Richard W. Hertzberg received his B.S. cum laude in Mechanical Engineering from the City College New York, his M.S. in Metallurgy from M.I.T. and his Ph.D. in Metallurgical Engineering from Lehigh University. A recipient of two Alcoa Foundation Awards of Outstanding Research Achievement, co-recipient of Lehigh University's Award of Outstanding Research, recipient of Lehigh University's College of Engineering Teaching Excellence Award, co-recipient of Lehigh University's award in Recognition of Outstanding Contributions to the University and recipient of the 2015 Distinguished Alumni Award from the Materials Science and Engineering Department of Lehigh University. Dr. Hertzberg has served as Research Scientist for the United Aircraft Corporation Research Labs, and Visiting Professor at the Federal Institute of Technology, Lausanne, Switzerland. As an active member of several engineering societies, he has been elected as a Fellow of the American Society for Metals and was recipient of the TMS 2000 Educator Award as the most outstanding material science educator in the nation. He was the 2017 recipient of the ICF Paul C. Paris Gold Medal from the International Congress on Fracture. He has authored approximately 230 scholarly articles, coauthored Fatigue of Engineering Plastics (Academic Press, 1980), and co-authored the fifth edition of Deformation and Fracture Mechanics of Engineering Materials. Dr. Hertzberg has also been an invited lecturer in the United States, Asia, Israel, and Europe, and has served as a consultant to government and industry. He was previously Chair, Materials Science and Engineering Dept., and Director of the Mechanical Behavior Laboratory of the Materials Research Center at Lehigh University. Currently, he is New Jersey Zinc Professor Emeritus of Materials Science and Engineering.Richard P. Vinci received his B.S. degree in 1988 from the Massachusetts Institute of Technology, and his M.S. and Ph.D. degrees in 1990 and 1994, respectively, from Stanford University, all in Materials Science and Engineering. After holding postdoctoral and Acting Assistant Professor appointments at Stanford University, in 1998 he joined Lehigh University where he was a Professor of Materials Science and Engineering and the Director of the Mechanical Behavior Laboratory. His research focused on the mechanical properties of thin metallic films and small-scale structures with applications such as metallization for Micro-ElectroMechanical Systems, substrates for solid-state optical devices, and synthetic biomaterials. He has published more than 70 technical papers and is the holder of one U.S. patent, with others pending. From 2001 to 2003, he held a P. C. Rossin Assistant Professorship. From 2004 to 2006, he was the Class of 1961 Associate Professor of Materials Science and Engineering. Dr. Vinci has been a recipient of the NSF CAREER Award, the ASM International Bradley Stoughton Award for Young Teachers, the Lehigh University Junior Award for Distinguished Teaching, the P. C. Rossin College of Engineering Teaching Excellence Award, and the Donald B. and Dorothy L. Stabler Award for Excellence in Teaching.Jason L. Hertzberg received his B.S. in Metallurgical Engineering from the University Scholars Program at Pennsylvania State University and both a M.S.E. and Ph.D. in Materials Science and Engineering from the University of Michigan, having received numerous academic awards at both institutions, including the Engineering Alumni Society Merit Award in Materials Science and Engineering, College of Engineering, University of Michigan and is their Chair of the External Advisory Board. He is also a California-registered Professional Metallurgical Engineer. He currently serves as a Corporate Vice President, Director of the Mechanical Engineering Practice, and a Principal Engineer at Exponent, Inc., a leading engineering and scientific consulting firm. He has extensive experience solving complex technical problems in a variety of industries and routinely leads multidisciplinary failure analysis investigations. Dr. Hertzberg addresses issues related to the mechanical behavior and environmental degradation of materials, and often works with companies addressing the technical aspects of product recalls as well as interacting with the Consumer Product Safety Commission. His expertise includes analysis of products before they are sold, management of change during production, use of risk methodologies, substantiation of product performance claims, product recall investigations of a wide range of products, and evaluation of proposed correction action plans. Dr. Hertzberg also has a background in mobile computing and substantiation of claims, having served as the Director of Competitive Analysis and Strategy for Palm, Inc. Dr. Hertzberg often serves as an invited lecturer, and is a co-author of several patent applications in the area of mobile computing.

