Pub 42 Copper and Copper Alloy Castings PDF

Presentation on Physical testing
by B.Raghunathan
Need for witnessing of physical and chemical testing in
a testing laboratory arises due to the following :-
• Welding procedure and welder qualification test pieces.
• Raw material certificate is not original and authenticity cannot be
established, hence the need for re verification of the
material properties .
• Marking on raw material is not clear .
TUV INDIA, Member of TÜV NORD Group 30/01/2013 1

by B.Raghunathan
• Material got subsequently heat treated which has
affected the reported physical properties .
• End user / customer wants re verification of material
properties as part of his requirement .
• Additional tests as called for by customer not carried out

by B.Raghunathan
• We generally witness the following tests
• Tensile tests
• Impact tests
• Hardness tests
• Bend tests

by B.Raghunathan
• We generally witness the following tests
• Flaring tests
• Flattening tests
• Intergrannular corrosion tests
• Macro
• Micro

by B.Raghunathan
In the foregoing slides we will discuss about how the test pieces
are selected and what are the salient points that we need to
observed during testing .
We will not dwell into machining and testing of test pieces as
these are dealt with applicable test standards .

by B.Raghunathan
The Tensile test
The purpose of this test is to confirm the strength of the
material or welding .
Results for ultimate tensile strength (UTS) , Yield stress (YS)
and elongation percentage are important for all forms of
material .
UTS and YS are expressed in MPa , Kg/mm2 or Psi .
Elongation results are expressed in percentage value of gage

length .
by B.Raghunathan
The Tensile test
In addition to the above tests we also have requirement for
Reduction in Area (RA) expressed in percentage of the material
diameter in case of forging and studs .
We also have Z direction tensile test , called through thickness
test where we only look for RA and the results have to meet the
end user requirement .

by B.Raghunathan
The Tensile test
In the case of transverse weld test pieces we have to look for

the UTS .
And in the case of all weld test piece we have to look for UTS ,
YS ,EL and RA .

by B.Raghunathan
The Tensile test
While the testing laboratory takes care of the testing activities ,
we as surveyors , who originate the request for testing ,
witnessing the testing in the lab, and subsequently certifying
the results have more responsibilities to take care off .
We will be discussing in the subsequent slides about these
responsibilities .

by B.Raghunathan
The Tensile test
• Selection of tensile test piece for plate is transverse to the

direction of rolling in case of plates .
• In case of normalised plate rolling direction has no relevance ,
still it is correct to select the test piece as stated above .
• In case the material where transverse to rolling direction
could not be established it is prudent carry out testing in
both transverse and longitudinal to direction of rolling .
• The lower value result should be considered

by B.Raghunathan
The Tensile test
• The material taken up for check testing should be stamped
by the surveyor only with oval tuv stamp.
• Ideally the material selected for check testing should have a
unique check test number generated by the seller
or fabricator dealing with the material .
• This unique number is stamped on the test piece and balance
plate adjacent to test piece, before cutting .

by B.Raghunathan
The Tensile test
• Both the test piece and adjacent plate area are then stamped
by our surveyor with TUV oval stamp.
• In most of the cases surveyor asking for check testing is
different than the surveyor witnessing the test in the lab ,
then the material test request challan of the party sending the
test piece to lab should also be signed by the surveyor asking
for check test, clearly indicating the tests required .

by B.Raghunathan
The Tensile test
• Testing should only be witnessed in NABL approved
laboratory.
. Before witnessing the testing surveyor has to verify
the calibration validity of the machine .
• Material receipt challan should be checked for originating
surveyors recommendation .
• Ideally for a testing lab the material grade should be
unknown.
by B.Raghunathan
The Tensile test
• The marking on the test piece should be checked with
reference to the marking reported on the challan.
• Dimension of the test piece should be personally verified
using a valid calibrated instrument .
• Parallel machined part is the reference area .
• All the four faces of the parallel machined part must be truly
parallel.
• No machining error or surface damage is permitted here .

