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MATERIAL TESTING
OBJECTIVE
Objective of this Module to understand the Importance and Procedure of Various Material Testing which are done in house for Mechanical Properties, Chemical Properties & for Microstructure evaluation of Steel. In this Module a brief discussion is done on the Mechanical properties of Steel.
MATERIAL TESTING
To know the Properties of material we do the Material Testing. In Steel we do the following Testing to know the Material Properties:
1. Mechanical Properties i.e., Strength, Hardness, Toughness, fatigue etc. 2. Microstructure i.e., structure, grain size, inclusion etc. 3. Chemical Properties i.e., % of alloying elements presents in steel.
Rigidity Modulus of elasticity Modulus of rigidity Bulk modulus Flexural Modulus etc.
MECHANICAL PROPERTIES
MECHANICAL PROPERTIES
1. ELASTICITY: It is defined as non-permanent deformation. It is ability of material to resume its original size and shape, after the force is removed. It is defined as permanent deformation. It is the ability of material to be permanently deformed without fracture even after the removal of force. Strength may defined as the capacity of metal to withstand load. It is the ability of material to be permanently deformed without breaking when a force is applied. Hardness of material is defined as the resistance of material to scratch, wear or penetration of its surface by harder bodies. The property fracturing a material without warning or appreciable deformation is called brittleness.
2. PLASTICITY:
3. STRENGTH:
4. DUCTILITY:
5. HARDNESS:
6. BRITTLENESS:
MECHANICAL PROPERTIES
7. TOUGHNESS: Toughness is the property of material which enables material to be twisted, bent or stretched under a high stress before rupture. Stiffness is the property of material which enables material to resist deformation. Resilience is the capacity of a material to absorb or store energy , or to resist shock and impact. Malleability is the property of material of getting permanently deformed by compression without rupture. The failure of metal under alternating stresses is known as fatigue failure. A time dependent, permanent deformation at high temperatures, occurring at constant load or constant stress.
8. STIFFNESS:
9. RESILIENCE:
10. MALLEABILITY:
11. FATIGUE:
12. CREEP:
MATERIAL TESTING
To know the Mechanical Properties of steel we do the following Testing: 1. Tensile testing 2. Hardness Testing 3. Impact Testing 4. Drop-Weight Wear and Tear Test 5. Bend Test
NAME OF FACILITY/MACHINE
UNIVERSAL TENSILE TESTING MACHINE WITH ROBOT IMPACT TESTING MACHINE MICRO & MACRO VICKERS HARDNESS TESTER
MAKE
ZWICK ROELL, GERMANY TINUS OLSEN, USA ZWICK ROELL, UK
CAPACITY
1200 KN 542 JOULES Test Forces : 0.1, 0.5, 1, 3, 5, 10, 30 kgf Test Scales : HV0.1, HV0.5, HV1, HV3, HV5, HV10, HV30 and Knoop scales MAGNIFICATION : 10X & 50X XY RANGE : 50x50 MM ANGLE RANGE : 0 to 360 80000 JOULES 150 TON 28 Analytical Channels with Low Nitrogen Channel OXYGEN & HYDROGEN DETECTION MAGNIFICATION : 1500X GRAIN SIZE, INCLUSION RATING, MICRO STRUCTURE ANALYSIS
4 5 6 7 8
PROFILE PROJECTOR DROP WEIGHT TEAR TESTER BEND TEST MACHINE OPTICAL EMISSION SPECTROMETER OXYGEN/HYDROGEN DETECTOR METALLURGICAL MICROSCOPE
MITUTOYO, JAPAN ZWICK ROELL, GERMANY MICRO CONTROL SYSTEM SHIMADZU, JAPAN LECO CORP., USA OLYMPUS, JAPAN
9 ANALYZER & CAMERA STERIO ZOOM MICROSCOPE WITH ILLUMUNATION & SWIVAL
10
OLYMPUS, JAPAN
1. TENSILE TESTING
UNIVERSAL TENSILE TESTING MACHINE WITH ROBOT,MAKE-ZWICK ROELL, GERMANY, CAPACITY-1200 KN
1. TENSILE TESTING
RECTANGULAR TENSION TEST SPECIMEN
1. TENSILE TESTING
Terminology
Ultimate Tensile Strength The ultimate tensile strength (UTS) is the maximum resistance to fracture. It is equivalent to the maximum load that can be carried by one square inch of crosscross-sectional area when the load is applied as simple tension Elongation A measurement of ductility expressed in terms of the stretch having occurred over a given length on a standard tensile specimen at time of fracture, usually based upon an original length of 2 inches. Yield Strength The stress beyond which stainless steel undergoes important permanent flow commonly specified as that stress producing a 0.2% offset from the linear portion of the stress-strain curve. stressYield Point Load at which a material deforms permanently without increase in the load.
