Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials

st
Faculty of Eng. 1 Year Civil Eng.
Sheet (1)
Materials Eng. Dept. T. Machines& S. Gages

1-What are the various types of testing machines? What is the most common type of
machine used in the testing of engineering materials? Why is it used so commonly?
2-What do precision, sensitivity, and accuracy mean?
3-What are the disadvantages to be expected in the screw gear machine? Has the
hydraulic machine any disadvantage? Explain.
4-What are the advantages of hydraulic testing machines?
5-When can it be considered preferable to use in testing vertical or horizontal testing
machine? Give examples.
6-What are the general requirements of testing machines?
7-What is meant by calibration of testing machines?
8-Explain briefly, how can you calibrate the universal testing machine using the
proving ring?
9- What is meant by a strain gage?
10-What are the different types of strain gages?
11-Derive a formula for the magnification factor of Huggenberger tensometer, dial
indicator, and Marten extensometer?
12-Mention the advantages and disadvantages of mechanical, optical and electrical
strain gages?
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (2)
Materials Eng. Dept. Static Tension Test

1- A tension test was carried out on a long standard specimen of 1cm diameter. The
following data were obtained:
P, Kg 0 500 800 1100 1300 1500 1650 1750 1700 1500
∆l, mm 0 0.05 0.08 1 1.5 3.5 6 9 11 15
Draw P-∆l curve and calculate the following:
a- Modulus of elasticity b-Ductility c- 0.25% proof stress
d- Working stress if the factor of safety equals 2 e- Modulus of toughness
2- A tension test was carried out on along mild steel specimen of 1.5 cm diameter. The
following data were recorded.
Load, kg 0 2400 4500 4300 5100 6000 6600 7000 7200 6800 6000
∆L, mm 0 0.06 0.12 0.15 3 8 13 18 26 30 32

Draw the stress-strain diagram and find the following:

a- Yield stress b- Modulus of resilience c- Stiffness
d- % elongation e- Ultimate tensile strength f- Modulus of toughness
3- A tension test was carried out on a rod of 15 mm in diameter and 30 cm long. The
mechanical properties of the rod material were as follows; a modulus of elasticity of
4.5x104 N/mm2, yield strength of 200 N/mm2 and an ultimate tensile strength of 300
N/mm2. Determine the following:
a- The load required to produce an elongation of 6.25 mm.
b- The load required to produce yielding.
c- The resilience of the rod.

4- A tension test was carried out on a specimen of 20 mm diameter. Some of the test
results were recorded as follows:-
Proportional limit Maximum Failure
Load (KN) 60 110 95
Extension (mm) 0.5 30 40
The elongation % was 20%, and the smallest cross-sectional area (at failure) was
1.57 cm2. Find the following:
a- Ultimate tensile strength b- Stiffness c- The % of reduction of cross-section area
d- Modulus of toughness e- True stress and true strain at initial necking
f- The fracture shape of test specimen and reason of failure.

5- A tension test was carried out on a long low-carbon steel test specimen .
The following data were recorded.
Load, KN 0 86 122 134 140 138 116
∆l, mm 0 6 15 25.8 39.6 53.5 70.5
Diameter, mm 23 22.7 22 21.6 20.9 18 14.8
Draw the load-extension diagram and find:
a- 0.1 % proof stress b-The design stress if the factor of safety equals 1.5
c- The modulus of toughness d- Stiffness e- Ultimate tensile strength g-
True stress and true strain at load = 138 KN.

6- A tension test was carried out on a steel specimen of 20 mm diameter and gauge
length of 100mm until failure. The load and corresponding diameter of the test
specimen were as follows:
Load (ton) 7 10 13 15 16 14.5 13
Diameter (mm) 19.99 19.94 19.55 18.89 18.37 17.85 16.74
Find the following:
a- The tensile strength b- The reduction in cross-section area percentage
c- The true strain at load =15 ton d- The modulus of elasticity e-The true strain at
failure f- The elongation of specimen at load = 7 ton if the Poisson's ratio of steel
is 0.25 g- The fracture shape of test specimen

7- A tension test was carried out on a short standard test specimen of mild steel of
15mm diameter. The following results were recorded.
Load at Max. Strain at Min. diameter Gauge length at
proportional load (ton) proportional limit at fracture fracture (mm)
limit(ton) (mm/mm) (mm)
7.5 12.5 0.0012 7.5 133
Determine the following:
a- Stress at proportional limit b- Ultimate strength c- Modulus of elasticity
d- Elongation % e- True stress at load = 7.5 ton f- True strain at fracture
g- What is the fracture shape of the test specimen?