• Foreword xviiPreface to the Sixth Edition xixThe Comet and Titanic Disasters: Fiction Foreshadows Truth ! xixAdditional References for Video Entitled "The Comet and Titanic Disasters: Fiction Foreshadows Truth!!" xixStress Intensity Factor Formulations xxElliptical and Penny-Shaped Stress Intensity Factors xxMultiplicity of Y-calibration Factors xxDesign Concepts xxEstimation of Crack Tip Plastic Zone Size and Shear Lip Development xxCompact-Tension Fracture Toughness Test xxFatigue Fracture xxiExtensive Folder of Powerpoint Slides xxiiChapter Thirteen: Final Thoughts xxiiDedication xxiiAcknowledgments xxiiAbout the Authors xxvSection One Recoverable and Nonrecoverable Deformation 1Chapter 1 Elastic Response of Solids 31.1 Mechanical Testing 31.2 Definitions of Stress and Strain 41.3 Stress–Strain Curves for Uniaxial Loading 81.4 Nonaxial Testing 231.5 Multiaxial Linear Elastic Response 271.6 Elastic Anisotropy 341.7 Thermal Stresses and Thermal Shock-Induced Failure 50Chapter 2 Yielding and Plastic Flow 632.1 Dislocations in Metals and Ceramics 632.2 Slip 812.3 Yield Criteria for Metals and Ceramics 882.4 Post-Yield Plastic Deformation 902.5 Slip in Single Crystals and Textured Materials 1022.6 Deformation Twinning 1112.7 Plasticity in Polymers 120Chapter 3 Controlling Strength 1433.1 Strengthening: A Definition 1433.2 Strengthening of Metals 1433.3 Strain (Work) Hardening 1513.4 Boundary Strengthening 1553.5 Solid Solution Strengthening 1583.6 Precipitation Hardening 1643.7 Dispersion Strengthening 1703.8 Strengthening of Steel Alloys by Multiple Mechanisms 1723.9 Metal-Matrix Composite Strengthening 1753.10 Strengthening of Polymers 1773.11 Polymer-Matrix Composites 182Chapter 4 Time-Dependent Deformation 1894.1 Time-Dependent Mechanical Behavior of Solids 1894.2 Creep of Crystalline Solids: An Overview 1914.3 Temperature–Stress–Strain-Rate Relations 1954.4 Deformation Mechanisms 2024.5 Superplasticity 2054.6 Deformation-Mechanism Maps 2084.7 Parametric Relations: Extrapolation Procedures for Creep Rupture Data 2154.8 Materials for Elevated Temperature Use 2204.9 Viscoelastic Response of Polymers and the Role of Structure 227Section Two Fracture Mechanics of Engineering Materials 249Chapter 5 Fracture: An Overview 2515.1 Introduction 2515.2 Theoretical Cohesive Strength 2535.3 Defect Population in Solids 2545.4 The Stress-Concentration Factor 2605.5 Notch Strengthening 2645.6 External Variables Affecting Fracture 2655.7 Characterizing the Fracture Process 2665.8 Macroscopic Fracture Characteristics 2695.9 Microscopic Fracture Mechanisms 278Chapter 6 Elements of Fracture Mechanics 2996.1 Griffith Crack Theory 2996.2 Charpy Impact Fracture Testing 3076.3 Related Polymer Fracture Test Methods 3116.4 Limitations of the Transition Temperature Philosophy 3126.5 Stress Analysis of Cracks 315FAILURE ANALYSIS CASE STUDY 6.1: Fracture Toughness of Manatee Bones in Impact 3276.6 Design Philosophy 3286.7 Relation Between Energy Rate and Stress Field Approaches 3306.8 Crack-Tip Plastic-Zone Size Estimation 3326.9 Fracture-Mode Transition: Plane Stress Versus Plane Strain 336FAILURE ANALYSIS CASE STUDY 6.2: Analysis of Crack Development during Structural Fatigue Test 3396.10 Plane-Strain Fracture-Toughness Testing of Metals and Ceramics 3416.11 Fracture Toughness of Engineering Alloys 3446.12 Plane-Stress Fracture-Toughness Testing 3556.13 Toughness Determination from Crack-Opening Displacement Measurement 3586.14 Fracture-Toughness Determination and Elastic-Plastic Analysis with the J Integral 3606.14.1 Determination of JIC 3626.15 Other Fracture Models 3686.16 Fracture Mechanics and Adhesion Measurements 371Chapter 7 Fracture Toughness 3837.1 Some Useful Generalities 3837.2 Intrinsic Toughness of Metals and Alloys 3897.3 Toughening of Metals and Alloys Through Microstructural Anisotropy 4027.4 Optimizing Toughness of Specific Alloy Systems 4117.5 Toughness of Ceramics, Glasses, and Their Composites 4167.6 Toughness of Polymers and Polymer-Matrix Composites 4267.7 Natural and Biomimetic Materials 4347.8 Metallurgical Embrittlement of Ferrous Alloys 4407.9 Additional Data 449Chapter 8 Environment-Assisted Cracking 4638.1 Embrittlement Models 4658.2 Fracture Mechanics Test Methods 4728.3 Life and Crack-Length Calculations 492Chapter 9 Cyclic Stress and Strain Fatigue 4999.1 Macrofractography of Fatigue Failures 4999.2 Cyclic Stress-Controlled Fatigue 5039.3 Cyclic Strain-Controlled Fatigue 5299.4 Fatigue Life Estimations for Notched Components 5419.5 Fatigue Crack Initiation Mechanisms 5459.6 Avoidance of Fatigue Damage 547Chapter 10 Fatigue Crack Propagation 55910.1 Stress and Crack Length Correlations with FCP 55910.2 Macroscopic Fracture Modes in Fatigue 568FATIGUE FAILURE ANALYSIS CASE