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1. TENSILE TESTING
The Strength of a material when it is called upon to withstand loads which produce a tensile stress in it, is defined as the tensile strength of material.
1. TENSILE TESTING
The Tensile Strength or ultimate tensile strength (UTS) is the maximum load divided by the original cross-sectional area of the specimen.
2. HARDNESS TESTING
Hardness is the property of a material that enables it to resist plastic deformation, penetration, indentation and scratching. These tests are commonly used in industry and research work because they provide an easy and reliable method for evaluating the effect of hot and cold working processes and heat treatments, upon the basic properties of metals. There are number of arbitrary definitions of hardness, on the basis of which hardness testing method is selected. Some of these are: 1. Resistance to permanent indentation under static or dynamic loads Indentation Hardness. 2. Energy absorption under impact load Rebound hardness. 3. Resistance of scratching Scratch Hardness. 4. Resistance to abrasion - Wear Hardness. In the Industry, the Indentation Hardness is most commonly used. In the metallurgical sense, it has become a practice to understand hardness as the indentation hardness only, unless otherwise specified.
INDENTATION HARDNESS
The amount of resistance offered by a metal for indentation or penetration is defined as the Indentation Hardness. In Industry, some hardness test are used as described under: 1. Brinell Hardness Test. 2. Rockwell Hardness Test. 3. Vicker Hardness Test.
Brinell Hardness Test is best for measuring hardness of gray iron casting consisting of soft flake graphite, iron and hard iron carbide.
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The Vickers hardness test has received fairly wide for research work because it provides a continuous scale of hardness, for a given load, from very soft metals with a DPH of 5 to extremely hard materials with a DPH of 1500. The loads ordinarily used with this test range from 1 to 120kg, depending upon hardness of metal to be tested. In spite of these advantages, the Vickers hardness test has not been widely accepted for routine testing because it is slow, requires careful surface preparation of the specimen, and allows greater chance for personal error in the determination of the diagonal length.
IMPACT TEST
IMPACT TESTING MACHINE , TINUS OLSEN, USA , 542 JOULES
IMPACT TEST
A simple tensile test does not reveal the brittle nature of the metals, and if only the tensile test data are relied upon the and the object put into use, failure is certain. It is therefore, necessary to test the specimen under shock or sudden loading condition. Strength data are mostly academic. In actual use and practice, we rarely come across the ideal case of gradually applied loads. When we sit on chair, our weight of few kilograms is applied to the chair, suddenly. When an electric motor is put on, the shaft takes a sudden torque of the full r.p.m., being at zero r.p.m. just before. Many instances can be cited when loads at=re borne by engineering components suddenly. There are four types of impact tests. They are: 1. Izod 2. Charpy 3. Fremont,and 4. Amsler. Of the above, the first and second are commonly employed. These machines are standardized in all respects, including the specimen to be used in them.
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IMPACT TEST
The principle employed in all impact testing procedures is that a material absorbs a certain amount of energy before it breaks. The quantity of energy thus absorbed is characteristic of the physical nature of the material. If it is brittle, it breaks rapidly, i.e., absorbs a lesser quantity of energy, and if tough, it needs more energy in order to fracture. The methods of testing are also very similar. A swinging hammer is made to strike the specimen held firmly in a vice. The hammer breaks the specimen on accounts of it potential energy. The height of rise of the hammer on the other side indicates the residual energy of the hammer. The energy actually absorbed by the specimen in order to fracture is given by the difference between initial and final energies of the hammer.
The standard specimen for Impact test is a square rod of 10 mm side. There is a 2mm deep, 45 notch made at a distance of 28 mm from the end of the specimen. The root of the notch is finished with a 0.25mm radius.
IMPACT TEST
The actual testing procedure as follows: 1. 2. 3. 4. 5. The pendulum weight is brought up and clamped. The specimen is fixed in the vice. The scale is adjusted to read zero. The pendulum weight is released from the clamp. The energy absorbed by the specimen is read on the scale to give the impact strength of the material.
The Impact strength, as explained above is the energy absorbed by the material. It is expressed in ft.lbs., or kilogram force metres.