by B.Raghunathan
The Tensile test
• Check for location of gage marks and measure the distance
using a valid calibrated vernier.
• The gage length should be in proportion to the size of the test
piece .
• The gage reference punches should not be deep .
• The gage length recommended by SA 370 of ASME code Sec

II A

by B.Raghunathan
The Tensile test
• The gage length recommended by SA 370 of ASME code
Sec II A and the dimensions are as shown in Fig 3 an 4

of SA 370.
• Following requirement of the code has to be met .

by B.Raghunathan
The Tensile test
• Following requirement of the code has to be met

by B.Raghunathan
The Tensile test
• Gage lengths of material as per IS standard are 5.65 times
square root of cross sectional area .
• For welded test pieces the recommendation made by ASME
Sec IX or the applicable code has to be met .
• In the case of welded test piece ,please check and ensure that
dimension and surface condition of the test piece ,
both in the weld and base metal adjacent to it are same .

by B.Raghunathan
The Tensile test

by B.Raghunathan
The Tensile test
• As you can see from the sketch above , the intension of the
code Is to have the test piece fracture either in the weld
metal or close to the weld metal .
• It is not really correct to exceed this dimension .
• Any increase beyond 13 mm added length , will have
more chance of fracturing the test piece on the base metal .

by B.Raghunathan
The Tensile test
• If the welding procedure qualification test does not call for
heat treatment , then check for any undue sign of heat
treatment on the test piece .
• If the test piece fails in weld metal then tally the value with
the base metal required value .
• If the value is less than minimum UTS required for base metal
then the test gets rejected .

by B.Raghunathan
The Tensile test
• If the test piece fails in base metal , check the value of the
UTS .
• It the UTS is less than 95 % of the minimum UTS value for
base metal , then test gets rejected .
• If the test piece fails in base metal and if the value obtained is
more than that permitted for base metal , then also the test
gets rejected .

by B.Raghunathan
The Tensile test
• If the test piece has failed in case of raw material testing
there is nothing like retest . However the following
paragraph from SA 20 does permit on the condition stated .

by B.Raghunathan
The Tensile test

by B.Raghunathan
The Tensile test
0.2 percent offset method explained
. In some materials, the stress at which the material changes
from elastic to plastic behavior is not easily detected. In this
case, the offset yield strength is determined. A line is
constructed parallel to the initial portion of the stress-strain
curve but offset by (0.2% of GL ) from the origin. The 0.2%
offset yield strength is the stress at which the constructed line
intersects the stress-strain curve as shown in the sketch .

by B.Raghunathan
The Tensile test

by B.Raghunathan
The Tensile test
The yield strength, corresponding to the yield point, is
often defined by an offset method. Line AB is drawn at a
slope equal to Young's modulus. Point A corresponds to
a definite or stated amount of permanent set, usually 0.2
percent of the original gauge length, although 0.01, 0.1,
and 0.5 are occasionally used.

by B.Raghunathan
The Impact test
• Test conducted for toughness of material .
• Notched bar impact test specimens are used .
• Toughness is measured from loss of energy due to impact .
• Loss of energy is indicated on machine scale in jules
• More the loss of energy the more tougher the material is .
• Two types of notches are used , Charpy V and Izod Key hole
• Charpy V notch test is more popular .

by B.Raghunathan
The Impact test
• Initial activities like verification of test piece with reference to
vendor document and verification of machine calibration is
is as explained earlier .
• Hence not repeated .
• The machined test piece comes with an extended slightly
sticking part indicating the reference marking and the
surveyors stamp .

by B.Raghunathan
The Impact test
• Check this stamp and marking before sawing it of from the
main test piece .
• Check the size of the test piece .
• A standard test piece has dimension of 10 mm SQ and a
length of 55 mm .
• The notch area and also the test piece as hole should not
have any burrs or tool marks .

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test
• Now we check the method of establishing the impact test
reduction temperature .
• The subsize test impact test piece need to be one of the sub
sizes recommended by SA 370 of ASME SEC II A code
• For temperature reduction we get guidance from SA 333 of
ASME SEC IIA code .

