Documente Academic
Documente Profesional
Documente Cultură
Chapter
One (1)
pis/yth/jb502/chapter1
pis/yth/jb502/chapter1
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
MATERIAL TESTING
DEFINITION
The determination of the properties of a substance in comparison with a standard
or specification.
PURPOSES OF MATERIAL TESTING
Materials are tested for one or more of the following purposes:
a)
To access numerically the fundamental mechanical properties of ductility,
malleability, toughness etc.
b)
To check chemical composition.
c)
To determine suitability of a material for a particular application.
d)
To determine data i.e. force deformation (or stress) values to draw up sets of
specifications upon which the engineer can base his design.
e)
To determine the surface defects in raw materials or processed parts.
SIGNIFICANCE OF MATERIAL TESTING
a)
To determine the material properties, and
b)
To determine the integrity of the material or component
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
CLASSIFICATION OF TESTS
Tests on materials may be classified as;
a) Destructive tests
b) Non-destructive tests
DESTRUCTIVE TESTS
In destructive testing, the component or specimen either breaks or remains no
longer useful for further use.
The purpose of destructive testing is to determine the mechanical properties of
materials.
Example : Tensile test, impact test, torsion test, etc.
NON-DESTRUCTIVE TESTS
In non-destructive testing, a component does not break and so even after being
tested it can be used for the purpose for which it was made.
The purpose of non-destructive testing is to revealing (dedahkan) defects in
components that could impair (jejaskan) their performance when put in service
Example : radiography, ultrasonic inspection etc.
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
NON-DESTRUCTIVE TEST
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
ADVANTAGES
DISADVANTAGES
The sample or test pieces will be destroyed after the test. This
will result in increased the cost for testing.
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
The most basic test is simply to break the sample by applying a tensile force.
Compression test are also common.
In engineering, hardness is usually defined in terms of resistance of the material to
penetration by a hard ball or point.
Various forms of bending test are also often used, as is torsion of cylindrical rods or
tubes.
pis/yth/jb502/chapter1
10
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
11
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
LOADING SYSTEM
Equipment of a variety of types is used for applying forces (loads) to test specimens.
Test equipment ranges from very simple devices to complex systems that are
controlled by digital computer.
2 common configurations of relatively simple devices called universal testing
machines:
a) The mechanical-screw-driven machine
b) The hydraulic system machine
pis/yth/jb502/chapter1
12
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
13
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
These general types of testing machine first became widely used in the period 1900
to 1920, and they are still frequently used today.
The mechanical-screw-driven machine
Testing machines of these types can be used for tension, compression, or bending,
and torsion machines.
pis/yth/jb502/chapter1
14
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
The closed-loop servo-hydraulic concept is the basic of the most advanced test
systems in use today.
Integrated electronic circuitry has increased the sophistication of these system.
Also digital computer control and monitoring of such test systems has steadily
developed.
Sensors for measuring loads and displacements using electrical signals are important
features of testing machines.
pis/yth/jb502/chapter1
15
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
16
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Example:
The Annual Book of ASTM Standards is published yearly and consists of more than
60 volumes, approximately ten (10) of which include a significant number of standards
for mechanical tests.
The details of the test methods differ depending on the general class of materials
involved, such as metals, concrete, plastics, rubber, and glass, and ASTM Standards
are organized according to such classes of materials.
The numbers identifying some of the major standards for mechanical testing are given
in table below:
pis/yth/jb502/chapter1
17
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
18
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
The Department of Standards Malaysia (STANDARDS MALAYSIA) is an agency under the ambit
(control) of Ministry of Science, Technology and Innovation (MOSTI).
STANDARDS MALAYSIA was officially launched on 28 August 1996 following the incorporation of
Standards and Research Institute of Malaysia (SIRIM) into SIRIM Berhad.
STANDARDS MALAYSIA took over the statutory (berkanun) roles in standardization, formerly carried out
by SIRIM.
In performing its duties and functions, STANDARDS MALAYSIA is governed by Standards of Malaysia
Act 1996 (Act 549).
OBJECTIVES
The Objectives of establishment of STANDARDS MALAYSIA are as follows:
a)
To promulgate and promote the national standards. (untuk menyebarluaskan dan menggalakkan
piawaian kebangsaan)
b)
c)
To maintain the credibility, integrity and competency of the national standardisation and
accreditation systems (Untuk mengekalkan kredibiliti, integriti dan kecekapan bagi penstandardan
kebangsaan dan sistem akreditasi)
d)
To safeguard the interest of Malaysia at regional and international level in the fields of
standardisation and accreditation. (Untuk melindungi kepentingan Malaysia di peringkat serantau
dan antarabangsa dalam bidang standardisasi dan akreditasi.)
EXAMPLE:
Tensile test : MS ISO 6892 : 2002
[Metallic Material-Tensile Testing At Ambient Temperature)
pis/yth/jb502/chapter1
19
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
British Standards are the standards produced by BSI Group which is incorporated under a Royal
Charter (piagam diraja) (and which is formally designated as the National Standards Body (NSB)
for the UK).