BEND TEST
This is a simple test which indicates the behavior of the metal under bending loads. The metal piece under test is fixed in a vice vertically and bent through an angle of 90. Some designers specify that the bending should be continued further. In such cases, the sheet is taken of the vice and hammered so as to double it. Thus it is bent through an angle of 180. Reversed Bend Test: This is a more drastic test than the bend test. The specimen, after being bent, is straightened and again bent in the opposite direction. Instead of performing the test with a vice and hammer, if it is conducted in a sheet metal press, the magnitude of the bending load can also be measured. The above test serve only as guides, in addition to the conventional tensile test data regarding the percentage elongation. The ease with which the sheet or plate is bent or reverse bent gives us an idea about the work-hardening tendency of the metal, in addition to its formability.
2. ASTM A36 TENSILE ASTM A370 CHEMICAL ASTM A751 IMPACT ASTM A673 (SUPPLEMENTARY)
SAMPLING LOCATION
Sampling Location means from where we can take sample to perform the testing from the plate: 1. API 5L 2. ASTM A36
TT (Transverse tensile test) taken at locations B, C, F, or G CIL (Charpy impact longitudinal) taken at any location, A through H
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SAMPLING LOCATION
Sampling Location means from where we can take sample to perform the testing from the plate: 3. IS 2062 4. EN 10025
SAMPLE SIZE
API 5L
160mm x 700mm (for Transverse Samples) 350mm x 700mm (for Transverse/Longitudinal Samples)
ASTM A36
70mm x 400mm (Normal case) 250mm x 400mm (In case of Impact requirement)
EN 10025
250mm x 550mm
IS 2062
250mm x 550mm
MICROMICRO-STRUCTURE
1. Metallography
Metallography is the science and art of preparing a metal surface for microstructual analysis of features by grinding, polishing and etching. A systematic method to examine microstructure of materials (mainly metallic materials).
MICROMICRO-STRUCTURE
1. Metallography
Most engineering alloys are polycrystalline. This means that each piece of a metal is made up of a large number of tiny crystals, or grains, each having a regular crystal structure (for example, FCC, BCC, or HCP) Materials specialists are interested to see the grain boundaries in order to estimate the grain sizes. The average grain size in metals is usually in the order of several to tens of micrometers, which can be measured only by the use of an optical or light microscope Microstructure: It is the geometric arrangement of grains and the different phases present in a material Grain Boundaries: It is the interface between two grains in a polycrystalline material where the crystal is disordered due to rapid change in crystallographic directions
MICROMICRO-STRUCTURE
1. Metallography
Why Metallography ? To Study and characterization of materials To Ensure the correlation between properties and structure To Predict properties of materials To Design alloys with new properties To Check if the material has been correctly processed Requirements of Sample for Success Metallography: Be flat and free from imperfections Stable mounting No chipping Free of all debris Ideally smooth and flawless. Uses of Metallography: Shows grain size, inclusions, impurities Quality control in metal processing Failure analysis Research studies Alloy development
MICROMICRO-STRUCTURE
1. Metallography
Steps in metallographic sample preparation: 1. Sectioning 2. Mounting 3. Grinding Rough & Fine 4. Polishing Rough & Fine 5. Etching
1. Sectioning
Why sectioning? 1. Size limitation of specimen to be examined under optical microscope. 2. To select a small area for microscopic examination from a large sample. Abrasive Cutting is the most common sectioning method. The abrasive cut-off disc is usually made by silicon carbide particles, or diamond particles (called Diamond saws).