8- A tension test was carried out on a long mild steel specimen of 15mm diameter.
The modulus of elasticity, E = 2 x 106 kg/cm2 and maximum elongation = 40mm.
Some of the test results were recorded as follows:
Applied load (ton)
At proportional limit At maximum At failure
6.28 10.99 9.42
Sketch the stress-strain diagram and estimate:
a- Tensile strength b- Modulus of resilience c-Ductility
d- True stress and true strain at load = 6.28 ton.
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (3)
Materials Eng. Dept. Static Compression Test

1- State the limitation

ation of compression test.
test
2- Why a barrel shape is formed in the test specimen during compression test?
3- What is the purpose of spherical bearing block in compression testing machines?
machines
4- Draw the stress-strain
strain diagram for a ductile, semi ductile and brittle material under
compression-explain
explain the fracture characteristic for these material under this test.
5- Explain the different methods of estimating the modulus of elasticity for the materials
of non-linear stress-strain behavior

6- The following data were obtained in the compression test of a cast iron cylindrical
specimen of 35mm in diameter and 250 mm in height. The load (P) and the
corresponding decrease in height (∆L)
( were as follows: -

P (KN) 0 27 68 102 136 203 272

∆L (mm) 0 0.056 0.14 0.208 0.28 0.457 0.71
Draw the ordinary stress-strain
strain diagram and determine the following: -
i) The crushing stress ii) The initial tangent modulus
2
iii) The secant modulus at a stress of 2100 kg/cm iv) Modulus of toughness.
v) Modulus of resilience.

7- A reinforced
forced concrete column of cross-section
cross section as shown in the figure
and a height of 300 cm. The section is reinforced by four steel bars of 20 60mm
mm diameter each. If the column carries a load of 80 ton, find the load
carried by the steel and concrete the contraction in the column is 0.5 mm.
Findd also the stress on the steel bars and on the concrete. Es = 206 GPa,
Ec= 14 GPa. 40mm

8- A compression test was carried out on a brass cylinder of 32 mm in diameter and gauge
length of 150 mm. Based on the shown stress-strain
stress diagram calculate the following:
following
a- The proportional limit stress
b- The modulus of elasticity
c- The modulus of resilience
d- The modulus of Toughness
e- Secant modulus at stress 210 MPa
f- Ultimate compressive strength
g- Contraction %
h- Explain the fracture characteristic
of test specimen.
9- A compression test was carried out on a brass cylinder of 1000 mm2 cross section
area. and gauge length of 200 mm. The following data were recorded:
Load, ton 0 2.7 6.75 10.1 12.5 17.5 20.0 27.0
∆L, mm 0 0.055 0.1375 0.205 0.255 0.365 0.445 0.70
Draw the stress-strain diagram and find:
i- 0.2 % proof stress ii- The modulus of Toughness
iii- Secant modulus at stress 210 MPa iv- Ultimate compressive strength
v- Contraction %
vi- Explain the fracture characteristic of test specimen.
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (4)
Materials Eng. Dept. Static Bending Test

1- Discuss the effect of specimen dimensions and type and rate of loading on the
test results?
2- What is the purpose the cold bend test? Explain the characteristic of fracture in this
test?
3- Explain how we can obtain a beam of uniform bending strength?
4- Draw the a schematic sketch for the bending stress distribution on a rectangular cross
section from a material having:
i- The same stiffness in compression and tension
ii- Stiffness in tension is greater than in compression
5- Why the span length to depth ratio (L/d) in bending range from 6-12.
6- A cast iron beam of circular cross-section was tested in bending under a central load
and supported over a span of 80mm. If the modulus of resilience of this grade of cast
iron equals 0.196 kg.cm and the loads and corresponding deflections measured
during the test are as follows:
Load (kg) 150 300 450 600 750 900 1050 1100
Deflection (mm) 1.05 2.1 3.15 4.2 5.25 6.8 8.88 failure

Draw the load-deflection diagram and determine: -

a) Diameter of cross section.
b) Modulus of rupture.
c) Modulus of elasticity.
d) Explain the fracture behavior of the beam.