STUDY 10.1: Stress Intensity Factor Estimate Based on Fatigue Growth Bands 57110.3 Microscopic Fracture Mechanisms 57210.4 Crack Growth Behavior at ΔK Extremes 57810.5 Influence of Load Interactions 59210.6 Environmentally Enhanced FCP (Corrosion Fatigue) 60010.7 Microstructural Aspects of FCP in Metal Alloys 60610.8 Fatigue Crack Propagation in Engineering Plastics 61810.9 Fatigue Crack Propagation in Ceramics 62810.10 Fatigue Crack Propagation in Composites 632Chapter 11 Analyses of Engineering Failures 64511.1 Typical Defects 64711.2 Macroscopic Fracture Surface Examination 64711.3 Metallographic and Fractographic Examination 65111.4 Component Failure Analysis Data 65211.5 Case Histories 652CASE 1: Shotgun Barrel Failures 653CASE 2: Analysis of Aileron Power Control Cylinder Service Failure 658CASE 3: Failure of Pittsburgh Station Generator Rotor Forging 660CASE 4: Stress Corrosion Cracking Failure of the Point Pleasant Bridge 661CASE 5: Weld Cold Crack-Induced Failure of Kings Bridge, Melbourne, Australia 664CASE 6: Failure Analysis of 175-mm Gun Tube 665CASE 7: Hydrotest Failure of a 660-cm-Diameter Rocket Motor Casing 670CASE 8: Premature Fracture of Powder-Pressing Die 673CASE 9: A Laboratory Analysis of a Lavatory Failure 67411.6 Additional Comments Regarding Welded Bridges 676Chapter 12 Consequences of Product Failure 68312.1 Introduction to Product Liability 68312.2 History of Product Liability 68412.3 Product Recall 697RECALL CASE STUDY: The "Unstable" Ladder 708Chapter 13 Final Thoughts 71313.1 Funding Highway and Bridge Repairs 71313.2 Nonredundant Bridges 71513.3 Dee Bridge Collapse, Chester, England (1847) 71613.4 A Final Reflection 718Appendix A Fracture Surface Preservation, Cleaning and Replication Techniques, and Image Interpretation 721A.1 Fracture Surface Preservation 721A.2 Fracture Surface Cleaning 721A.3 Replica Preparation and Image Interpretation 723Appendix B K Calibrations for Typical Fracture Toughness and Fatigue Crack Propagation Test Specimens 727Appendix C Y Calibration Factors for Elliptical and Semicircular Surface Flaws 731Appendix D Suggested Checklist of Data Desirable for Complete Failure Analysis 733Author Index 737Materials Index 749Subject Index 755

Richard W. Hertzberg received his B.S. cum laude in Mechanical Engineering from the City College New York, his M.S. in Metallurgy from M.I.T. and his Ph.D. in Metallurgical Engineering from Lehigh University. A recipient of two Alcoa Foundation Awards of Outstanding Research Achievement, co-recipient of Lehigh University's Award of Outstanding Research, recipient of Lehigh University's College of Engineering Teaching Excellence Award, co-recipient of Lehigh University's award in Recognition of Outstanding Contributions to the University and recipient of the 2015 Distinguished Alumni Award from the Materials Science and Engineering Department of Lehigh University. Dr. Hertzberg has served as Research Scientist for the United Aircraft Corporation Research Labs, and Visiting Professor at the Federal Institute of Technology, Lausanne, Switzerland. As an active member of several engineering societies, he has been elected as a Fellow of the American Society for Metals and was recipient of the TMS 2000 Educator Award as the most outstanding material science educator in the nation. He was the 2017 recipient of the ICF Paul C. Paris Gold Medal from the International Congress on Fracture. He has authored approximately 230 scholarly articles, coauthored Fatigue of Engineering Plastics (Academic Press, 1980), and co-authored the fifth edition of Deformation and Fracture Mechanics of Engineering Materials. Dr. Hertzberg has also been an invited lecturer in the United States, Asia, Israel, and Europe, and has served as a consultant to government and industry. He was previously Chair, Materials Science and Engineering Dept., and Director of the Mechanical Behavior Laboratory of the Materials Research Center at Lehigh University. Currently, he is New Jersey Zinc Professor Emeritus of Materials Science and Engineering.Richard P. Vinci received his B.S. degree in 1988 from the Massachusetts Institute of Technology, and his M.S. and Ph.D. degrees in 1990 and 1994, respectively, from Stanford University, all in Materials Science and Engineering. After holding postdoctoral and Acting Assistant Professor appointments at Stanford University, in 1998 he joined Lehigh University where he was a Professor of Materials Science and Engineering and the Director of the Mechanical Behavior Laboratory. His research focused on the mechanical properties of thin metallic films and small-scale structures with applications such as metallization for Micro-ElectroMechanical Systems, substrates for solid-state optical devices, and synthetic