Sharpe - Microspecimen Tensile Tests of A533-B Steel

William N. Sharpe, Jr. 1, David Danley 2 and David A.
LaVan 3
MICROSPECIMEN
T E N S I L E T E S T S O F A533-B S T E E L
R E F E R E N C E : Sharpe, W. N., Jr., Danley, D., and LaVan, D. A., " M i c r o s p e c i m e n Tensile Tests of A533-B Steel," Small Specimen Test Techniques, ASTM STP 1329, W. R. Corwin, S. T. Rosinski, and E. van Walle, Eds., American Society for Testing and Materials, 1998.
ABSTRACT: Miniature tensile specimens of A533-B steel were tested as part of the
ASTM Cross-Comparison Exercise on Determination of Material Properties Through the Use of Miniature Mechanical Testing Techniques. The microspecimens are 3 mm long with
a test section -0.3 mm square. Thin slices were cut from the supplied block of material by wire EDM and the microspecimens were machined from the slices with a benchtop CNC mill. Specimens were cut so that the tensile axes were in three orthogonal directions to investigate the anisotropy of the steel block. A total of 47 microspecimens were pulled in a small test machine with an air bearing to reduce friction in the moving grip. Strain was measured directly on the specimen with a laser-based interferometric technique that used two tiny reflective indentations as gage markers. The entire stress-strain curve was recorded. In addition, five macrospecimens with cross-sections 3.2 mm square were tested in a conventional test machine using foil strain gages. The coefficient of variation (ratio of standard deviation to mean value) of the microspecimen tests is on the order of 5% for both the yield and ultimate stresses. This sample block of A533-B steel is slightly anisotropic with regard to yield stress, but not ultimate stress. The yield stress - on the order of 440 MPa - and the ultimate stress - on the order of 600 MPa - are consistent with other results. The microspecimens showed yield and ultimate stresses approximately 5% lower than those measured on the macrospecimens.
KEYWORDS: interferometry, lasers, microspecimens, mechanical properties, A533-B steel
1Decker Professor and Chair, Department of Mechanical Engineering, Johns Hopkins University, Baltimore, MD 21218 2Undergraduate Student, Department of Mechanical Engineering, Johns Hopkins University, Baltimore, MD 21218 3Graduate Student, Department of Mechanical Engineering, Johns Hopkins University, Baltimore, MD 21218
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Copyright9 1998 by ASTM International
www.astm.org
498
SMALLSPECIMEN TEST TECHNIQUES
This paper reports the measurement of monotonic stress-strain curves of A533-B steel as part of the ASTM Cross-Comparison Exercise on Determination of
Material Properties Through the Use of Miniature Mechanical Testing Techniques. The miniature tension specimens are 3 mm long with a test section -0.3 mm
square. They are pulled in a small test machine with an air bearing to reduce friction in the moving grip, and strain is measured directly on the specimen with a laser-based technique. A system to measure the monotonic uniaxial tensile stress-strain curve of a material consists of four components - - grips, a mechanism to pull the specimen, a load cell, and a means of measuring the strain of the specimen. The first three components can be constructed by following more-or-less traditional procedures, but it is difficult to accurately measure the strain in the gage section of a small specimen. The unique feature of this work is the capability of measuring strain over a gage length of 300 I.tm (0.012 inch) by laser interferometry using tiny reflective indentations in the specimen surface. This Interferometfic Strain/Displacement Gage (ISDG) has been developed over the past 25 years into a mature technology and used most recently for extensive studies of elastoplastic strains at notch roots under monotonic and cyclic loading conditions [1, 2]. A review article describes some early applications of the ISDG [3]. The first version of the microsample testing machine [4,5] consisted of the ISDG, a load frame with the movable grip supported by a thin cross-member, a homemade load cell, and manual extension of the specimen by a micrometer head. It was improved by the addition of a commercial load cell and a motor-driven screw displacement mechanism, and the second version was used for some preliminary studies [6]. The load frame was then changed to one in which the movable grip slid in a lubricated slot, and an extensive series of tests was conducted on specimens taken from the base metal, weld metal, and heataffected-zone of steel weldments [7]. In the final version used for the results reported here, the movable grip is supported by a linear air bearing. The ISDG is described in the briefest form in the next section; a more complete presentation of the optical principles as well as details of typical measurement systems is given in a NASA report [8]. The specimens are machined from thin slices and polished prior to applying the reflective indentations with a Vickers microhardness tester. Those techniques and procedures are given in detail in the section entitled 'Specimen Preparation'. The mechanism for pulling the specimen along with the procedures for conducting a tensile test and analyzing the data is then described. Microspecimens were cut from a two-inch cube of A533-B steel supplied by the ASTM coordinator, and details of the specimen locations and orientations are given in the section 'Specimen Location and Orientation'. Typical results as well as a complete table of data are then presented. The paper concludes with a discussion of the results. THE INTERFEROMETRIC STRAIN/DISPLACEMENT GAGE The Interferometric Strain/Displacement Gage, or ISDG, is an optical technique for measuring the relative displacement between two reflective gage marks. These marks are actually indentations that are impressed in the specimen surface with a Vickers microhardness tester. When they are illuminated with a laser, the diffracted reflections from each of the facets of the pyramidal-shaped indentations overlap and interfere to produce fringes. As the two indents move relative to each other, the fringe patterns also move; their motion can be measured with photosensors and related to the strain.
Copyright by ASTM Int'l (all rights reserved); Fri Sep 21 11:26:04 EDT 2012 Downloaded/printed by Universidade Federal do Rio Grande do Sul pursuant to License Agreement. No further reproductions authorized.