7- A simply supported beam of a rectangular cross-section as shown in the

2b
figure is loaded by a uniform distributed load of 2 ton/m over a span of 4 m.
Find the dimension of the cross-section of the beam.
b
8- A cast iron beam of a circular cross-section was simply supported over a span of 50 cm
and tested in bending under concentrated load at its mid-span. The modulus of
elasticity is 800 ton/cm2. Find the following:
i- The diameter of the beam if the resilience is 0.2 ton.cm and the load at proportional
limit is 2000 Kg.
ii-The maximum Load on the beam if the maximum bending strength is 2.8 ton/cm2.

9- A timber beam was centrally loaded; the distance between supports being 90 cm, the
cross-section of the beam was 2.5 cm breadth and 5 cm depth. If the loads and
corresponding deflections are as follows: -
Load (kg) 0 100 200 300 400 500 600 700 750
Deflection (mm) 0 4.75 9.52 14.3 19.02 23.86 27.2 36.10 failure

Draw the load deflection diagram and determine:

i) Extreme fiber stress at limit of proportionality ii) Modulus of rupture.
iii) Modulus of resilience iv) Modulus of toughness v) Stiffness of material
10- A cantilever 1.2 m consisting of a steel tube with external and internal diameters of 6
and 5 cm respectively, carries a concentrated load of W kg at the free end. Neglecting
the weight of the tube, it is required to find the value of W if the maximum bending
stress is not to exceed 1.3 ton/cm2.

11- A timber beam of circular cross section simply supported over a span of 50 cm was
tested in bending under a central load. If the modulus of elasticity of this wood was
790 ton/cm2 and the loads versus mid span vertical deflection were as follows:
P, KN 0 6 10 14 18 22 26 27 28
Deflection, mm 0 0.5 0.8 1.2 1.5 2.0 3.0 4.0 5.0
Draw the load-deflection diagram and determine:
i- Diameter of the beam ii- Elastic bending strength iii- Modulus of rupture.
iv- Modulus of resilience v- Modulus of toughness
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (5)
Materials Eng. Dept. Static Shear Test

1- Discuss the feasibility of determining the shear strength of brittle materials by the
torsion test?
2- Discuss the fracture characteristic of brittle and ductile materials under torsion test?
3- Explain why ductile materials under torsion test fracture on a right section,
whereas brittle materials fracture on a helical section?
4- Determine the number of rivets required to transmit a load of 6 ton in two cases of
riveted connections as shown in Figs. (a) and (b) if the diameter of rivet is 16 mm and
the allowable shear stress in rivet is 0.84 ton/cm2.
6 ton 3 ton
6 ton 6 ton

3 ton
(a) (b)
5- A shaft of 50 mm in diameter and 0.75 m long has a concentric hole drilled for a
portion of its length. Find the diameter and maximum length of the hole so that when
the shaft is subjected to a torque of 1.67 KN.m, the maximum shearing stress will not
exceed 7.5 MN/m2 and the total angle of twist will not be greater than 1.5: Consider G
= 80 GN/m2.
6- A torsion test was carried out on a solid mild steel rod specimen of 16 mm diameter
and 160 mm length. The results of the test until rupture were as follows:
- the torque at elastic limit is 2000 Kg.cm - the maximum torque is 4500 Kg.cm
- the angle of twist at the elastic limit is 20 degree
- the maximum angle of twist is 600 degree
Find the following:
i- The elastic shear strength ii- The Ultimate shear strength
iii- The modulus of toughness iv- The modulus of rigidity

7- A torsion test was carried out on a mild steel specimen of 3 cm diameter and 20 cm
length. The following data was recorded:
Torque, Kg. cm 0 1000 2000 2500 3000 3500 4000 4500
θ, degree 0 10 20 30 50 100 250 600

Draw torque -angle of twist diagram and find the following:

i- Elastic shear strength
ii- Modulus of rigidity
iii- Operating stress in shear if the factor of safety is 2
iv- Ultimate shear strength
v- Discuss the fracture shape of test specimen.
vi- Draw the shear stress distribution on the cross-section of the specimen.
8- A torsion test was carried out on a mild steel rod specimen of 200 mm length. The
results of the test until rupture were as follows:

T, KN.cm 0 10 20 25 30 35 40 45
θ, in degree 0 10 20 30 50 100 250 600

Draw the T-θ θ diagram and find:

i- The diameter of the rod if the modulus of rigidity equals 90 KN/mm2
ii- Elastic shear strength iii- Modulus of toughness iv- Ultimate shear strength

9- A torsion test was carried out on a hollow mild steel rod specimen of 15 mm
diameter and 150 mm length. The results of the test until rupture were as follows:
T, ton.cm 0 0.4 0.8 1. 0 1.2 1.4 1.6 1.75 1.9 2
θ, in degree 0 4 8 20 50 100 150 250 500 800