biomaterials. He has published more than 70 technical papers and is the holder of one U.S. patent, with others pending. From 2001 to 2003, he held a P. C. Rossin Assistant Professorship. From 2004 to 2006, he was the Class of 1961 Associate Professor of Materials Science and Engineering. Dr. Vinci has been a recipient of the NSF CAREER Award, the ASM International Bradley Stoughton Award for Young Teachers, the Lehigh University Junior Award for Distinguished Teaching, the P. C. Rossin College of Engineering Teaching Excellence Award, and the Donald B. and Dorothy L. Stabler Award for Excellence in Teaching.Jason L. Hertzberg received his B.S. in Metallurgical Engineering from the University Scholars Program at Pennsylvania State University and both a M.S.E. and Ph.D. in Materials Science and Engineering from the University of Michigan, having received numerous academic awards at both institutions, including the Engineering Alumni Society Merit Award in Materials Science and Engineering, College of Engineering, University of Michigan and is their Chair of the External Advisory Board. He is also a California-registered Professional Metallurgical Engineer. He currently serves as a Corporate Vice President, Director of the Mechanical Engineering Practice, and a Principal Engineer at Exponent, Inc., a leading engineering and scientific consulting firm. He has extensive experience solving complex technical problems in a variety of industries and routinely leads multidisciplinary failure analysis investigations. Dr. Hertzberg addresses issues related to the mechanical behavior and environmental degradation of materials, and often works with companies addressing the technical aspects of product recalls as well as interacting with the Consumer Product Safety Commission. His expertise includes analysis of products before they are sold, management of change during production, use of risk methodologies, substantiation of product performance claims, product recall investigations of a wide range of products, and evaluation of proposed correction action plans. Dr. Hertzberg also has a background in mobile computing and substantiation of claims, having served as the Director of Competitive Analysis and Strategy for Palm, Inc. Dr. Hertzberg often serves as an invited lecturer, and is a co-author of several patent applications in the area of mobile computing.

• Foreword xviiPreface to the Sixth Edition xixThe Comet and Titanic Disasters: Fiction Foreshadows Truth ! xixAdditional References for Video Entitled "The Comet and Titanic Disasters: Fiction Foreshadows Truth!!" xixStress Intensity Factor Formulations xxElliptical and Penny-Shaped Stress Intensity Factors xxMultiplicity of Y-calibration Factors xxDesign Concepts xxEstimation of Crack Tip Plastic Zone Size and Shear Lip Development xxCompact-Tension Fracture Toughness Test xxFatigue Fracture xxiExtensive Folder of Powerpoint Slides xxiiChapter Thirteen: Final Thoughts xxiiDedication xxiiAcknowledgments xxiiAbout the Authors xxvSection One Recoverable and Nonrecoverable Deformation 1Chapter 1 Elastic Response of Solids 31.1 Mechanical Testing 31.2 Definitions of Stress and Strain 41.3 Stress–Strain Curves for Uniaxial Loading 81.4 Nonaxial Testing 231.5 Multiaxial Linear Elastic Response 271.6 Elastic Anisotropy 341.7 Thermal Stresses and Thermal Shock-Induced Failure 50Chapter 2 Yielding and Plastic Flow 632.1 Dislocations in Metals and Ceramics 632.2 Slip 812.3 Yield Criteria for Metals and Ceramics 882.4 Post-Yield Plastic Deformation 902.5 Slip in Single Crystals and Textured Materials 1022.6 Deformation Twinning 1112.7 Plasticity in Polymers 120Chapter 3 Controlling Strength 1433.1 Strengthening: A Definition 1433.2 Strengthening of Metals 1433.3 Strain (Work) Hardening 1513.4 Boundary Strengthening 1553.5 Solid Solution Strengthening 1583.6 Precipitation Hardening 1643.7 Dispersion Strengthening 1703.8 Strengthening of Steel Alloys by Multiple Mechanisms 1723.9 Metal-Matrix Composite Strengthening 1753.10 Strengthening of Polymers 1773.11 Polymer-Matrix Composites 182Chapter 4 Time-Dependent Deformation 1894.1 Time-Dependent Mechanical Behavior of Solids 1894.2 Creep of Crystalline Solids: An Overview 1914.3 Temperature–Stress–Strain-Rate Relations 1954.4 Deformation Mechanisms 2024.5 Superplasticity 2054.6 Deformation-Mechanism Maps 2084.7 Parametric Relations: Extrapolation Procedures for Creep Rupture Data 2154.8 Materials for Elevated Temperature Use 2204.9 Viscoelastic Response of Polymers and the Role of Structure 227Section Two Fracture Mechanics of Engineering Materials 249Chapter 5 Fracture: An Overview 2515.1 Introduction 2515.2 Theoretical Cohesive Strength 2535.3 Defect Population in Solids 2545.4 The Stress-Concentration