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test

by B.Raghunathan
The Impact test

by B.Raghunathan
The hardness test

by B.Raghunathan
The hardness test
The Brinell hardness test method consists of indenting the test
material with a 10 mm diameter hardened steel or carbide ball
subjected to a load of 3000 kg. 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.

by B.Raghunathan
The Brine hardness test
The Brinell harness number is calculated by dividing

the load applied by the surface area of the indentation .

by B.Raghunathan
The Brinell hardness test
The diameter of the impression is the average of two
readings at right angles and the use of a Brinell
hardness number table can simplify the determination of the
Brinell hardness.

by B.Raghunathan
On tests of extremely hard metals a tungsten carbide
ball is substituted for the steel ball.
Compared to the other hardness test methods, the
Brinell ball makes the deepest and widest indentation,
so the test averages the hardness over a wider amount
of material, which will more accurately account for
multiple grain structures and any irregularities in the
uniformity of the material.

by B.Raghunathan
This method is the best for achieving the bulk or macro-
hardness of a material, particularly those materials with
heterogeneous structures.

by B.Raghunathan
The Rockwell hardness test
Rockwell scale is a hardness scale based on the indentation
hardness of a material. The Rockwell test determines the
hardness by measuring the depth of penetration of an
indenter under a large load compared to the penetration
made by a preload. There are different scales, denoted by a
single letter, that use different loads or indenters. The result
is a dimensionless number noted as HRA, where A is the
scale letter.

by B.Raghunathan
The hardness test
The determination of the Rockwell hardness of a material
involves the application of a minor load followed by a major
load, and then noting the depth of penetration, vis a vis,
hardness value directly from a dial, in which a harder material
gives a higher number. The chief advantage of Rockwell
hardness is its ability to display hardness values directly, thus
obviating tedious calculations involved in other hardness
measurement techniques.
by B.Raghunathan
The hardness test
In order to get a reliable reading the thickness of the test-
piece should be at least 10 times the depth of the
indentation. Also, readings should be taken from a flat
perpendicular surface, because convex surfaces give lower
readings. A correction factor can be used if the hardness
of a convex surface is to be measured.

by B.Raghunathan
Rockwell Hardness Test
. The Rockwell hardness test method consists of indenting the
test material with a diamond cone or hardened steel ball
indenter. The indenter is forced into the test material under a
preliminary minor load F0 (Fig. 1A) usually 10 kgf. When
equilibrium has been reached, an indicating device, which
follows the movements of the indenter and so responds to
changes in depth of penetration of the indenter is set to a
datum position
by B.Raghunathan
.While the preliminary minor load is still applied an additional
major load is applied with resulting increase in penetration
(Fig. 1B). When equilibrium has again been reach, the
additional major load is removed but the preliminary minor
load is still maintained. Removal of the additional major
load allows a partial recovery, so reducing the depth of
penetration (Fig. 1C).

by B.Raghunathan
. The permanent increase in depth of penetration, resulting
from the application and removal of the additional major
load is used to calculate the Rockwell hardness number.

Rock well hardness number HR = E - e
e = permanent increase in depth of penetration due to
major load F1 measured in units of 0.002 mm
E = a constant , 100 units for diamond indenter, 130

units for steel ball indenter
D = diameter of steel ball

by B.Raghunathan
F0 = preliminary minor load kgf,
.
F1 = additional major load kgf
F = total load F0+F1 Kgf

by B.Raghunathan

by B.Raghunathan
.Typical Application of Rockwell Hardness Scales
HRA . . . . Cemented carbides, thin steel and shallow
case hardened steel
HRB . . . . Copper alloys, soft steels, aluminium
alloys, malleable irons, etc.
HRC . . . . Steel, hard cast irons, case hardened
steel and other materials harder than 100 HRB

by B.Raghunathan
The Rock well hardness test

by B.Raghunathan
The Vickers hardness test
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 kgf
. 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.

