OML751

Testing of Materials
by
Department of Mechanical Engineering
St.Joseph’s College of Engineering, Chennai
 OML751 TESTING OF MATERIALS LTPC 3 0 03
OBJECTIVE:
To understand the various destructive and non-destructive testing methods of materials and its industrial
applications.

UNIT I INTRODUCTION TO MATERIALS TESTING 9

Overview of materials, Classification of material testing, Purpose of testing, Selection of material,
Development of testing, Testing organizations and its committee, Testing standards, Result Analysis,
Advantages of testing.
UNIT II MECHANICAL TESTING 9
Introduction to mechanical testing, Hardness test (Vickers, Brinell, Rockwell), Tensile test, Impact
test (Izod, Charpy) - Principles, Techniques, Methods, Advantages and Limitations, Applications.
Bend test, Shear test, Creep and Fatigue test - Principles, Techniques, Methods, Advantages and
Limitations, Applications.
UNIT III NON DESTRUCTIVE TESTING 9
Visual inspection, Liquid penetrant test, Magnetic particle test, Thermography test – Principles,
Techniques, Advantages and Limitations, Applications. Radiographic test, Eddy current test, Ultrasonic
test, Acoustic emission- Principles, Techniques, Methods, Advantages and Limitations, Applications.
UNIT IV MATERIAL CHARACTERIZATION TESTING 9
Macroscopic and Microscopic observations, Optical and Electron microscopy (SEM and TEM) -
Principles, Types, Advantages and Limitations, Applications. Diffraction techniques, Spectroscopic
Techniques, Electrical and Magnetic Techniques- Principles, Types, Advantages and Limitations,
Applications.
UNIT V OTHER TESTING 9
Thermal Testing: Differential scanning calorimetry, Differential thermal analysis. Thermo- mechanical
and Dynamic mechanical analysis: Principles, Advantages, Applications. Chemical Testing: X-Ray
Fluorescence, Elemental Analysis by Inductively Coupled Plasma-Optical Emission Spectroscopy and
Plasma-Mass Spectrometry.
TOTAL: 45 PERIODS
OUTCOMES:
● Identify suitable testing technique to inspect industrial component
● Ability to use the different technique and know its applications and limitations
TEXT BOOKS:
1. Baldev Raj, T.Jayakumar, M.Thavasimuthu “Practical Non-Destructive Testing”, Narosa Publishing House, 2009.
2. Cullity, B. D., “Elements of X-ray diffraction”, 3rd Edition, Addison-Wesley Company Inc., New York, 2000.
3. P. Field Foster, “The Mechanical Testing of Metals and Alloys” 7th Edition, Cousens Press, 2007.
REFERENCES:
1. Metals Handbook: Mechanical testing, (Volume 8) ASM Handbook Committee, 9th Edition, American Society for
Metals, 1978.
2. ASM Metals Handbook, “Non-Destructive Evaluation and Quality Control”, American Society of Metals, Metals
Park, Ohio, USA.
3. Brandon D.G., “Modern Techniques in Metallography”, Von Nostrand Inc. NJ, USA, 1986.
Pre Requisite:

Engineering Materials and Metallurgy and

Engineering Metrology

Post Requisite:

Research, Development of New Products, Project

 UNIT - I
INTRODUCTION TO MATERIALS
TESTING
Contents
➢ Overview of Materials
➢ Selection of Material
➢ Purpose of Testing
➢ Classification of Material Testing
➢ Development of Testing Methods
➢ Testing Organizations and its Committee
➢ Testing Standards
➢ Result Analysis
➢ Advantages of Testing
Overview of Materials
 Materials Science and Engineering – why?
➢To select a suitable material for a given purpose/use based on the considerations of
performance and cost.
➢To understand the property changes with respect to environment, load, etc.,
➢To understand the limitation of materials in manufacturing of components
➢To create a new material which will have some desirable properties.
✓ All engineering disciplines need to know about materials. Even the most
"immaterial", like software or system engineering depend on the development of
new materials, which in turn alter the economics, like software-hardware trade-offs.
✓ Increasing applications of system engineering are in materials manufacturing
(industrial engineering) and complex environmental systems.
 Materials Science and Engineering – why?
Historic Perspective
➢ Materials are very important in development of human civilization. In
respect, their names are associated in history, e.g. stone age, Bronze
age, Iron age, etc.
➢ With time humans discovered new materials and also techniques to
produce known materials. This is an ongoing process for coming
centuries, i.e. no end in sight.
➢ Material science is the study of materials and their applications.
 Scope of Materials Science
➢ Mechanical Engineers search for high temp material (gas turbines, jet engines), light
weight materials (automobile parts, structures, aircraft parts, etc.,), wear resistance
(Bearing Material)– can operate more efficiently and to avoid undesirable effects such
as fatigue failure, wear, creep.
➢ Aerospace & Automobile Engineers search for materials having high strength to
weight ratio.
➢ Electrical Engineers search for materials by which the electrical devices or machines
can be operate at a faster rate with minimum power losses.
➢ Electronic Engineers search for material that are useful in the fabrication &
minimization of too many electronic devices
➢ Chemical Engineers search for highly corrosion –resistant materials.
 What is Material?
➢ Materials are made up of matter. A material is a substance or mixture of
substances that constitutes an object. Materials can be pure or impure, living or
non-living matter. Materials are anything that have weight and occupy some
space. The matter is existing in the forms of solids and fluids (liquid and
gases).
➢ Materials consist of atoms and molecules. It has different properties such as
good enough in hard, strong, ductile, brittle, malleable, heat conductors,
electrical conductors, magnetic property or non-magnetic nature. This is
because of their structure.
➢ The behaviour of these solid materials is depends on the crystal geometry .
 What is Material?
➢ Raw materials can be processed in different ways to influence their properties,
by purification, shaping or the introduction of other materials. New materials
can be produced from raw materials by synthesis.
➢ Materials can be classified based on their physical and chemical properties, or
on their geological origin or biological function.
➢ In industry, materials are inputs to manufacturing processes to produce
products or more complex materials.
➢ Material selection is a process to determine which material should be used for
a given application.
 Classification of Solid Material
Based on the crystal structure ,
➢ Crystalline Material - the material in which the atoms / molecules are arranged in some regular
repetition pattern are called crystalline materials.
➢Types: Monocrystal- single crystal
Polycrystalline- many crystals separated by well defined boundaries
➢ Examples: Engineering Materials- metals, many ceramics, minerals
➢ Non- Crystalline Material - the material in which the atoms / molecules are arranged in an
irregular manner are called as Non- Crystalline materials. It is also called as amorphous
materials.
➢ These materials are super cooled liquids having a very high viscosity.
➢ Examples: Glass, Rubber and Polymers .
Classification of Engineering Material
Selection of Engineering
Material
❖ Material selection is one of the important step in the process of designing any physical object.

❖ In the context of product design, the main goal of material selection is to minimize cost while

meeting product performance goals---optimum design.

❖ Systematic selection of the best material for a given application begins with properties and costs of

candidate materials.

❖ It is essential that a designer should have a thorough knowledge of the properties of the materials

and their behavior under working conditions.

❖ Systematic selection for applications requiring multiple criteria is more complex.

❖ Reality often presents limitations, and the utilitarian factor must be taken in consideration.

❖ The cost of the ideal material, depending on shape, size and composition, may be prohibitive, and

the demand, the commonality of frequently utilized and known items, its characteristics and even

the region of the market dictate its availability.

MATERIAL SELECTION PROCESS
CRITERIA FOR SELECTION OF MATERIALS
FACTORS AFFECTING SELECTION OF MATERIALS
 Mechanical Properties of Materials
• Strength → ability to resist external forces
• Stiffness → ability to resist deformation under stress
• Elasticity → property to regain its original shape
• Plasticity → property which retains the deformation produced under load
• Ductility → property of a material to be drawn into wire form with using tensile force
• Brittleness → property of breaking a material without any deformation
• Malleability → property of a material to be rolled or hammered into thin sheets
• Toughness → property to resist fracture under impact load
• Machinability → property of a material to be cut
• Resilience → property of a material to absorb energy
• Creep → material undergoes slow and permanent deformation when subjected to
constant stress with high temperature
• Fatigue → failure of material due to cyclic loading
• Hardness → resistant to indentation, scratch
Purpose of Testing
of Materials
 Why Materials are tested ?
➢ Ensure quality

➢ Test properties

➢ Prevent failure in use

➢ Make informed choices in using materials

➢ To determine the FOS.