SHARPE ET AL. ON A533-B STEEL
499
The principle of the ISDG, which is actually equivalent to Young's two-slit interference phenomenon, is illustrated in Figure 1. A tensile strain causes the fringes to move toward the incident laser beam. Rigid-body motion will also cause the fringes to move, so it is necessary to average the movement of the two fringe patterns. The equation relating strain, e, to fringe movement is =
Am 1 + Am 2 ~,
(I)
2d 0
sin (z0
where Am] and Am2 are the relative fringe shifts of patterns 1 and 2, do is the original distance between the indentations, i.e. the gage length, ~ is the wavelength of the laser, and o.0 is the angle between the incident laser beam and the fringe patterns.
Fable 1 I 2
L T
d0
Fdn~ l
Figure 1. Schematic of the ISDG. When the fringe peaks have moved from point 1 to point 2 for both patterns in Figure 1, a relative displacement of 'one' has occurred. Using typical values of ~, = 0.6328 gm and oR)= 42 ~ this corresponds to a relative displacement between the two indentations of approximately one gm. If the initial spacing, do, between the indents is 200 gm, then a strain of 0.005 has occurred. Obviously greater resolution is needed. The fringe patterns are converted to electrical signals with linear diode arrays - one for each pattern. The arrays have 512 diodes - each with an aperture of 13 g m by 2.5 mm packaged in a 16-pin chip; the total size of the array is 2.5 mm by 12.6 mm. The arrays are inserted in circuit boards containing amplifying circuitry and mounted in plastic mini-boxes attached to translation stages which are mounted on adjustable rods. This provides the two degrees-of-freedom necessary to position the diode array in the center of the fringe pattern. Each diode array is accessed by a motherboard which samples each diode in turn and provides an output signal from 0 to 5 volts. In a typical setup, the spacing between maximum (or minimum) intensity is approximately 80 diodes on the array. If one identifies local peaks by simply taking the largest value, then the smallest resolvable fringe movement is 1/80. Since the two fringe pattems are averaged, the minimum strain resolution occurs when one pattem moves one
500
diode. Recall that the relative displacement for both fringes moving from one peak to the next is approximately one ~tm. The strain resolution is therefore approximately 1/2 x 1/80 x 1/200 = 31 microstrain if a 200 I-tm gage length is used. This resolution can be increased by a factor of 100 by fitting a curve to selected intensity data points surrounding a minimum and interpolating between the diode locations. A resolution of 0.3 microstrain is not really meaningful; it is estimated that the resolution is approximately 5 microstrain. The ISDG, as used for these tests, has a relative uncertainty o f + 3% and a resolution of - 5 microstrain. The range depends upon the yield stress of the metal because large plastic deformation causes the grains to distort in the neighborhood of the indentations; however, a range of several percent strain is usually achievable. The sampling rate is - 3 data points per second. The above is a very brief description of the ISDG; a more complete presentation of the optical principles as well as details of typical measurement systems are given in a review article [3] and a NASA report [8]. Figure 2 is a photograph of a pair of indentations in a microtensile specimen. The spacing between indentations is 300 ~tm. This specimen is polished more carefully than is normally the case. In fact, strain measurements are easily made on specimens polished with 600 grit wet-dry SiC abrasive paper as long as the final polishing marks are in the direction of loading so that the reflections from the scratches do not impinge on the fringe patterns
[6].
Figure 2. Photograph of a pair of indentations in a polished microtensile specimen. The spacing between the indentations is 300 I.tm. The influence of the ISDG indentations on the strain measurement was examined by testing specimens with indentations of various sizes and spacings. A typical indent is approximately 25 I.tm square and 5 ktm deep; the specimen is ~ 300 lxm thick. The concern about an indentation is that the local plastic deformation might affect the overall response as yielding begins. One would not expect the indentations to affect the response unless the specimen were very thin or the indentations so close together that they generated a stress concentration.
S H A R P E ET AL. O N A 5 3 3 - B S T E E L
501
GAGE EFFECTS 900 .200 gm' ' / , /, ' ' ' ' i ' '
600 ~n"
300
\! 200 gm ~
10-0 gm
- / ~ ................L~~176
.......... ~0o.~ .................
/[
0 * i i i ] i i i = i
0.0
0.5 1.0 STRAIN - percent
1.5
Figure 3. Effect of indentation depth and spacing on the measured strain. The top number is the indentation depth in micrometers; the bottom number is the spacing between them. Figure 3 shows the results of strain measurements with different indentation configurations. These tests were conducted prior to the current series and the initial loading is not as well aligned. The steel in this case was HY-100 and tests on large specimens show a very sharp break at the yield stress - - almost elastic-perfectly plastic. The results in Figure 3 show that an indentation depth of 5 ktm and a spacing of 300 ~tm gives a very sharp, smooth transition in the yielding region. Obviously very small indentations would have less of an effect, but the interference fringes from them are dimmer. Indentation depths of 5 I.tm (Vickers microhardness tester load of 200 grams) and spacing of 300 ~tm were used for the tests reported herein.
SPECIMEN PREPARATION
The small size of the specimens precludes the use of gripping systems such as wedge- Or pin-grips. The most suitable method is to design the ends of the tensile microspecimens so that they fit into a mating grip - - the same concept as used in 'buttonhead' specimens. The shape chosen here is 'dog-biscuit' with Vee-shaped ends. Figure 4 is a schematic of the specimen shape. Although not shown in the schematic, the gage section has a large radius of curvature to make a smoother transition to the fillets at the ends of the test section. The stress concentration factor associated with this radius is approximately 1.01.
L
r
3.1
-I
Figure 4. Schematic of the microspecimen.