by B.Raghunathan
The area of the sloping surface of the indentation is
calculated. The Vickers hardness is the quotient
obtained by dividing the kgf load by the square mm area
of indentation. F = Load in kgf ,
d = two diagonals, d1 and d2 in mm HV = Vickers hardness

by B.Raghunathan

by B.Raghunathan
When the mean diagonal of the indentation has been
determined the Vickers hardness may be calculated from
the formula, but is more convenient to use conversion
tables. The Vickers hardness should be reported like 800
HV/10, which means a Vickers hardness of 800, was
obtained using a 10 kgf force.

by B.Raghunathan
Although thoroughly adaptable and very precise for testing
the softest and hardest of materials, under varying loads, the
Vickers machine is a floor standing unit that is more
expensive than the Brinell or Rockwell machines.

by B.Raghunathan
Several different loading settings give practically identical
hardness numbers on uniform material, which is much better
than the arbitrary changing of scale with the other hardness
testing methods. The advantages of the Vickers hardness test
are that extremely accurate readings can be taken, and just one
type of indenter is used for all types of metals and surface
treatments

by B.Raghunathan
The hardness test

by B.Raghunathan
The hardness test

by B.Raghunathan
The hardness test

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Presentation on Physical testing

• Welding procedure and welder qualification test pieces.

• Raw material certificate is not original and authenticity cannot be

established, hence the need for re verification of the

• Marking on raw material is not clear .

TUV INDIA, Member of TÜV NORD Group 30/01/2013 1

affected the reported physical properties .

• End user / customer wants re verification of material

properties as part of his requirement .

• Additional tests as called for by customer not carried out

TUV INDIA, Member of TÜV NORD Group 30/01/2013 2

• We generally witness the following tests

TUV INDIA, Member of TÜV NORD Group 30/01/2013 3

• We generally witness the following tests

• Intergrannular corrosion tests

TUV INDIA, Member of TÜV NORD Group 30/01/2013 4

observed during testing .

We will not dwell into machining and testing of test pieces as

these are dealt with applicable test standards .

TUV INDIA, Member of TÜV NORD Group 30/01/2013 5

The Tensile test

The purpose of this test is to confirm the strength of the

Results for ultimate tensile strength (UTS) , Yield stress (YS)

and elongation percentage are important for all forms of

UTS and YS are expressed in MPa , Kg/mm2 or Psi .

Elongation results are expressed in percentage value of gage

The Tensile test

In addition to the above tests we also have requirement for

Reduction in Area (RA) expressed in percentage of the material

diameter in case of forging and studs .

We also have Z direction tensile test , called through thickness

end user requirement .

TUV INDIA, Member of TÜV NORD Group 30/01/2013 7

The Tensile test

In the case of transverse weld test pieces we have to look for

TUV INDIA, Member of TÜV NORD Group 30/01/2013 8

The Tensile test

While the testing laboratory takes care of the testing activities ,

we as surveyors , who originate the request for testing ,

witnessing the testing in the lab, and subsequently certifying

the results have more responsibilities to take care off .

We will be discussing in the subsequent slides about these

TUV INDIA, Member of TÜV NORD Group 30/01/2013 9

• Selection of tensile test piece for plate is transverse to the

• In case of normalised plate rolling direction has no relevance ,

still it is correct to select the test piece as stated above .

• In case the material where transverse to rolling direction

could not be established it is prudent carry out testing in

both transverse and longitudinal to direction of rolling .

• The lower value result should be considered

TUV INDIA, Member of TÜV NORD Group 30/01/2013 10

• The material taken up for check testing should be stamped

by the surveyor only with oval tuv stamp.

• Ideally the material selected for check testing should have a

unique check test number generated by the seller

or fabricator dealing with the material .

• This unique number is stamped on the test piece and balance

plate adjacent to test piece, before cutting .

TUV INDIA, Member of TÜV NORD Group 30/01/2013 11

by our surveyor with TUV oval stamp.

• In most of the cases surveyor asking for check testing is

different than the surveyor witnessing the test in the lab ,

test piece to lab should also be signed by the surveyor asking

for check test, clearly indicating the tests required .