Factor 2605.5 Notch Strengthening 2645.6 External Variables Affecting Fracture 2655.7 Characterizing the Fracture Process 2665.8 Macroscopic Fracture Characteristics 2695.9 Microscopic Fracture Mechanisms 278Chapter 6 Elements of Fracture Mechanics 2996.1 Griffith Crack Theory 2996.2 Charpy Impact Fracture Testing 3076.3 Related Polymer Fracture Test Methods 3116.4 Limitations of the Transition Temperature Philosophy 3126.5 Stress Analysis of Cracks 315FAILURE ANALYSIS CASE STUDY 6.1: Fracture Toughness of Manatee Bones in Impact 3276.6 Design Philosophy 3286.7 Relation Between Energy Rate and Stress Field Approaches 3306.8 Crack-Tip Plastic-Zone Size Estimation 3326.9 Fracture-Mode Transition: Plane Stress Versus Plane Strain 336FAILURE ANALYSIS CASE STUDY 6.2: Analysis of Crack Development during Structural Fatigue Test 3396.10 Plane-Strain Fracture-Toughness Testing of Metals and Ceramics 3416.11 Fracture Toughness of Engineering Alloys 3446.12 Plane-Stress Fracture-Toughness Testing 3556.13 Toughness Determination from Crack-Opening Displacement Measurement 3586.14 Fracture-Toughness Determination and Elastic-Plastic Analysis with the J Integral 3606.14.1 Determination of JIC 3626.15 Other Fracture Models 3686.16 Fracture Mechanics and Adhesion Measurements 371Chapter 7 Fracture Toughness 3837.1 Some Useful Generalities 3837.2 Intrinsic Toughness of Metals and Alloys 3897.3 Toughening of Metals and Alloys Through Microstructural Anisotropy 4027.4 Optimizing Toughness of Specific Alloy Systems 4117.5 Toughness of Ceramics, Glasses, and Their Composites 4167.6 Toughness of Polymers and Polymer-Matrix Composites 4267.7 Natural and Biomimetic Materials 4347.8 Metallurgical Embrittlement of Ferrous Alloys 4407.9 Additional Data 449Chapter 8 Environment-Assisted Cracking 4638.1 Embrittlement Models 4658.2 Fracture Mechanics Test Methods 4728.3 Life and Crack-Length Calculations 492Chapter 9 Cyclic Stress and Strain Fatigue 4999.1 Macrofractography of Fatigue Failures 4999.2 Cyclic Stress-Controlled Fatigue 5039.3 Cyclic Strain-Controlled Fatigue 5299.4 Fatigue Life Estimations for Notched Components 5419.5 Fatigue Crack Initiation Mechanisms 5459.6 Avoidance of Fatigue Damage 547Chapter 10 Fatigue Crack Propagation 55910.1 Stress and Crack Length Correlations with FCP 55910.2 Macroscopic Fracture Modes in Fatigue 568FATIGUE FAILURE ANALYSIS CASE STUDY 10.1: Stress Intensity Factor Estimate Based on Fatigue Growth Bands 57110.3 Microscopic Fracture Mechanisms 57210.4 Crack Growth Behavior at ΔK Extremes 57810.5 Influence of Load Interactions 59210.6 Environmentally Enhanced FCP (Corrosion Fatigue) 60010.7 Microstructural Aspects of FCP in Metal Alloys 60610.8 Fatigue Crack Propagation in Engineering Plastics 61810.9 Fatigue Crack Propagation in Ceramics 62810.10 Fatigue Crack Propagation in Composites 632Chapter 11 Analyses of Engineering Failures 64511.1 Typical Defects 64711.2 Macroscopic Fracture Surface Examination 64711.3 Metallographic and Fractographic Examination 65111.4 Component Failure Analysis Data 65211.5 Case Histories 652CASE 1: Shotgun Barrel Failures 653CASE 2: Analysis of Aileron Power Control Cylinder Service Failure 658CASE 3: Failure of Pittsburgh Station Generator Rotor Forging 660CASE 4: Stress Corrosion Cracking Failure of the Point Pleasant Bridge 661CASE 5: Weld Cold Crack-Induced Failure of Kings Bridge, Melbourne, Australia 664CASE 6: Failure Analysis of 175-mm Gun Tube 665CASE 7: Hydrotest Failure of a 660-cm-Diameter Rocket Motor Casing 670CASE 8: Premature Fracture of Powder-Pressing Die 673CASE 9: A Laboratory Analysis of a Lavatory Failure 67411.6 Additional Comments Regarding Welded Bridges 676Chapter 12 Consequences of Product Failure 68312.1 Introduction to Product Liability 68312.2 History of Product Liability 68412.3 Product Recall 697RECALL CASE STUDY: The "Unstable" Ladder 708Chapter 13 Final Thoughts 71313.1 Funding Highway and Bridge Repairs 71313.2 Nonredundant Bridges 71513.3 Dee Bridge Collapse, Chester, England (1847) 71613.4 A Final Reflection 718Appendix A Fracture Surface Preservation, Cleaning and Replication Techniques, and Image Interpretation 721A.1 Fracture Surface Preservation 721A.2 Fracture Surface Cleaning 721A.3 Replica Preparation and Image Interpretation 723Appendix B K Calibrations for Typical Fracture Toughness and Fatigue Crack Propagation Test Specimens 727Appendix C Y Calibration Factors for Elliptical and Semicircular Surface Flaws 731Appendix D Suggested Checklist of Data Desirable for Complete Failure Analysis 733Author Index 737Materials Index 749Subject Index 755