502
The first step in specimen preparation was to cut thin slices from the two-inch A533-B cube with a wire Electric Discharge Machine (EDM). The nominal thickness of these slices was 375 l.tm (0.015") and the slices were either approximately 50 mm x 50 mm or 25 mm x 50 mm (slice locations and orientations are described later). From these slices, coupons approximately 1.5 cm square were cut with a handheld rotary grinder. One microtensile specimen was cut from each coupon with a computer numerically controlled (CNC) bench mill. The coupon was clamped to the mill table with a special jig having an opening to allow access to the middle of the coupon. The machining program cut out the specimen in three passes; the last cut being approximately 12 p.m. The mill's slowest feed rate of 1 mm per minute was used with a cutting speed of 1500 RPM. A four-flute, premium micro-carbide end mill with a diameter of 0.79 mm was used and continuously lubricated with a stream of mineral oil coolant. Figure 5 is a photograph of a microtensile specimen after its outline has been cut in the coupon. Note that the specimen is still attached at each end; the machining program raised the cutting tool between cuts on each side of the specimen. This microspecimen was cut using an earlier design without the large radius for the gage section.
Figure 5. Photograph of a specimen coupon after machining. The central test region is approximately 1.7 mm long. The microspecimen, still attached to the coupon, was then polished, indented, and measured. Standard metallographic polishing techniques were used with the minimum usable surface finish being produced by 600 grit wet-dry SiC abrasive paper. That polishing can be done by pressing down on the coupon with a finger; after all, it is only the central portion of the coupon that must be polished. A better procedure, and the one that was used for the majority of specimens, is to glue the coupon to a fiat piece of plastic with CrystalBond wax and polish it finally on 1200 grit wet-dry SiC abrasive paper. This gives a better final surface finish and makes it easier to hold the coupon during polishing. Only the front side received the final polish, but the back was polished to 600 grit. Indentations which form the gage points for strain measurement with the ISDG were applied with a Vickers microhardness tester while the microspecimen was still attached to the coupon. Figure 2 is a micrograph of a pair of indentations in a highly polished specimen. The width of the specimen was measured - - front and b a c k - - with the measuring eyepiece of the microhardness tester at 100x. The microspecimens were usually a little wider on the back side than on the front; the end mill may bend as it cuts. It is difficult to
503
set the vertical height of the mill to be exactly the same for each specimen/shim sandwich, so the end mill may bend more in one coupon than in the next. The spacing between the indentations was also measured with the eyepiece at 100x. After this preparation, the microspecimen was cut from the coupon with a handheld motorized rotary grinder. The specimen's thickness was measured by mounting it on edge and using the microhardness tester again. LOADING SYSTEM With the availability of the ISDG, commercial load cells, and translation stages, the main task in developing the microtensile test system has been associated with the movable grip of the load frame. The original load frame [4] was machined by EDM from a single piece of stainless steel and was 12 mm by 20 mm by 3 mm thick. The grips mated with the ends of the microtensile specimens which were simply dropped into place. The movable grip was attached to a very thin (125 Bin) cross member which held it in alignment, but required little force for deflection. Successful tests were run with this frame [4,5], but its major drawback was its limited range of deflection. The microspecimens have some variability in dimensions and size from the machining process, and if they are not exactly right, one has to shim the sides of the Vee-shaped grip ends to make them fit in the machine. This idea of a flexible holder for the movable grip was attractive, but it was abandoned in favor of a more conventional approach. The second generation load frame was completely different in concept in that the movable grip slid in a lubricated slot. Replaceable grips, having the same Vee shape, were attached to the fixed and movable parts of the load frame with screws and the specimen was held in place with tiny screws. That system worked well and was used for an extensive study of microspecimens taken from a weldment [7]. The sliding rod in the lubricated slot was replaced by a linear air bearing to make the current version which is shown in Figure 6. The grips (each fastened with two small hexhead cap screws) are removable so that different shaped specimens can be tested if desired.
Figure 6. Photograph of the specimen in the grips. The linear air beating is at the right.
504
The grip on the right is fastened to the movable rod that is part of the commercially available linear air bearing - - Model 100B from Warren Industrial Machine - Nelson Air - run at approximately 30-40 psi shop air. The air bearing and the fixed grip are mounted on an aluminum plate; the entire frame can be moved from the test system for insertion of the specimen with the aid of a low-power stereo microscope. The microspecimen sits in shallow Vee-shapes machined into the grips; these are approximately 200 ~tm deep, i.e. the specimen sticks up above the surface of the grip. A single #000-120 screw holds each end of the specimen in place. The screw does not restrict the axial motion of the specimen; it just holds the end of the specimen down snugly in the Vee. Figure 7 is a schematic of the microsample test machine. The pull-rod is attached to a wire about 25 cm long which is, in turn, attached to a 20 pound load cell, Model ELFTC500-20 from Entran. The load cell is mounted on a motorized translation stage, Model MB2504P40J from Velmex, which has its own speed controller. The load frame is mounted on a stiff vertical translation stage so that the centerline of the pull-rod can be at the same level as the load cell. The two linear diode arrays are mounted on aluminum rods attached t6 the base of the test machine. Each rod can be rotated and the array is mounted on a translation stage which enables adjustment perpendicular to the plane of the incident laser beam and the fringe pattern. The diodes do not normally have to be moved, but these adjustments make the initial setup easy.
Laser Array
iTmTrrl
El
Array
rrrrmm
Air Bearing
Load Cell
Motorized Translation
Speclmer
Base
,/
Figure 7. Schematic showing the components of the microsample test machine.
SPECIMEN LOCATION AND ORIENTATION

