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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.
4.1 Describe material testing 4.1.1 Explain the purpose and types of material testing deformation
4.1.6 Define Non-Destructive Test 4.1.7 Explain the methods for non destructive test
4.1.3 Define Destructive Test 4.1.4 Explain the principle of hardness tests
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.
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.
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.
Testing Type
Destructive Testing
NonDestructive Testing
Hardness Testing
Impact Testing
Brinell Test
Izod Test Penetration Test Magnet Powder Test Ultrasound Test X-ray 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.
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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
Cannot be used for thin materials. Ball may deform on very hard materials
Surface area of indentation is measured.
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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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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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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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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.
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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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 with jagged edges or shear lips, then the fracture was ductile.
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Impact Fracture
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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 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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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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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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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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Quiz time
Which
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