Richard W. Hertzberg received his B.S. cum laude in Mechanical Engineering from the City College New York, his M.S. in Metallurgy from M.I.T. and his Ph.D. in Metallurgical Engineering from Lehigh University. A recipient of two Alcoa Foundation Awards of Outstanding Research Achievement, co-recipient of Lehigh University's Award of Outstanding Research, recipient of Lehigh University's College of Engineering Teaching Excellence Award, co-recipient of Lehigh University's award in Recognition of Outstanding Contributions to the University and recipient of the 2015 Distinguished Alumni Award from the Materials Science and Engineering Department of Lehigh University. Dr. Hertzberg has served as Research Scientist for the United Aircraft Corporation Research Labs, and Visiting Professor at the Federal Institute of Technology, Lausanne, Switzerland. As an active member of several engineering societies, he has been elected as a Fellow of the American Society for Metals and was recipient of the TMS 2000 Educator Award as the most outstanding material science educator in the nation. He was the 2017 recipient of the ICF Paul C. Paris Gold Medal from the International Congress on Fracture. He has authored approximately 230 scholarly articles, coauthored Fatigue of Engineering Plastics (Academic Press, 1980), and co-authored the fifth edition of Deformation and Fracture Mechanics of Engineering Materials. Dr. Hertzberg has also been an invited lecturer in the United States, Asia, Israel, and Europe, and has served as a consultant to government and industry. He was previously Chair, Materials Science and Engineering Dept., and Director of the Mechanical Behavior Laboratory of the Materials Research Center at Lehigh University. Currently, he is New Jersey Zinc Professor Emeritus of Materials Science and Engineering.Richard P. Vinci received his B.S. degree in 1988 from the Massachusetts Institute of Technology, and his M.S. and Ph.D. degrees in 1990 and 1994, respectively, from Stanford University, all in Materials Science and Engineering. After holding postdoctoral and Acting Assistant Professor appointments at Stanford University, in 1998 he joined Lehigh University where he was a Professor of Materials Science and Engineering and the Director of the Mechanical Behavior Laboratory. His research focused on the mechanical properties of thin metallic films and small-scale structures with applications such as metallization for Micro-ElectroMechanical Systems, substrates for solid-state optical devices, and synthetic biomaterials. He has published more than 70 technical papers and is the holder of one U.S. patent, with others pending. From 2001 to 2003, he held a P. C. Rossin Assistant Professorship. From 2004 to 2006, he was the Class of 1961 Associate Professor of Materials Science and Engineering. Dr. Vinci has been a recipient of the NSF CAREER Award, the ASM International Bradley Stoughton Award for Young Teachers, the Lehigh University Junior Award for Distinguished Teaching, the P. C. Rossin College of Engineering Teaching Excellence Award, and the Donald B. and Dorothy L. Stabler Award for Excellence in Teaching.Jason L. Hertzberg received his B.S. in Metallurgical Engineering from the University Scholars Program at Pennsylvania State University and both a M.S.E. and Ph.D. in Materials Science and Engineering from the University of Michigan, having received numerous academic awards at both institutions, including the Engineering Alumni Society Merit Award in Materials Science and Engineering, College of Engineering, University of Michigan and is their Chair of the External Advisory Board. He is also a California-registered Professional Metallurgical Engineer. He currently serves as a Corporate Vice President, Director of the Mechanical Engineering Practice, and a Principal Engineer at Exponent, Inc., a leading engineering and scientific consulting firm. He has extensive experience solving complex technical problems in a variety of industries and routinely leads multidisciplinary failure analysis investigations. Dr. Hertzberg addresses issues related to the mechanical behavior and environmental degradation of materials, and often works with companies addressing the technical aspects of product recalls as well as interacting with the Consumer Product Safety Commission. His expertise includes analysis of products before they are sold, management of change during production, use of risk methodologies, substantiation of product performance claims, product recall investigations of a wide range of products, and evaluation of proposed correction action plans. Dr. Hertzberg also has a background in mobile computing and substantiation of claims, having served as the Director of Competitive Analysis and Strategy for Palm, Inc. Dr. Hertzberg often serves as an invited lecturer, and is a co-author of several patent applications in the area of mobile computing.