Figure 8 shows the location of the slices taken from the two-inch cube of A533 B steel. 'RD' refers to the rolling direction; that is usually designated as the 'L' direction in ASTM terminology. The labeling scheme and the orientation for the ' A ' slices is shown in Figure 9. All of the specimens taken from the A slices were loaded in the rolling direction and specimens were taken from all four slices. The 'X' in a label refers to the slice number. The labeling scheme for the 'B' and 'C' slices is shown in Figure 10. Those specimens with an odd last digit were tested in the S direction and those with an even last digit tested in the T direction.

A 533 B Class I Sample Block
505
Label In this corner
-~y
A4 A3. \
/
.
/f
9 Label in this corner
zo" i
11
=
L
. .
II~--
el In this corner
Figure 8. Schematic for slicing the two-inch steel cube.

A 533 B Class 1 Sample Block
Slice A
AX
I
AXl AX2
I
AX3
T I
AXS
RD
~X4
T
AXS
T I
AX8 AXS
I
AX7
Figure 9. Labeling scheme and orientation for the A slices.

A 533 B Class I Sample BlOck Slice B A 533 B Class I Sample Block Slice C
si IBxIl:lBx IlIIc:lcxl L ILsI Ic

T T
Figure 10. Labeling scheme and orientation for the B and C slices.
506
SMALL SPECIMEN TEST TECHNIQUES
Each slice was ~ 0.375 mm thick. Assuming that the EDM process consumes 0.25 ram, each slice requires 0.625 mm thickness. If the A slices had been used throughout, there is the potential of measuring 720 specimens from the cube [(50 mm/0.625 mm) x 9]. The macrotensile specimens were taken from the remaining pieces of the sliced cube shown in Figure 8 and loaded in the T direction. The specimens have the same general shape as the microtensile specimens with Vee-shaped ends that fit into mating grips. The overall length of a specimen is 3.2 cm and the test section is nominally 3.2 m m by 3.2 ram. The specimens were loaded in an electrohydraulic test machine having a 9 kN load cell. Strain was measured on opposite sides of the specimen with EA-06-062AP-120 foil gages from MicroMeasurements. Two gages were used so that bending strains could be averaged out. The specimens were loaded in the elastic region initially and the load train adjusted to minimize the bending in the specimen. However, there was always some difference in the measured strains which required the averaging procedure. Load and strains were recorded by a computer-based data acquisition system. Five tests were run with very nearly identical results as will be seen in the next section. RESULTS Figure 11 presents a typical stress-strain curve from a specimen tested in the rolling direction. The 0.2 percent strain offset line used to define the yield stress is shown as are two sets of error bars based on the relative uncertainties in stress and strain measurement.
A15
800
200
oi,1
i ....
i ....
i ....
0.0
0.5
1.0
STRAIN
1.5
2.0
2.5
3.0
- percent
Figure 11. A representative stress-strain curve. The 0.2 percent strain offset used to define the yield stress is drawn on the plot. Relative uncertainty bars are shown at two points on the curve.
S H A R P E ET AL. ON A533-B STEEL
507
A total of 47 microtensile tests and 5 macrotensile tests were run. Table 1 shows the distribution. The ultimate stress was not measured on all microspecimens; some were saved for possible metallographic examination or further testing. Table 1. Test matrix. Direction Number of Tests Run 27 10 10 5 Yield Stress Measured 27 10 10 5 Ultimate Stress Measured 18 6 6 5
RD S T - micro T - macro