2. Mounting
2. Mounting
Mounting is required when Sample is small or oddly shaped to be handled. When the sample edge area needs is to be examined. Why mounting ? Small samples are at times difficult to hold safely during grinding and polishing operations, and their shape may not be suitable for observation on a flat surface. They are therefore mounted inside a polymer block or mount. Cold mounting can be done using two component resins (epoxies) as liquid to start with but which set solid shortly after mixing. It requires very simple facilities consisting of a cylindrical ring which serves as a mould and a flat piece which serves as the base of the mould. The sample is placed on the flat piece within the mould and the mixture poured in and allowed to set. Cold mounting takes few minutes to hours to complete Hot-mounting: the sample is surrounded by an organic polymeric powder (Bakelite) which melts under the influence of heat (about 200 0C). Pressure is also applied by a piston, ensuring a high quality mould free of porosity and with intimate contact between the sample and the polymer
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3. Grinding
Grinding removes the damages on the surface produced by sectioning At the end of grinding phase, the only grinding marks present must be from the last grinding step Such marks will be removed by polishing Grinding materials: Abrasive papers (coated with silicon carbide grits) Commonly, a series of abrasive papers are used, from coarse to fine one Grit sequence: 120-, 240-, 320-, 400-, & 600-mesh Grinding is done using rotating discs covered with silicon carbide paper and water There are a number of grades of paper, with 120, 180, 240, 400, 600, grains of silicon carbide per square inch 120 grade represents the coarsest particles and this is the grade to begin the grinding operation. Always light pressure is applied at the centre of the sample
3. Grinding
Grinding is continued until all the blemishes have been removed, the sample surface is flat, and all the scratches are in a single orientation The sample is washed with water and moved to the next grade, orienting the scratches from the previous grade normal to the rotation direction. This makes it easy to see when the coarser scratches have all been removed After the final grinding operation on 600 paper, the sample is washed in water followed by alcohol wash and dried before moving to the polishers Artifact structure from improper grinding
Surface deformation from improper grinding should be avoid, otherwise the microstructure may be obscured as shown below
4. Polishing
4. Polishing
After being ground to a 600-grit finish, the sample is polished to produce a flat and scratch-free surface with high reflectivity. Coarse polishing: abrasives in the range of 30 ~ 3 m using diamond grits of several micrometers Fine polishing: abrasives in the range of 1 m using diamond grits of 1 m, followed by 0.3 ~ 0.05 m alumina slurries. The polishers consist of rotating discs covered with soft cloth impregnated with a pre-prepared slurry of hard powdery alumina particles (Al2O3), the size ranges from 0.5 to 0.03 m Begin with the coarse slurry and continue polishing until the grinding scratches have been removed
4. Polishing
Polishing sequence
4. Polishing
Artifacts from improper polishing Polishing should produce a scratch-free surface. Excessive pressure may cause artifact of second phase particles as shown below.
4. Polishing
It is of vital importance that the sample is thoroughly cleaned using soapy water, followed by alcohol, and dried before moving onto the final stage. Any contamination of the final polishing disc will make it impossible to achieve a satisfactory polish. Examining the specimen in the microscope after polishing should reveal mirror like surface.
5. Etching
What is Etching ? Etching is controlled corrosion process resulting from electrolytic action between surface areas of different potential. Etching reveals the microstructure of a material by selective dissolution of the material from the surface. The purpose of etching is two-fold. 1. Grinding and polishing operations produce a highly deformed, thin layer on the surface which is removed chemically during etching. 2.To attack the surface with preference for those sites with the highest energy, leading to surface relief which allows different crystal orientations, grain boundaries, precipitates, phases and defects to be distinguished in reflected light microscopy. Using chemical to dissolve selectively the surface of materials in order to reveal the inhomogeneous nature in microscopic scale.
5. Etching
Different Kind of Etchant used for Steel:
Etchant
Nital (2 ml HNO3 + 98 ml ethanol) Picral (10 g Picric acid + 100 ml ethanol) Nital (2 ml HNO3 + 98 ml ethanol) Picral (10 g Picric acid + 100 ml ethanol) Vilella (1 g Picric acid + 5 ml HCl + 100 ml ethanol) Vilella (1 g Picric acid + 5 ml HCl + 100 ml ethanol)
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Sample
Steels and cast irons Carbon & low alloy steels Steels and cast irons Carbon & low alloy steels High carbon & high alloy steels High carbon & high alloy steels
Microscopic Examination
Microscopic Examination
Crystallites (grains) and grain boundaries. Vary considerably in size. Can be quite large Crystallites (grains) can be quite small (mm or less) necessary to observe with a microscope.
Microscopic techniques:
Optical microscopy is used to obtain an enlarged image of a small object. In general, a microscope consists of a light source, a condenser, an objective, and an ocular or eyepiece. The scope of optical microscope is limited by the wavelengths of the light used and by the materials available for manufacturing the lenses.
Microscopic Examination
Optical Microscope
Microscopic Examination
Determination of the Grain Size according to ASTM E 112
INCLUSION
Inclusion distribution form different API 5L X65 steels
MICROSTRUCTURE
200 X
GRAIN SIZE : 7.70 PEARLITE : 22.58 %
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SPECTROMETER
OPTICAL EMISSION SPECTROMETER, SHIMADZU, JAPAN