• Foreword xviiPreface to the Sixth Edition xixThe Comet and Titanic Disasters: Fiction Foreshadows Truth ! xixAdditional References for Video Entitled "The Comet and Titanic Disasters: Fiction Foreshadows Truth!!" xixStress Intensity Factor Formulations xxElliptical and Penny-Shaped Stress Intensity Factors xxMultiplicity of Y-calibration Factors xxDesign Concepts xxEstimation of Crack Tip Plastic Zone Size and Shear Lip Development xxCompact-Tension Fracture Toughness Test xxFatigue Fracture xxiExtensive Folder of Powerpoint Slides xxiiChapter Thirteen: Final Thoughts xxiiDedication xxiiAcknowledgments xxiiAbout the Authors xxvSection One Recoverable and Nonrecoverable Deformation 1Chapter 1 Elastic Response of Solids 31.1 Mechanical Testing 31.2 Definitions of Stress and Strain 41.3 Stress–Strain Curves for Uniaxial Loading 81.4 Nonaxial Testing 231.5 Multiaxial Linear Elastic Response 271.6 Elastic Anisotropy 341.7 Thermal Stresses and Thermal Shock-Induced Failure 50Chapter 2 Yielding and Plastic Flow 632.1 Dislocations in Metals and Ceramics 632.2 Slip 812.3 Yield Criteria for Metals and Ceramics 882.4 Post-Yield Plastic Deformation 902.5 Slip in Single Crystals and Textured Materials 1022.6 Deformation Twinning 1112.7 Plasticity in Polymers 120Chapter 3 Controlling Strength 1433.1 Strengthening: A Definition 1433.2 Strengthening of Metals 1433.3 Strain (Work) Hardening 1513.4 Boundary Strengthening 1553.5 Solid Solution Strengthening 1583.6 Precipitation Hardening 1643.7 Dispersion Strengthening 1703.8 Strengthening of Steel Alloys by Multiple Mechanisms 1723.9 Metal-Matrix Composite Strengthening 1753.10 Strengthening of Polymers 1773.11 Polymer-Matrix Composites 182Chapter 4 Time-Dependent Deformation 1894.1 Time-Dependent Mechanical Behavior of Solids 1894.2 Creep of Crystalline Solids: An Overview 1914.3 Temperature–Stress–Strain-Rate Relations 1954.4 Deformation Mechanisms 2024.5 Superplasticity 2054.6 Deformation-Mechanism Maps 2084.7 Parametric Relations: Extrapolation Procedures for Creep Rupture Data 2154.8 Materials for Elevated Temperature Use 2204.9 Viscoelastic Response of Polymers and the Role of Structure 227Section Two Fracture Mechanics of Engineering Materials 249Chapter 5 Fracture: An Overview 2515.1 Introduction 2515.2 Theoretical Cohesive Strength 2535.3 Defect Population in Solids 2545.4 The Stress-Concentration Factor 2605.5 Notch Strengthening 2645.6 External Variables Affecting Fracture 2655.7 Characterizing the Fracture Process 2665.8 Macroscopic Fracture Characteristics 2695.9 Microscopic Fracture Mechanisms 278Chapter 6 Elements of Fracture Mechanics 2996.1 Griffith Crack Theory 2996.2 Charpy Impact Fracture Testing 3076.3 Related Polymer Fracture Test Methods 3116.4 Limitations of the Transition Temperature Philosophy 3126.5 Stress Analysis of Cracks 315FAILURE ANALYSIS CASE STUDY 6.1: Fracture Toughness of Manatee Bones in Impact 3276.6 Design Philosophy 3286.7 Relation Between Energy Rate and Stress Field Approaches 3306.8 Crack-Tip Plastic-Zone Size Estimation 3326.9 Fracture-Mode Transition: Plane Stress Versus Plane Strain 336FAILURE ANALYSIS CASE STUDY 6.2: Analysis of Crack Development during Structural Fatigue Test 3396.10 Plane-Strain Fracture-Toughness Testing of Metals and Ceramics 3416.11 Fracture Toughness of Engineering Alloys 3446.12 Plane-Stress Fracture-Toughness Testing 3556.13 Toughness Determination from Crack-Opening Displacement Measurement 3586.14 Fracture-Toughness Determination