Figure 12 shows 15 of the 27 microtensile tests in the rolling direction to illustrate the variation among the results. These are the first 15 tests and are not separately labeled. The scatter in the results looks worse than it really is. In Figure 12 at 1 percent strain, the extreme stresses are 450 and 525 M P a - - differing from the mean of 488 MPa by + 8%.
800
~. . . . . . . . . . . . . . . . . . . .
A533-B Results 15 Tests
I ....
600 f ........................................................................................................... ~
i i i i
I I I I
i i i i
I I I i
I I I I
I I I L
0.0
0.5
1.0
STRAIN
1.5
2.0
2.5
3.0
- percent
Figure 12. Fifteen of the 27 microtensile tests in the rolling direction.
508
SMALL SPECIMEN TEST TECHNIQUES
Figures 13 and 14 show the 5 tests from the B slices in the S and T direction.
5 Tests in S Direction
800 .... ~ .... ~ .... ~ ........ ~ .... 800 ,,,~ 5 Tests in T Direction ........ ~ .... ~ ........
nm 6 0 0
......................
! ........
t ...............................
600
400 w rr Fo3 2O0
400
0:
Io3 2O0
..... i ..........................................................
0 ..i .... I ............ 1.0 1.5 2.0 I .... 2.5 3.0
0
0.0
,,,I
0.5
............
1.0 1.5
i ........
2.0 2.5 3.0
0.0
0.5
STRAIN - percent
STRAIN - percent
Figure 13. Five microtensile tests from the B slices in the S direction.
Figure 14. Five microtensile tests from the B slices in the T direction.
The five macrotensile tests in the T direction are plotted in Figure 15; they are all nearly identical. Failure of the foil strain gages caused the tests to terminate at 1 percent strain.
5 Macrotenslle Tests in T Direction REFERENCE
800
,.~ . . . . . . . . . . . .
DATA
~ . . . . . . . .
800
'"l
....
!i . . . .
I ........
I ....
600 o.
......... i ........... ! .......... t ..............................
n~
600
400 w
400
cr
I03 200 200
.................................
,.I 0.0 ............ 1.0 1.5
Ro, f~1ol
Ref [10] Ref [11]
i .... 2.0 i.,. 2,5 3.0
0 0.0
...... 0.5
,I,,..i 1.0
........ 1.5 2.0
. . . .
0 3.0
2.5
0.5
STRAIN - percent
STRAIN - percent
Figure 15. The 5 macrotensile tests in the T direction.
Figure 16. Stress-strain curves for A533 B from other sources.
Some representative A533 B stress-strain curves are plotted in Figure 16. They were located by the Center for Information and Numerical Data Analysis and Synthesis (CINDAS) at Purdue University with the assistance of J. F. Chaney. The curve from [9] is from an Electric Power Research Institute (EPRI) report. The two curves labeled [10], which are nearly identical, are also from an EPRI report and are replicate tests on the same material. The stress-strain curve labeled [11] was measured in Europe. These curves agree well in shape and magnitude with the results of this test program. Note that ASTM A533 specifies that the minimum yield strength is 345 MPa for a Class 1 material and the ultimate strength is 550 - 690 MPa; the specimen block meets those requirements.
509
The measured yield and ultimate stresses for all tests are given in Table 2. The averages and standard deviations are also given for each set o f data. Note that the C V (ratio o f standard deviation to mean value) is similar to that stated in A S T M A20 (5% for yield and 3% for ultimate) for steel plate. The macrotensile test results listed in the last two columns are all nearly identical.
Table 2. The yield and ultimate stresses for all the tests.
Microspecimen Tests
Macrospecimen Tests Test T

