CHAPTER 4 : MATERIAL TESTING

JF302 MATERIAL TECHNOLOGY 1

MATERIAL TESTING

This topic provides an understanding on the purposes of materials testing and deformities in certain materials. It also explains on the definition and principle on mechanical properties of materials, destructive and non-destructive tests.

4.0 MATERIAL TESTING Summary

4.1 Describe material testing 4.1.1 Explain the purpose and types of material testing deformation

c. Rockwell Test d. Shore Test

4.1.2 Define mechanical properties in material testing

4.1.5 Explain principle and results of toughness tests

a. Izod Test b. Charpy Test

a. Strength b. Hardness c. Elasticity d. Plasticity e. Ductility f. Toughness g. Brittleness

4.1.6 Define Non-Destructive Test 4.1.7 Explain the methods for non destructive test

a. Penetration test b. Magnet powder test c. Ultrasound test d. X-ray test

4.1.3 Define Destructive Test 4.1.4 Explain the principle of hardness tests

a. Brinell Test b. Vickers Test

Purpose of Material Testing

Ensure quality (as aspect of control in production) Test properties (mechanical properties) Prevent failure in use (observed any defect in component) Make informed choices in using materials

Types of Testing
1.

Destructive testing the material may be physically tested to destruction. Will normally specify a value for properties such as strength, hardness, toughness, etc. Non-Destructive testing does not affect the structural integrity of the sample. Samples or finished articles are tested before being used. ( A measurement that does not effect the specimen in any way) e.g., liquid penetration, x-ray, etc.

2.

Mechanical Properties of Metals

Strength It is the ability of a material to resist the externally applied forces without breaking or yielding. The internal resistance offered by a part to an externally applied force is called *stress.

Hardness Hardness is the ability to withstand indentation or scratches by harder substances

Elasticity It is the property of a material to regain its original shape after deformation when the external forces are removed. This property is desirable for materials used in tools and machines. It may be noted that steel is more elastic than rubber.

Mechanical Properties of Metals

Plasticity It is property of a material which retains the deformation produced under load permanently. This property of the material is necessary for forgings, in stamping images on coins and in or namental work.

Ductility This is a property the metal contains which enables it to be drawn easily or stretched to a desired shape without fracturing, whilst retaining the shape. A ductile material must be both strong and plastic. The ductility is usually measured by the terms, percentage elongation and percentage reduction in area. The ductile material commonly used in engineering practice (in order of diminishing ductility) are mild steel, copper, aluminium, nickel, zinc, tin and lead.

Toughness It is the property of a material to resist fracture due to high impact loads like hammer blows. The toughness of the material decreases when it is heated. It is measured by the amount of energy that a unit volume of the material has absorbed after being stressed up to the point of fracture. This property is desirable in parts subjected to shock and impact loads.

Mechanical Properties of Metals

Brittleness It is the property of a material opposite to ductility. It is the property of breaking of a material with little permanent distortion. Brittle materials when subjected to tensile loads, snap off without giving any sensible elongation. Cast iron is a brittle material.

Testing Type

Destructive Testing

NonDestructive Testing

Hardness Testing

Impact Testing

Brinell Test

Izod Test Penetration Test Magnet Powder Test Ultrasound Test X-ray Test

Vickers Test Charpy Test

Rockwell Test

Shore Test

DESTRUCTIVE TESTING
HARDNESS TESTING

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Hardness testing
The Brinell hardness test method consists of indenting (lekuk) the test material with a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000 kg. For softer materials the load can be reduced to 1500 kg or 500 kg to avoid excessive indentation. The full load is normally applied for 10 to 15 seconds in the case of iron and steel and for at least 30 seconds in the case of other metals. The diameter of the indentation left in the test material is measured with a low powered microscope. The Brinell harness number is calculated by dividing the 11 load applied by the surface area of the indentation.

Hardness testing formula

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BRINELL TESTING

The indenter is pressed into the metal Softer materials leave a deeper indentation

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Brinell Test

Uses ball shaped indentor.

Cannot be used for thin materials. Ball may deform on very hard materials
Surface area of indentation is measured.
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Hardness testing machine

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Exercise

Brinell testing uses a metal ball with 10 mm diameter size and the material used is aluminium alloy(K=5). As a result, the value of dent diameter is 2.5 mm. Calculate the load used and Brinell hardness value. Solution

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Vickers Testing

The Vickers hardness test method consists of indenting the test material with a diamond indenter, in the form of a right pyramid with a square base and an angle of 136 degrees between opposite faces subjected to a load of 1 to 100 kg. The full load is normally applied for 10 to 15 seconds. The two diagonals of the indentation left in the surface of the material after removal of the load are measured using a microscope and their average calculated. The area of the sloping surface of the indentation is calculated. The Vickers hardness is the quotient obtained by dividing the kg load by the square mm area of indentation.
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Vickers testing formula

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Vickers hardness test

Uses square shaped pyramid indentor. Accurate results.

Measures length of diagonal on indentation.