and Elastic-Plastic Analysis with the J Integral 3606.14.1 Determination of JIC 3626.15 Other Fracture Models 3686.16 Fracture Mechanics and Adhesion Measurements 371Chapter 7 Fracture Toughness 3837.1 Some Useful Generalities 3837.2 Intrinsic Toughness of Metals and Alloys 3897.3 Toughening of Metals and Alloys Through Microstructural Anisotropy 4027.4 Optimizing Toughness of Specific Alloy Systems 4117.5 Toughness of Ceramics, Glasses, and Their Composites 4167.6 Toughness of Polymers and Polymer-Matrix Composites 4267.7 Natural and Biomimetic Materials 4347.8 Metallurgical Embrittlement of Ferrous Alloys 4407.9 Additional Data 449Chapter 8 Environment-Assisted Cracking 4638.1 Embrittlement Models 4658.2 Fracture Mechanics Test Methods 4728.3 Life and Crack-Length Calculations 492Chapter 9 Cyclic Stress and Strain Fatigue 4999.1 Macrofractography of Fatigue Failures 4999.2 Cyclic Stress-Controlled Fatigue 5039.3 Cyclic Strain-Controlled Fatigue 5299.4 Fatigue Life Estimations for Notched Components 5419.5 Fatigue Crack Initiation Mechanisms 5459.6 Avoidance of Fatigue Damage 547Chapter 10 Fatigue Crack Propagation 55910.1 Stress and Crack Length Correlations with FCP 55910.2 Macroscopic Fracture Modes in Fatigue 568FATIGUE FAILURE ANALYSIS CASE STUDY 10.1: Stress Intensity Factor Estimate Based on Fatigue Growth Bands 57110.3 Microscopic Fracture Mechanisms 57210.4 Crack Growth Behavior at ΔK Extremes 57810.5 Influence of Load Interactions 59210.6 Environmentally Enhanced FCP (Corrosion Fatigue) 60010.7 Microstructural Aspects of FCP in Metal Alloys 60610.8 Fatigue Crack Propagation in Engineering Plastics 61810.9 Fatigue Crack Propagation in Ceramics 62810.10 Fatigue Crack Propagation in Composites 632Chapter 11 Analyses of Engineering Failures 64511.1 Typical Defects 64711.2 Macroscopic Fracture Surface Examination 64711.3 Metallographic and Fractographic Examination 65111.4 Component Failure Analysis Data 65211.5 Case Histories 652CASE 1: Shotgun Barrel Failures 653CASE 2: Analysis of Aileron Power Control Cylinder Service Failure 658CASE 3: Failure of Pittsburgh Station Generator Rotor Forging 660CASE 4: Stress Corrosion Cracking Failure of the Point Pleasant Bridge 661CASE 5: Weld Cold Crack-Induced Failure of Kings Bridge, Melbourne, Australia 664CASE 6: Failure Analysis of 175-mm Gun Tube 665CASE 7: Hydrotest Failure of a 660-cm-Diameter Rocket Motor Casing 670CASE 8: Premature Fracture of Powder-Pressing Die 673CASE 9: A Laboratory Analysis of a Lavatory Failure 67411.6 Additional Comments Regarding Welded Bridges 676Chapter 12 Consequences of Product Failure 68312.1 Introduction to Product Liability 68312.2 History of Product Liability 68412.3 Product Recall 697RECALL CASE STUDY: The "Unstable" Ladder 708Chapter 13 Final Thoughts 71313.1 Funding Highway and Bridge Repairs 71313.2 Nonredundant Bridges 71513.3 Dee Bridge Collapse, Chester, England (1847) 71613.4 A Final Reflection 718Appendix A Fracture Surface Preservation, Cleaning and Replication Techniques, and Image Interpretation 721A.1 Fracture Surface Preservation 721A.2 Fracture Surface Cleaning 721A.3 Replica Preparation and Image Interpretation 723Appendix B K Calibrations for Typical Fracture Toughness and Fatigue Crack Propagation Test Specimens 727Appendix C Y Calibration Factors for Elliptical and Semicircular Surface Flaws 731Appendix D Suggested Checklist of Data Desirable for Complete Failure Analysis 733Author Index 737Materials Index 749Subject Index 755