No.
Test No.
RD RD Yield- UltMPa MPa
Test S
No.
Test T
No.
T 458 441 454 450 454 643 648 643 645 648
Yield- UltMPa MPa
Yield- UltMPa MPa
Yield- UltMPa MPa
A15 A16 A17 A18 A19 A21 A22 A23 A24 A25 A26 A27 A28 A31 A32 A33 A34 A35 A36 A38 A41 A42 A43 A44 A45 A46 A47
AVG MPa SD MPa
463 428 432 515 458 457 459 470 437 495 501 441 464 441 450 450 476 458 432 432 419 419 458 450 457 432 432
453
596 590 624 614 645 664 599 632 599 616 644 595 573 574 619 585 612 589
609
Bll B13 B21 B23 B31 C11 C13 C21 C23 C31
451 463 424 437 406 464 438 438 444 413
649 590 611 596 580 556
B12 B14 B22 B24 B32 C12 C14 C22 C24 C32
438 467 439 417 425 497 457 425 419 406
634 657 626 587 578 556
T2 T4 T6 T7 T9
438
597
432
606
451
645
24
25
19
31
28
39
6.6
2.5
CV %
5.2
4.1
4.3
5.2
6.5
6.4
1.5
0.4
510
A statistical analysis of the data in Table 2 was conducted to evaluate the correlation between mean values. The 't' statistic as explained in Dally et al [12] is listed in Table 3 and compared with the t(0.05) value from the Student's t distribution at a confidence level of 95%. If the t value for the data sets is greater than the t(0.05) value, then there is a 95 % chance that the difference in the means is significant and not due simply to random variations. Table 3. 't' statistics Yield Strengths t t(0.05) Ultimate Strengths t t(0.05) Micro vs Macro in T direction t t(0.05) Yield 2.55 1.77 Ultimate 2.21 1.83 RvsS 0.96 1.72 RvsT 0.44 1.72 SvsT 0.21 1.81 RvsS 1.78 1.69 RvsT 2.26 1.69 SvsT 0.56 1.73
Table 3 shows that the yield strength in the RD direction is different than that in the S or T direction for the microsamples tested. However there are no significant differences in the ultimate strengths. The microspecimens show yield and ultimate strengths that are significantly different from those measured on macrospecimens, but the values are only approximately 5% lower. The ratio of the grain size to the specimen size is larger for the microspecimens, so this result is not unexpected. CLOSING COMMENTS The techniques and procedures used to measure the stress-strain curves of microspecimens have proved to be repeatable. The coefficient of variation (ratio of standard deviation to mean value) is on the order of 5% for both the yield and ultimate stresses which is only slightly larger than would be expected from sampling plate steel using conventional tests. That shows that the tests are repeatable and the results are not subject to large variations introduced by the test procedures. Repeatability does not mean the results are accurate, but the comparisons with other results show that the shape and magnitude of the stress-strain curve is similar to those obtained by standard methods. The direct comparison between microspecimens and macrospecimens tested in the T direction shows that the measured yield and ultimate stresses ar~ only approximately 5% lower in the smaller specimens. These tests were conducted as part of a cross-comparison exercise. The baseline data for the A533-B steel is provided in this volume by the organizers [13]. Table 4 of that paper compares the tensile properties measured via miniature testing techniques with the baseline data. The results reported in this paper are listed in the row labeled 'Organization C' and show an almost exact agreement with the baseline data. Microspecimen testing is easily conducted. All of the microspecimen tests were run by a Junior majoring in mechanical engineering. The EDM slicing was done at the Applied
51 1
Physics Laboratory by a professional machinist, but the rest of the specimen preparation and actual conduct of the tests was done by Mr. Danley. He was able to learn the complete process (not including the data analysis) in a couple of days. This sample block of A533-B steel is slightly anisotropic with regard to yield stress, but not ultimate stress. The material has fine equiaxed grains so one should expect it to be isotropic. The yield stress on the order of 440 MPa and the ultimate stress on the order of 600 MPa are consistent with other results. A test system to measure strains on both sides of microtensile specimens is under development. This will enable the averaging of two strains to eliminate the effect of bending - - the same approach used for the macrospecimens. Specimen preparation (polishing and indenting both sides) will be more involved and the test setup will take longer, but the effort is probably worthwhile. Other ways of preparing the specimen are under consideration. Instead of milling out the specimen, wire EDM could be used. A ram EDM electrode has been prepared which punches out specimens of the proper shape. That has been used to prepare specimens of nanocrystalline materials which have been successfully tested. Chemical machining, with the specimen shape masked, could be effective. These more elaborate preparation techniques may be required for other materials; the results reported here show that milling is quite satisfactory for steel. The indentations have negligible effect on the results in this report. For thinner or smaller specimens, the indentations could be made smaller and a more powerful laser used. Tests are currently being conducted on polysilicon specimens that are only 3.5 micrometers thick. The ISDG gage is two gold lines deposited onto the specimen. That same approach could be taken for other kinds of specimens. The effect of grain size relative to the sample size is obviously an issue as one moves to very small specimens. If one wishes to extract microspecimens from a larger sample or component and infer the macroscopic properties, then one must have a good understanding of the phenomenon. This test procedure would allow a controlled study of this effect with enough samples to make statistically meaningful conclusions. In closing, the work reported here shows that this microspecimen test procedure can be an effective tool in studying the mechanical properties of inhomogeneous samples, components, and structures. It would also be very effective in evaluating new materials that are made in small quantities during the development phase ACKNOWLEDGMENTS This work was supported by grants from the National Science Foundation and the National Center for Excellence in Metalworking operated by Concurrent Technology Corporation. The contributions over the years of undergraduate and graduate students to development of the test techniques and procedures is greatly appreciated.
512
REFERENCES
[1] Sharpe, W. N., Jr. and Wang, K. C., "Evaluation of a Modified Monotonic Neuber Relation," Journal of Engineering Materials and Technology_. Vol. 113, pp. 1-8, (1991). Sharpe, W. N., Jr., Yang, C. H., and Tregoning, R. L., "An Evaluation of the Neuber and Glinka Relations for Monotonic Loading," Journal of Applied Mechanics, pp. $50-$56, (1992). Sharpe, W. N., Jr., "Applications of the Interferometric Strain/Displacement Gage," Optical Engineering. Vol. 21, pp. 483-488 (1982). Sharpe, W. N., Jr. and Fowler, R. O., "A Novel Miniature Test Machine", ASTM STP 1204. Small St~cimen Test Techniaues AoDlied to Nuclear Reactor Vessel Thermal Annealin~ and Plant Life Extension. pp. 386-401, (1993). Sharpe, W. N., Jr. and Mckeown, D. E., "A Miniature Test Machine", Proceedings of the 1993 SEM "50th Anniversary" Sorin~, Conference on Exoerimental Mechanics, pp. 547 - 555, (1993). Sharpe, W. N., Jr. and Markey, B. A., "Microsample Testing of Weldments", Advances in Engineering Measurements, The British Society of Strain Measurement, Edinburgh, pp. 64 - 68, (1994). Sharpe, W. N., Jr., Zeng, H., Yuan, B., and Wallace, S., "A Technique for Microsample Testing of Weldments", Fracture '94, The Fourth National Conference on Fracture, University of the Witwatersrand, Johannesburg, 11 pgs., (1994). Sharpe, W. N., Jr., "An Interferometric Strain/Displacement Measurement System", NASA Technical Memorandum 101638, (1989). Shih, C. F., et al, "Methodology for Plastic Fracture", Third Quarterly Report to the Electric Power Research Institute, 1 Nov. 1976 to 31 Jan. 1977.
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[101 Reddy, G. B. and D. J. Ayres, "High Temperature Elastic-Plastic and Creep Properties for SA533 Grade B Class I and SA508 Materials", EPRI-NP--2763, Electric Power Research Institute, (December 1983). [11] Milne, I., "Failure Assessment Diagrams and J Estimate: A Comparison for Ferritic and Austenitic Steels", International Journal of Pressure Vessels and Piping, Vol. 13, pp. 107-125, (1983).
[12] Dally, J. W., W. F. Riley, and K. G. McConnell, "Instrumentation for Engineering