(Factor of Safety is the ratio comparing the actual stress on a

material and the safe useable stress)
 Importance of Testing of Materials
➢ The testing of materials has got immense important because it gives the required data,
ie., mechanical and other required properties for the designing and analysis of the
structures for its safe, reliable and cost effective functioning.
➢ When one uses the data derived from tests, the following questions arise:
1. What tests should be carried out to give the required data?
2. How precisely are these tests conducted and who guarantees it?
3. What does the data actually mean?
4. Are these data produced reliable?
5. Are data obtained from small test specimens meaningful when large
structures are being designed?
6. What will be the effect in operating environment?
 Importance of Testing of Materials
➢ These questions arise when one need to establish the response
of these materials various types of loading like tensile,
compressive or shear, for short-term or long-term duration, or
cyclic.
➢ Further, their behaviour in the presence of high or low
temperatures or other environments which might significantly
modify their behaviour is essential.
Classification of
Material Testing
 CLASSIFICATION OF MATERIAL TESTING
MATERIAL TESTING

DESTRUCTIVE TESTING NON-DESTRUCTIVE TESTING

TENSILE TESTING VISUAL INSPECTION

HARDNESS TESTING LIQUID PENETRANT TESTING
FLEXURAL TESTING ULTRASONIC TESTING
IMPACT TESTING LASER TESTING METHODS
TORSION TESTING EDDY CURRENT TESTING
SHEAR TESTING ELECTROMAGNETIC TESTING
CREEP AND FATIGUE TESTING
 Classification of Material Testing
➢ Destructive Testing (DT)
✓ Destructive testing (DT) includes methods where the materials are broken
down in order to determine mechanical properties, such as strength,
toughness and hardness.
✓ In practice it means, for example, finding out if the quality of a weld is
good enough to withstand extreme pressure or to verify the properties of
a material.
➢ Non Destructive Testing (DT)
✓ Non-destructive tests (NDT) – samples or finished articles are
tested before being used. Eg: Weighing, Measurements. etc
 DESTRUCTIVE TESTING
❖ In destructive testing, the properties of a material are evaluated by
breaking the test specimen by following a standard test procedure.
❖ A minimum of 5 test specimens is required to arrive at the approximate
value of the property of the material.
❖ Wastage of material - to be noted in the case of destructive testing.

❖ Examples of destructive testing of the material include

tensile strength testing, flexural strength testing,
compression strength testing, impact strength testing,
and hardness testing etc.,
 NON-DESTRUCTIVE TESTING
❖Non-destructive testing (NDT) is a testing and analysis technique used by industry to
evaluate the properties of a material, component, structure or system for characteristic
differences or welding defects and discontinuities without causing damage to the original
part.
❖NDT also known as non-destructive examination (NDE), non-destructive inspection (NDI)
and non-destructive evaluation (NDE).
❖ Various Non-Destructive Testing procedures are listed below.
➢ Acoustic Emission Testing (AET)
➢ Electromagnetic Testing (ET)
➢ Laser Testing Methods (LM)
➢ Liquid Penetrant Testing (PT)
➢ Ultrasonic Testing (UT)
➢ Eddy Current Testing (ECT)
Use of NDT:
➢ Components are not destroyed
➢ Can test for internal flaws
➢ Useful for valuable components
➢ Can test components that are in use
Testing Organizations and its
Committee
 INTERNATIONAL ORGANIZATION FOR TESTING
❖ American Association of Textile Chemists and Colorists (AATCC)
❖ American National Standards Institute (ANSI)
❖ ASTM International
❖ American Society of Heating, Refrigeration and Air-Conditioning Engineers
(ASHRAE)
❖ Electrostatic Discharge Association
❖ European Reference Materials
❖ Federal Institute for Material Research and Testing (FIMRT)
❖ Society of Automotive Engineers (SAE)
 GLOBAL MATERIAL TESTING RESEARCH
LABORATORIES

❖ Metallurgical Services in Mumbai, India

❖ Micom Laboratories
❖ Razi Metallurgical Research Center, (RMRC)
❖ Rocky Mountain Laboratories
❖ SEMATECH
❖ Evans Analytical Group, FEI Company
❖ Lucideon
Testing Standards
 MATERIAL TESTING STANDARDS

❖ Material Testing Standards provide a unified reference for test

methods, equipment, and industry-specific usage scenarios and
specifications for a wide array of materials and test environments.

