L24 MEEP
Mechanical Testing of
Metals
1
• Many types of metals are used in the
fabrication of engg components.
• Metals are tested and pass rigid standards set
by regulatory bodies for safe and efficient
performance.
• Evaluation of mechanical properties is done to
confirm suitability for a given application.
1
• Mechanical testing subjects a specimen or
test pieces of standard form & size to tests on
special machines.
• Selection of a metal depends on qualities
needed for the component –
1. Stress level
2. Load variation
3. Temp variation
4. Pressure variation
3
Tests are done under various loading conditions -
✔ Static – Load increased gradually by tension
or compression or torsion or bending.
✔ Dynamic – Load increases rapidly as in an
impact test.
✔ Repeated or fatigue (static & impact) – Load
repeatedly varied during test either in value
or direction or both. 4
Mechanical Properties of Metals
Strength – Determined by Tensile Test
• It is the load a metal can withstand
without fracturing.
• Greater the load carried indicates the
ultimate strength of the metal.
5
Mechanical Properties of Metals
Ductility – Determined by Tensile Test
• Property of the metal that enables it to be
drawn into wires easily, without fracturing,
while retaining the shape.
6
Mechanical Properties of Metals
Hardness – Determined by Brinell Hardness Test
Measure of resistance to surface deformation
due to impact or wear.
7
Mechanical Properties of Metals
Impact Resistance – Determined by Impact
Test
Measure of resistance to impact after -
• Machining
• Heat treatment
• Casting
This test is useful for determining differences
in materials , due to heat treatment , working
and casting , which would not be otherwise 8
indicated by tensile test.
IZOD IMPACT TESTER
Izod impact strength test
•The test is named after the English
engineer Edwin Gilbert Izod (1876–1946).
•The Izod impact strength test is
an ASTM standard method of determining the
impact resistance of materials.
•A pivoting arm is raised to a specific height
(constant potential energy) and then released.
•The arm swings down hitting a notched sample,
breaking the specimen.
IZOD IMPACT STRENTH TEST
•The energy absorbed by the sample is calculated
from the height the arm swings to , after hitting
the sample.
•A notched sample is generally used to determine
impact energy.
Mechanical Properties of Metals
Elasticity – Determined by Tensile Testing
A metal has elastic qualities if it returns to
its original condition , after being subjected
to a load, under its yield point.
1
2
Mechanical Properties of Metals
Toughness – Determined by Impact Test
• Ability to withstand varying loads.
• Some metals are tough but brittle; a more
suitable combination is to have toughness ,along
with strength and pliability(quality to easily
bend).
1
3
Tensile Testing
Machine
Testing of Strength, Ductility and Elasticity
Properties of Metals
• A round bar sample is turned on a lathe, leaving
an accurate, predetermined diameter section in
between - shape is similar to a dumb bell.
1
4
1
5
Tensile Testing
Machine
Testing of Strength, Ductility and Elasticity
Properties of Metals
• Tensile testing machine grips the sample
vertically between two vertical circular
chucks.
• Then pressure is applied to stretch the
sample. 1
6
10
• During the initial stretching of test piece, till
elastic limit is reached, cross sectional area
of the material reduces.
• Maximum loading occurs at the ultimate
Load and at this stage extension will start.
• Normally it starts at about the centre of the
specimen & is rapidly followed by failure.
18
When load is increased the sample starts to
elongate in direct proportion to applied load in the
elastic stage, until it reaches point A.
When sample reaches
Yield Point, B, there is
a failure of crystalline
structure of the metal.
19
Impact Testing Machine
Testing Properties of Toughness &
Impact Resistance of Metals
• Charpy pendulum machine is used, the sample
is called as Single Edge Notch Bend (SENB).
• Sample is a 10 sq mm machined bar, 55mm
long with a 'V' notch in the center at one side.
• The notch is machined accurately and at correct
location.
20
19
Charpy impact test
• Machine has a pendulum of known weight
which is restrained at a recognized height.
• The pendulum swings across a steel table
designed to hold the sample.
• Sample is positioned within the supports with
the V notch facing away from the pendulum.
23
• Pendulum is released to strike & fracture the
sample. It continues its swing after impact.
Distance to which the pendulum rises after
impact is measured & recorded automatically.
• Impact strength is then calculated from the
weight of pendulum, height of pendulum at
release and after impact.
• The amount of energy absorbed by metal is
measured in Joules.
24
Brinell Hardness Testing Machine
Testing the Hardness Properties of Metals
• Hardness is determined by using a hardness
testing machine. A HARDENED CARBON STEEL
BALL or a DIAMOND is used.
• An indentation is produced in the sample under
a known weight. The area of indentation is
measured. 25
23
● A 3T hydraulic load is applied to the ram for
between 10-30 secs. The load and timing
are dependent on the material under test.
● Ball leaves an indentation on the surface
and its dia is measured.
● Then area of curved surface of indentation
is calculated.
● Sample is given a Brinell Hardness Number
(BHN). Units are kg/mm2.
27
28
29
Creep
• Creep may be defined as the slow plastic
deformation of a material under a constant
stress.
• A material may fail under creep conditions at a
much lower stress and elongation than would be
ascertained in a straight tensile test.
30
Creep
•Creep strength is the highest stress, the
metal can withstand for a specified
time , without exceeding the specified
deformation at a given(working) temp.
Creep Testing ● During a creep test,
specimen is loaded in
tension & heated in a
furnace.
● Ends are covered to
prevent oxidation.
● An extensometer is
provided and the
total creep or %
elongation is plotted 32
Fatigue
• Fatigue may be defined as the failure of a
material due to repeatedly applied stress.
• Failure of a metal under repeated pulsating or
reversing stresses is termed FATIGUE.
• The stress required to bring about such a
failure may be much less than that required to
break the material in a tensile test.
• In fatigue test ,a machine that can give a great
number of stress reversals in a short duration
of time is employed. 33
Fatigue Testing
34
Fabrication Tests
• Simple tests are carried out to check ductility.
• Needed to know suitability of metal for
particular fabrication techniques.
• Evaluated by appearance of metal after the test –
absence of tear, cracks or fracture.
35
Flanging is done by bending over the edge of
metal sheets using a flanging machine, the
process reinforces the bent edge or creates a
connection consisting of multiple components.
BEND TEST
•This is a test which is carried out on Boiler
plate materials and consist of bending a
straight plate specimen through 180 deg
around a former.
•For the test to be satisfactory ,no cracks
should occur at the outer surface of the
plate.
Bend Tests for Sheet
● Close bend test – Part is
bent & flattened;
specimen should not
show spring back & not
crack.
● Angle bend test- bent over
a former with a standard
nose angle & radius –
checked for spring back.
● When 1800 bend test is
conducted, test is repeated 38
till crack appears.
39
CREEP
•Creep is the property of materials that
results in progressive deformation when a
constant load is applied over time.
•Deformation occurs as a result of long-term
exposure to high levels of stress that are still
below the yield strength of the material