Measurements", John Wiley & Sons, (1984). [13] Rosinski, S. T. and W. R. Corwin "ASTM Cross-Comparison Exercise on Determination of Material Properties Through Miniature Sample Testing", ASTM STP 1329. Small Soecimen Test Techniaues, (1997).

Sharpe - Microspecimen Tensile Tests of A533-B Steel

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Sharpe - Microspecimen Tensile Tests of A533-B Steel

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William N. Sharpe, Jr. 1, David Danley 2 and David A.

KEYWORDS: interferometry, lasers, microspecimens, mechanical properties, A533-B steel

Copyright9 1998 by ASTM International

SMALLSPECIMEN TEST TECHNIQUES

SHARPE ET AL. ON A533-B STEEL

SMALLSPECIMEN TEST TECHNIQUES

.......... ~0o.~ .................

0.5 1.0 STRAIN - percent

Figure 4. Schematic of the microspecimen.

SMALLSPECIMEN TEST TECHNIQUES

SHARPE ET AL. ON A533-B STEEL

SMALLSPECIMEN TEST TECHNIQUES

Figure 7. Schematic showing the components of the microsample test machine.

SPECIMEN LOCATION AND ORIENTATION

SHARPE ET AL. ON A533-B STEEL

Label In this corner

9 Label in this corner

Figure 8. Schematic for slicing the two-inch steel cube.

Figure 9. Labeling scheme and orientation for the A slices.

si IBxIl:lBx IlIIc:lcxl L ILsI Ic

SMALL SPECIMEN TEST TECHNIQUES

S H A R P E ET AL. ON A533-B STEEL

A533-B Results 15 Tests

Figure 12. Fifteen of the 27 microtensile tests in the rolling direction.

SMALL SPECIMEN TEST TECHNIQUES

400 w rr Fo3 2O0

......... i ........... ! .......... t ..............................

........ 1.5 2.0

Figure 15. The 5 macrotensile tests in the T direction.

Figure 16. Stress-strain curves for A533 B from other sources.

SHARPE ET AL. ON A533-B STEEL

Macrospecimen Tests Test T

RD RD Yield- UltMPa MPa

Yield- UltMPa MPa

Yield- UltMPa MPa

Yield- UltMPa MPa

649 590 611 596 580 556

634 657 626 587 578 556

SMALLSPECIMEN TEST TECHNIQUES

SHARPE ET AL. ON A533-B STEEL

SMALLSPECIMEN TEST TECHNIQUES

[12] Dally, J. W., W. F. Riley, and K. G. McConnell, "Instrumentation for Engineering

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