❖ Ranging from medical devices that are implanted within a patient's

body, to key mechanical components relied upon by planes and
automobiles, these standards provide vital information and
instructions on how to attain it for many different industries.
 METALLIC MATERIAL TESTING STANDARDS
❖ Metallic Material Testing Standards focus on hardness, tensile, and
fatigue testing, approaching the issues from multiple angles to
provide a range of information.

❖ In addition, metallic material testing standards cover corrosion

testing, weld testing, and other areas of interest. Together,
standardized testing provides valuable information to determine the
reliability of metallic materials and the products and structures using
them.
 MEDICAL MATERIAL TESTING STANDARDS
❖ Medical Materials Testing addresses the testing and materials
and products that are designed to be compatible with the
human body, including dental materials, joint prostheses, and
other medical devices that will contact blood or other tissues.

❖ Given the vital nature of medical devices, testing procedures

for both the devices and their components is critical for their
safety and ongoing reliability.
 FLAMMABLE MATERIAL TESTING STANDARDS

❖ Fire related Material Testing Standards cover test procedures for a range of
industries. Personal Protective Equipment (PPE), aerospace, building
construction materials, insulation, and others all rely on strict material testing
procedures.

❖ These material testing standards also detail laboratory testing procedures to

measure flammability, burning characteristics, heat transfer, lower flammability
limit (LFL), lower explosive limit (LEL), and other vital characteristics.
 RADIATION MATERIAL TESTING STANDARDS
❖ Radiation Standards provide guides and standard practices for
testing the effects of radiation on electronics, their components, and
their systems. In addition to electronics, some of these methods can
be applied to other materials.

❖ These standards address both the source of the radiation and the
detector, as well as the test environment and applicability of the
results.
Result Analysis
 ➢ An example of Tensile Test Result is shown below.
➢ With reference to the Stress-Strain diagram, various essential parameters are obtained.
These parameters are marked in the plot against the corresponding stages.

➢ These parameters are to be

analyzed for each material
and this analysis should be
documented properly
because this analysis of
results will be very useful
for selecting a material for
a particular application.
Advantages of Testing
&
Application of Testing
 ADVANTAGES OF MATERIALS TESTING
➢ Materials testing helps us to understand and quantify whether a
specific material or treatment is suitable for a particular application.
➢ With the wide variety of materials and treatments available in the
marketplace, testing can help narrow down the choices to the most appropriate
selection for the intended use.
➢ Mechanical testing is an integral part of any design and manufacturing process –
and critical in aerospace.
➢ Its scope ranges from characterizing material properties to validating final
products.
➢ Ensuring safety is its core mission, but testing also plays an important role in
contributing to cost effective design, and technological evolution and superiority.
 APPLICATIONS OF MATERIALS TESTING
❖ Material Testing has a wide scope in various industries as follows

➢Electronics industries.
➢ Automotive industries.
➢ Medical industries.
➢ Construction industries.
➢ Textile industries. and many more…..
❖ Challenges of Material Testing includes:
➢Flexible testing equipment
➢Easy change over
➢Standard test methods
➢Achieving and maintaining accurate Alignment
➢Need for accurate alignment
 APPLICATIONS OF MATERIALS TESTING
➢ Materials testing machines are ideal for use in production, quality control,
education, research or laboratory settings.
➢ Due to the extensive testing capabilities mentioned above, these devices can be
used in a diverse range of applications within markets such as:

➢ Electronics, Automotive,
➢ Medical , Pharmaceuticals
➢ Building Materials
➢ Metals
➢ Plastics , Textiles
➢ Rubber, Wood
➢ Paper and Board , Packaging
THANK YOU

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