The BSI Group produces British Standards under the authority of the Charter, which lays down as
one of the BSI's objectives to:
Set up standards of quality for goods and services, and prepare and promote the general
adoption of British Standards and schedules in connection there with and from time to time
to revise, alter and amend such standards and schedules as experience and circumstances
require.
(Menetapkan standard kualiti bagi barangan dan perkhidmatan, dan menyedia dan menggalakkan
penggunaan umum Piawaian British dan jadual yang berkaitan di sana dan dari masa ke masa untuk mengkaji
semula, mengubah dan meminda apa-apa piawaian dan jadual sebagai pengalaman dan keadaan memerlukan)
EXAMPLE:
Tensile test : BS 18 : 1987 [British Standard Method for Tensile Testing of Metals)
pis/yth/jb502/chapter1
20
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
21
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
SIGNIFICANCE OF STANDARD
a) To protect the consumer rights
b) To protect the safety of consumer
pis/yth/jb502/chapter1
22
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
ENGINEERING MATERIAL
METAL
In chemistry, a metal is defined as an element
with a valence of 1, 2, or 3.
All metals possess metallic properties such as
luster (kilau), opacity (legap-tidak lutsinar), malleability,
ductility and electrical conductivity.
Typical examples of metallic materials are iron,
copper, aluminium, zinc, etc., and their alloys.
pis/yth/jb502/chapter1
23
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
CERAMIC
A ceramic can defined as a combination of one or
more metals with a non-metallic element.
Hence, metal oxides, carbides, nitrides, borides
and silicates are considered as ceramics.
They are characterised by high hardness, abrasion
resistance, brittleness and chemical inertness
(lengai), and are poor conductors of electricity.
Typical examples of ceramics include refractories
glasses, abrasives, clays and cements.
POLYMERS
Polymers are organic substances and
derivatives of carbon and hydrogen.
They are also known as plastics.
Most plastics are light in weight and are soft as
compared to metals.
They possess/are high corrosion resistance
and can be moulded into various shapes by the
application of heat and pressure. Typical
examples of polymers are polyester, phenolics,
polyethylene, nylon and rubber.
pis/yth/jb502/chapter1
24
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
COMPOSITES
A composite is a combination of two or more
materials that has properties different from its
constituents (juzuk/kandungan).
Typical examples of composites are wood, clad
metals, fibre glass, reinforced plastics,
cemented carbides, etc.
Composites as a class of engineering material
provide almost an unlimited potential for higher
strength, stiffness, and corrosion resistance
over the pure material systems of metals,
ceramics and polymers.
They will probably be the steel of the next
century.
pis/yth/jb502/chapter1
25
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
MECHANICAL PROPERTIES
Mechanical properties are the characteristics of a material
that are displayed when a force (load) is applied to the
material, OR
Mechanical properties are the properties that describe how a
material will respond to applied loads (or forces) OR
The mechanical properties of a material are those properties
that involve a reaction to an applied load.
These mechanical properties are determined by subjected
prepared specimens to standard laboratory tests designed to
evaluate the materials reaction to applied force.
The mechanical properties of metals determine the range of
usefulness of a material and establish the service life that can be
expected.
Mechanical properties are also used to help classify and identify
material.
They usually relate to the elastic and plastic behavior of the
material.
(Elastic deformation = recovered immediately upon unloaded,
Plastic deformation = not recovered upon unloaded and is therefore
permanent.)
pis/yth/jb502/chapter1
26
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
27
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
28
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Strength
The strength of metal is its ability to withstand various forces to which it is
subjected during a test or in service, or
Ability of a material to resist applied forces without yielding or fracturing
It is usually defined as tensile strength, compressive strength, proof stress, shear
strength, etc.
Strength of materials is a general expression for the measure of capacity of
resistance possessed by solid masses or pieces of various kinds to any cause
tending to produce in them a permanent. and disabling change of form.
pis/yth/jb502/chapter1
29
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Elasticity
This is the ability of a material to deform under load and
return to its original size and shape when the load is
removed.
A material is said to be perfectly elastic if the whole of the
stress produced by a load disappears completely on the
removal of the load, the modulus of elasticity of Youngs
modulus (E) is the proportionally constant between stress and
strain for elastic materials.
Figure below shows a tensile test specimen:
If it is made from an elastic material it will be the same length
before and after the load is applied.
All materials possess elasticity to some degree and each has
its own elastic limit.
If stressed beyond this limit, permanent deformation (plastic
deformation), and ultimately fracture, occurs.
At stress levels below the elastic limit the amount of
deformation is directly proportional to the applied force which
may be tensile or compressive.
pis/yth/jb502/chapter1
30
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Youngs modulus is the indicative of the property called stiffness; small values of E
indicate flexible materials and large value of E stiffness and rigidity. The property of
spring back is a function of modulus of elasticity and refers to the extent to which metal
spring back when an elastic deformation load is removed.