Draw the T-θ θ diagram and find:

i- Elastic shear strength ii- Modulus of toughness iii- Modulus of rigidity
v- Ultimate shear strength v- Modulus of elasticity if Poisson’s ratio is, ν = 0.3
vi- Discuss the fracture shape of test specimen.
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (6)
Materials Eng. Dept. Hardness Test

1- Define metal hardness and discuss the limitations of Brinell hardness test.
2- Compare between Brinell hardness test and Vicker’s hardness test from the view point
of: 1) Loads 2) Type of indenter 3) Applications
3- Explain the effect of making an indentation near the edge of specimen on the BHN,
state the minimum distance between the centre of the impression and the edge of the
specimen.
4- What are the advantages of Vickers hardness test compared with Brinell hardness test?
5- Explain the effect of an indentation near an old one on the BHN, and state the
minimum distance.
6- A Brinell test was carried out on a steel specimen using a ball of 10-mm diameter. If
the diameter of indentation was 4.1 mm. Calculate BHN;
i- What are the minimum dimensions of the tested specimen can be used?
ii- Determine the depth of indentation.
iii- What is the tensile strength of such specimen?

7- A Brinell test was carried out on a steel specimen using a ball of 10 mm diameter. If
the diameter of the indentation was 4.3 mm. Calculate the BHN and the tensile strength
of the material. (K=30)

8- Vickers hardness test was carried out on a steel specimen using a load of 50 kg. The
diagonal of impression was 0.75 mm. Determine VHN, the depth and area of
indentation. Find the load that should be used to measure the hardness of the specimen
if the diagonal of impression not exceed 0.6 mm.
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (7)
Materials Eng. Dept. Impact Test

3. Answer the following questions

a. Will the increase in temperature increase the influence of strain rate?
b. Which mechanical property is most influenced by strain rate?
c. How does the strain rate influence the following mechanical properties: Ultimate
tensile strength, ductility and stiffness?
d. What factors enhance the brittle fracture tendency of a material?
e. How do you produce tri-axial state of stress in an impact test?
f. What is the difference between Charpy and Izod tests?
g. What is transition temperature?
h. Could you make use of impact test results in design in the quantitative sense? How
are these results useful?

2. Write short notes on:

a- The concept of Izod and Charpy impact tests and their specimens
b- Moduli of resilience and toughness. Show the difference between brittle and ductile
materials by using these moduli.

3- Attribute the following observations for impact tests:

a- Izod and Charpy specimens are notched.
b- For Izod and Charpy tests, the specimen is arranged with notch toward and side away
from the striking edge respectively.
c- Charpy impact value increased with increasing angle of notch (60o-150o) and root
radius of notch.
d- Temperature has marked effect on the impact resistance
e- Izod and Charpy tests do not, and are not intended to, simulate shock loading in
service.

4- A 50 Kg weight slides without friction down a

steel rod that has a cross-sectional area of 1.5
cm2, as shown in a figure. Determine the W=50 Kg
maximum stress, the maximum strain, and 100 cm
impact factor when:
a) h = 0.0 b) h = 30 cm c) h = 60 cm h
(Es = 21000 Kg/mm2)

5- Compare the strain energy stored in each of the three steel bars shown the figure
below subject to the condition that the axial stress in the lower portion of the second
bar is equal to that in the first and third bars, namely 150 MPa. Take E= 200 GPa.
 A = 1000 mm2 A = 1000 mm2
2.5 m
A = 500 mm2
5m 5m
2
A = 500 mm
2.5 m

P1 P2 0.5 P1

6- A steel bar 20 mm diameter is enclosed in a bronze tube of 30 mm outside diameter

and 20 mm inside diameter. The composite bar of length 1.5 m is provided with a
light collar at its lower end and its upper end is fixed. A mass of 100 kg falls through
a distance of 50 mm on to the collar. Calculate the instantaneous stress produced in
the steel and bronze. Take Esteel = 200 GPa and Ebronze = 120 GPa.

