1·..·..·..·..· · ·I·..· , ·..·..·..·f · ·..·..·.._.. I· .
·f · ·..·..· ·..·..·I·..·..·_..· ·..·F·..· · ·I"·.. o· .. •••·..,',,· ··I -·..·..· I ··..· ·..·..· ·..~
·f ·..·..·..· ·1·..·..·_ ·1·..· · 1··..·..· ·..·..·I ..· · · I..·..· ·..·..·..·..· ~
51,200'" 66,140
.C-'''~
~.
'"
.~c ..~.~,,;~.;
41,240 56,180 71,120CYCLES TO FAILURE
~,'
I (~
')
~
,.
.,....,;:<--
t'
cr~c~"-'"
. ALLOY 17200 1/4HT.TEST.A1-1 122.5 KSI AVERAGESTRESS
\.z;;:;.,,..,-t;- ~._ ' .•.r " . -~.- ..
~ -100
9590
Z 85o 80~ 75~ 70
~ 65.
~ 6055
00 50
2S 45~ 40r;il 35
=:I 30
~ 25
~ 2015
10.........~.. _.
-50
241,610 1,107,470 1,973,330530,230 1,396,090 2,261,950
818,850 1,684,710 2,550,570CYCLES TO FAILURE
-----~
"'C
~~
t..H!.II
(.
+····..·..···············1·..•..•·•··•········..·..··+..····· + _ + _ ····1··..·..·_········ ..····+..·..·..··:············ .. ··1···· + + _ .,.-,.:-
-I
~:."~~.""
....,.\. ~--"~'
.......~ ..
63,800
61,790 .59,780
I··I·~-~--+ .._-----...·__._-
57,77053,750
55,760CYCLES TO FAILURE.
51,740
49,730
(").
)
ALLOY 17200 1I4HTTEST 40-2 124.8 KSIAVERAGE:STRESS
..0:--.1"..".;:;:-..;._.:.;.....""" .
47,720
o.. 45,710
20 I I I I I I I I I I
zsa ISrJJ
>l-olQ
~rJJ 10
~
~~ 5
~
[
1~....C.NQ\
.._ ;l'··
/---..,'~:::-._::)
)
ALLOY 17200 1I4HTTEST 6Q~1 129.4 KSI AVERAGE STRESS
C.=f'.;O;;:;;:;;'- ~'.'-"'-
30 I I I I I I I I ..~ I I I
-1- , ·······················1······················1·······....•..._•....-1-.-·__·····-(··_·············..·..1 ··'··· · ···1·····.."" "."••••.~ ..-I- ·..·······..1· ···1..·..······•····•·•··..·1···········:··..··..··1············ ······1····· ··..·..·..···1····..··· ·········1·..················,..I······················j-1-········..···..·······•···..··..······..······1 ......··..······..··....·1..·..············_....1..······•···•·•····..···1··········..··....;···1·······....··..····..···1·····..·..·..·········1·..··..······_·······..·····················
;:t;-
.. -;;
..' ..
.~C'~'~·"'"
':r
129,565 146,875135,335 152,645
CYCLES TO FAILURE118,025
112,255106,485
o
25Z -1-······.. ·.... ·.·..•·....·..·..·..·..·....·1···..·······..·..····..19i20 1-="=1,,,,-'='1=-',.,=-1..-:.'---=1.---,.-.-1.::.:-.:.:.:.l :..-k.::::::::I:::.==.t
t/) 15
~
~ 10
~~ 5
~~~
w.......
)'...,:....., .
.,--.:~
~
+..···· ..·,..· · _·.-·_ ·.._..·..·_· 1- ·· ·..·..· 1····· ..·· ·..·..·.._..1 ·..·..·..· · 1· · ·1·..· · ·· ·..·1· ..·..·· ·..·..·..·..· · ·..· ·_..·_·I ·..·..·..· ·j
"",
"'-.~'"
"
~c.~s.:<......·.
340,320
\
260,040206,520 286,800
1· ..· .... ··..· .. ·1 .......... ·······1..·.... ···+· .... ··..·.....
·l ·..·..·_..··· I== ·.. ··.· L·_· ··..· _·J...· · :: =..:l=..· ·..·..·..·..·L ·..· · ·j
. 233,280 313,560CYCLES TO FAILURE
179,760
·1 ·..·..·.._·..· ·1 · ·..·..· · 1·..·..· ··..1·..·..·..·;· ·1 · ·..· ·..- ..·~· I ·..·..·..· ·.. j
153,000
·1 ·..·..· 1· · ·..·..·..·..·..·+· ·..·..·..· ·1· ..·..·..·..· · ·1·..·..· · ·..·..·1-..· · ··..·..·1 ·..· ·1 · ·..·_..· ..
ALLOY 17200 1I4HTTEST 9-1 135.3 KSI AVERAGlt' STRESS..,::-",-..;-.,;:;;--..;.--:-"""
126,240
30 I I i I I I I I I' I I
Z 2S
9rr.J~
;;> 20~
~rr.J 15
~Cl "...
~IO~ 5
1ttl
"""~QC
. -(
r-~.l
..........;,r-..
....--.. .
\~)
)
ALLOY 17200 1I4HTTEST8-1 145.Z",KSI AVERAGE sTREss
~-'.-
65,826
-~.._." .. - .-
73,98668,546 76,766
"'-..
82,146 '.
.-'~
".
.,.
~i.<i.~::~_C~
.-,~J
')
ALWY 17200 1I4HTTEST 61-1 151.4 KSI AVERAGKSTRESS
~;:--.,:;.~.!.~~
.,~
".
----. ~c-'~~:';c,:
71,955 78,94574,285 81,275
85,935
76,615 83,605CYCLES TO FAILURE
) .
r:........l )
/"",,.'j
._~.~- .. ~~,;i..:~."'; ...·-:,.-.-_
<'1
)ALLOY 17200 1I4HT
TEST 71-1 166.5 KSI AVERAGE STRESS..:F-";<;;:"~~-".;·
:.--,i,;~
.;
18,905
18,31517,725
, 17,13515,955
16,545CYCLES TO FAILURE
15,365
14,775·14,185
13,595
~~l_1 I I I I I I I I· It:: 50
~ 45
~ 40
~ 35
~ 30
=:::l25~ 20
~ 15
10
5
o
1('D..."""...