In metal cutting, modulus of elasticity of the cutting tools and tool and holder affects their
rigidity.
Values of modulus of elasticity for some important metals are given in table below:
pis/yth/jb502/chapter1
31
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Plasticity
Plasticity is the property that enables the formation of permanent deformation in a
material.
It is the state of a material which has been loaded beyond its elastic limit so as to
cause the material to deform permanently. Under such conditions the material
takes a permanent set and will not return to its original size and shape when the
load is removed.
It is reverse of elasticity; a plastic material will retain exactly the shape it takes
under load, even after load is removed.
Under such conditions the material takes a permanent set and will not return to its
original size and shape when the load is removed.
Gold and lead are the highly plastic materials.
It is because of this property that certain synthetic materials are given the name
plastics.
These materials can be changed into required shape easily.
Example : When a piece of mild steel strip is bent at right angles into the shape of
bracket, it shows the property of plasticity since it does not spring back straight again.
pis/yth/jb502/chapter1
32
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Example : When a piece of mild steel strip is bent at right angles into the shape of
bracket, it shows the property of plasticity since it does not spring back straight again.
pis/yth/jb502/chapter1
33
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Ductility
It is the ability of a metal to withstand elongation or bending, or
A material that can undergo large plastic deformation without fracture / before
fracture occurs by applying a tensile load.
A ductile material allows a useful amount of plastic deformation to occur under tensile
load before fracture.
Due to this property, wires are made by drawing out through a hole.
Example: A material is manipulated by processes such as wire drawing, tube drawing,
and cold pressing low-carbon steel sheets into motor car body panels.
The material shows a considerable amount of plasticity during the ductile extension.
This is a valuable property in chains, rope etc., because they do not snap off, while in
service, without giving sufficient warning by elongation.
pis/yth/jb502/chapter1
34
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Malleability
This is the property by virtue of which a material may be
hammered or rolled into thin sheets without rupture.
Ability of material allows a useful amount of plastic
deformation to occur under compressive loading before
fracture occurs.
Such a material is required for manipulation by such
processes as forging, rolling, and rivet heading.
pis/yth/jb502/chapter1
35
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
pis/yth/jb502/chapter1
36
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
It is due to the attraction which the molecules have for each other; giving them power to
resist tearing apart.
The area under the stress-strain curve indicates the toughness (i.e. energy which can be
absorbed by the material upto the point of rupture.
Toughness is expressed as energy absorped (Nm) per unit volume of material
participating in absorption or Nm/m3 .
Brittleness
It is the property of a material that shows little or no plastic deformation before
fracture when a force is applied.
It is usually regarded as the opposite of ductility and malleability.
Lack of ductility is brittleness
When a body breaks easily when subjected to shocks it is said to be brittle.
For example : A steel rod can be bent but a grey cast iron rod snaps when you try to
bent it. Therefore grey cast iron is a brittle material.
pis/yth/jb502/chapter1
37
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Hardness
Hardness is usually defined as resistance of
material to penetration.
Ability of a material to withstand scratching
(abrasion) or indentation by another hard body.
It is an indication of the wear resistance of the
material
Hard material resist scratches or being worn out
by friction with another body.
Example : A hardened steel ball being pressed first
into a had material and then into a soft material by
the same load. The ball only makes a small
indentation in the hard material, but it makes a
very much deeper impression in the softer
material.
Hardness is primarily a function of the elastic limit (i.e. yield strength) of the material.
The modulus of elasticity also exerts a slight effect on hardness.
In the most generally accepted test, an indentor is pressed into the surface of the
material by slowly applied known load, and the extent of the resulting impression is
measured mechanically or optically.
A large impression for a given load and indentor indicates soft material, and the
opposite is true for small impression.
The converse of hardness is known as softness.
pis/yth/jb502/chapter1
38
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Fatigue
Failure in metals that are subjected to many reversed or repeated stresses.
When subjected to fluctuating or repeated loads (or stress), material tend to develop a
characteristic behavior which is different from that (or materials) under steady loads.
Fatigue is the phenomenon that leads to fracture under such conditions.
Fracture takes place under repeated of fluctuating stresses whose maximum value is
less than the tensile strength of the materials (under steady load).
Fatigue fracture is progressive, beginning as minute cracks that grow under the action
for the fluctuating stress.
pis/yth/jb502/chapter1
39
material testing
destructive test and non-destructive test material testing selection
three classes of test specimen
types of loading system using in universal testing machine
standard used in material testing
engineering material
mechanical properties of materials
Creep
The slow and progressive deformation of a material with time under a constant
stress.
Creep is the slow plastic deformation of metals under constant stress or under
prolonged loading usually at high temperature.
It can take place and lead to fracture at static stresses much smaller than those which
will break the specimen by loading it quickly.
Creep is specially takes care of while designing engines, boilers and turbines.
pis/yth/jb502/chapter1
40