7-The rod in the figure is composed of two parts `

( A and B). The part A is of 40 mm diameter

2m
A
and the part B is of 30 mm diameter. The
weight in the figure is released from height
h. Determine the value of h so that the
W=50 Kg

1.5 m
maximum stress produced in the rod is 250
MPa. Take E= 200 GPa for the rod material. h B

8- A simply supported beam is struck at its midpoint by a weight W=1kN falling freely
from a height of h= 100 mm above the top of the beam. The beam is 5 m long and of
circular cross-section 100 mm in diameter. Take E = 200 GN/m2. Determine the
maximum deflection of the beam.
Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Civil Eng.
Sheet (8)
Materials Eng. Dept. Fatigue Test

1- Define the fatigue limit and explain using S-N curves the effect of mean stress on the
fatigue strength of the materials.
2- Discuss the characteristic of fatigue failure
3- What is cumulative fatigue damage?
4- Define fatigue strength reduction factor. When does this factor become equal to stress
concentration factor?
5- Define notch sensitivity index?
6- Select the wrong statement. Fatigue crack initiates on surface because:
(a) In most cases stress is highest on the surface
(b) Surface is machined
(c) Surface is inherently weaker than the inside
(d) There may exist some stress concentration on the surface
7- Select the correct statement:
(a) Residual compressive stress improves fatigue strength
(b) Brittle and ductile materials seem to follow Goodman straight line for tensile mean
stress
(c) Mild steel continuously loses fatigue strength with increasing temperature
(d) Fatigue strength reduction due to stress concentration is always proportional to stress
concentration factors for all materials.
8- Miner's theory of cumulative fatigue damage assumes that:
(a) Higher stress placed upon a specimen followed by lower stress will case grater
damage
(b) Higher stress placed upon a specimen followed by lower stress will case lesser
damage
(c) Damage caused to specimen is independent of whether higher stress follows or
precedes the lower stress
(d) Damage depends upon higher stress only.
9- Which one is not a characteristic of fatigue fracture?
(a) Rough fracture surface
(b) Rough and smooth areas on fracture surface
(c) No plastic deformation
(d) Concordia markings on fracture surface
10-A survey of the stresses at the critical points of machine member was carried out and
the value of the maximum and minimum stresses at points A, B, C were as follows:
A B C
бmax, Kg/mm2 +12 +8 +4
2
бmin, Kg/mm -8 zero -2
If the properties of the steel member were as follows: Tensile strength = 40 kg/mm2,
yield strength = 24 kg/mm2, and endurance limit = 20 kg/mm2. Using soderberg rule
 show whether this member is safe or not if the factor of safety = 2 for static load and
= 3 for fatigue loading.
11- A part of machine is subjected to repeated load of mean stress equals to 1260
kg/cm2. Find the max. and min. stresses using Gerber’s, Goodman’s and Soderberg’s
rules. The tensile strength of the material is 4200 kg/cm2, yield strength is 3360
kg/cm2 and the fatigue limit is 2100 kg/cm2.
12- A part of machine is subjected to repeated load change from +3 to +1 tons. Find the
cross section area of this part using Goodman rule. The factor of safety = 2, the tensile
strength of the material = 40 kg/mm2, yield strength = 24 kg/mm2and the fatigue limit
= 18 kg/mm2. Find also the cross section area of the part using Soderberg’ rule.
13- The number of cycles to failure from the S-N curve for a certain steel are

Stress, MN/m2 Number of cycles to failure, cycles

350 2 000 000
380 500 000
410 125 000
If a component manufactured from this steel is subjected to 600 000 cycles at the
stress 350 MN/m2 and 150 000 cycles at the stress 380 MN/m2. How many cycles can
the component withstand at 410 MN/m2 before fatigue failure occurs. Assuming that
Miner’s cumulative damage theory applies.
 Zagazig University ‫ﺒﺴم اﷲ اﻝرﺤﻤن اﻝرﺤﻴم‬ Engineering Materials
st
Faculty of Eng. 1 Year Elect. Eng.
Sheet (9)
Materials Eng. Dept. Creep Test

1- Explain what is meant by creep

2- What are the four basic variables involved in creep tests? what are the possible
way of relating them graphically?
3- Describe the effect of (a) increased stress and (b) increased temperature on the
creep behavior of materials?
4- A creep tests were carried out on alloy for the purpose of determination;
(1) the stress that can be permitted at any temperature if the creep strain is to be
kept within 1% in 104 hours, and
(2) the rupture stress in 104 hours. The following are the obtained results: -
Temperature (oC) 800 850 900 950 1000 1050
Stress for 1% Creep (MPa) 58 45 35 25 17 12
Rupture Stress (MPa) 98 75 55 40 30 22

On the same plot, draw to scale the stress versus temperature curves for the
design and rupture stresses in 104 hours? State your comments.