Usually used on very hard materials
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Exercise

A metal with 50 kg load is tested in Vickers testing. As a result, the value of min distance between the sharp diagonal is 0.432 mm. Calculate the Vickers hardness value. Solution:

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Rockwell hardness tests

Gives direct reading. Rockwell B (ball) used for soft materials. Rockwell C (cone) uses diamond cone for hard materials. Rockwell hardness number (HR) HR= E - e E = a constant depending on form of indenter e = permanent increase in depth of penetration due to major load F1 measured in units of

Flexible, quick and easy to use. Below figure show Rockwell principle

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Shore Scleroscope Testing

The Scleroscope test consists of dropping a diamond tipped hammer, which falls inside a glass tube under the force of its own weight from a fixed height, onto the test specimen. The height of the rebound travel of the hammer is measured on a graduated scale.

The harder the material, the higher the rebound.

The shore scleroscope test does not normally mark the material under test. The Shore Scleroscope measures hardness in relation to the elasticity of the material. Advantages of this method are portability and non-marking of the test surface.
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DESTRUCTIVE TESTING
IMPACT TEST

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Izod test

Izod specimen is a cantilever beam with a notch on the tension side to ensure fracture when the impact load is applied Test specimen is held vertically. Strikes at 167 Joules. Notch faces striker.

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Charpy impact test

Strikes form higher position with 300 Joules. Test specimen is held horizontally. Notch faces away from striker.

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Impact Fracture
Brittle Fracture

Ductile Fracture

If the material breaks on a flat plane, the fracture was brittle

If the material breaks with jagged edges or shear lips, then the fracture was ductile.

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Impact Fracture

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Factors affecting Impact properties

If the dimensions of the specimen are increased, the impact strength also increases. When the sharpness of the notch increase, the impact strength required causing failure decreases. The temperature of the specimen under test gives an indication about the type of fractures like ductile, brittle or ductile to brittle transition. The angle of the notch also improves impact-strength after certain values. The velocity of impact also affects impact strength to some extent.
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NON-DESTRUCTIVE TESTING

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Non-Destructive Testing (NDT)

Non-Destructive testing does not affect the structural integrity of the sample. Samples or finished articles are tested before being used. ( A measurement that does not effect the specimen in any way) e.g., liquid penetration, x-ray, etc. NDT - general name for all methods which permit testing / inspection of materials / parts without impairing its future usefulness

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Types of defects

inherent defects - present during initial production of raw materials processing defects - resulted from the manufacturing process service defects - occurred during the operation

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Examples of causes of defects

Blowholes - gas trapped during solidification process Segregation - during solidification of alloy Scale - oxide formation on the surface of a metal heated to high temperature Stress - residual stress after cold working or rapid cooling quenching / hardening cracks - rapid volume change tempering cracks - rapid heating shrinkage cracks - rapid cooling grinding cracks - friction heating
also caused by residual stress, collapsed blowholes, improper rolling, sharp edge of dies etc. etc.

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Penetrant testing

Used for surface flaws (imperfection/kecacatan). The oil and chalk test is a traditional version of this type of testing. Coloured dyes are now used.

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Penetrant testing-application

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Magnetic particle testing

Used for ferrous metals. Detects flaws close to the surface of the material. The component to be tested must first be magnetized. Magnetic particles which can be dry or in solution are sprinkled(ditaburkan) onto the test piece. The particles stick to the magnetic field and flaws can be inspected visually by examining the pattern to see if it has been distorted. The component must be demagnetized after testing.

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Magnetic particle testing-application

Example of fluorescent magnetic particle inspection using UV light, with indications highlighted.
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Ultrasonic testing
Ultrasonic Sound waves are bounced off the component and back to a receiver. If there is a change in the time taken for the wave to return this will show a flaw. Operation. 1. The ultrasonic probe sends the sound wave through the piece. 2. The sound wave bounces off the piece and returns. 3. The results are then placed on the display screen in the form of peaks. 4. Where the peaks fluctuate this will show a fault in the piece. Uses. This is generally used to find internal flaws in large forgings, castings and in weld inspections.

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Ultrasound testing-application

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Radiography (X-ray) Testing

1. The

x-ray are released by heating the cathode. 2. They are then accelerated by the D.C. current and directed onto the piece by the tungsten anode. 3. The x-rays then pass through the test piece onto an x-ray film which displays the results. 4. The x-rays cannot pass through the faults as easily making them visible on the x-ray film. Uses. This is a test generally used to find internal flaws in materials. It is used to check the quality of welds, for example, to find voids or cracks.
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Radiography (X-ray) Testing-application

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Quiz time
Which

of the following is a destructive

test ?
A: magnet particle B: rockwell testing C: die penetrate testing D: ultrasonic testing

Quiz time

Ductility is the ability of a metal to ________ before it breaks. A: B: C: D: Bend Stretch or elongate Be forged Be indented

Quiz time

A Charpy test measures a welds ability to withstand _________ force. A: B: C: D: Impact Bending Penetrating Stretching

Quiz time

Hardness may be defined as the resistance to __________? Indentation