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Modules in
Materials Science and Engineering

SESSION TOPIC 3: Material Testing

LEARNING OBJECTIVES:

At the end of the session you can:

1. define and differentiate the different material testing.
2. identify the material test specific for the different types of engineering materials.

KEY TERMS
Coefficient of thermal
Material testing Tension test Compression test
expansion

Beam deflection test Shear/torsion test

CORE CONTENT

Introduction
Decision on what type of materials will be considered in the production must be properly checked
by an engineer. Selected materials should have been considered based on published table of engineering
materials testing. Material testing is a measurement of the characteristics and behavior of such
substances as metals, ceramics, or plastics under various conditions. The data thus obtained can be used
in specifying the suitability of materials for various applications—e.g., building or aircraft construction,
machinery, or packaging.

Tension test
A tensile test, also known as a tension test, is one of the most fundamental and common types of
mechanical testing. A tensile test applies tensile (pulling) force to a material and measures the specimen's
response to the stress. By doing this, tensile tests determine how strong a material is and how much it
can elongate. Tensile tests are typically conducted on electromechanical or universal testing instruments,
are simple to perform, and are fully standardized. By measuring the material while it is being pulled, the
complete profile of its tensile properties can be obtained. When plotted on a graph, this data results in
a stress/strain curve which shows how the material reacted to the forces being applied. The point of break
or failure is of much interest, but other important properties include the modulus of elasticity, yield
strength, and strain.

Compression test
Compression testing is one of the most fundamental types of mechanical testing, alongside tensile
and flexion tests. Compression tests are used to determine a material’s behavior under applied crushing
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loads, and are typically conducted by applying compressive pressure to a test specimen (usually of either
a cuboid or cylindrical geometry) using platens or specialized fixtures on a universal testing machine.
During the test, various properties of the material are calculated and plotted as a stress-strain
diagram which is used to determine qualities such as elastic limit, proportional limit, yield point, yield
strength, and, for some materials, compressive strength. Compression testing allows manufacturers to
assess the integrity and safety of materials, components, and products during several phases of the
manufacturing process. The potential applications can vary from strength testing of a car windshield to
endurance testing of concrete beams used in construction. Materials that exhibit high tensile
strength tend to (but do not always!) exhibit low compressive strength. Likewise, materials high in
compressive strength tend to exhibit low tensile strength. Therefore, compression testing is often used
on brittle materials such as concrete, metals, plastics, ceramics, composites, and corrugated materials like
cardboard. These materials are often used in a load-bearing capacity where their integrity under
compressive forces is critical.

Coefficient of thermal expansion

This test method covers the determination of the linear thermal expansion of rigid solid materials
using push-rod dilatometers. This method is applicable over any practical temperature range where a
device can be constructed to satisfy the performance requirements set forth in ASTM E-228 standard.
Thermal expansion is the tendency of matter to change its shape, area, and volume in response to a
change in temperature. Coefficients of linear thermal expansion (CTE) are required for design purposes
and are used, for example, to determine dimensional behavior of structures subject to temperature
changes, or thermal stresses that can occur and cause the failure of a solid artifact composed of different
materials when it is subjected to a temperature excursion.

Shear/torsion test
Torsion testing is a type of mechanical testing that evaluates the properties of materials or devices
while under stress from angular displacement. Torsion testing can be split into two distinct categories:
testing raw materials like metal wires or plastic tubing to determine properties such as shear strength and
modulus, or functional testing of finished products subjected to torsion, such as screws, pharmaceutical
bottles, and sheathed cables. The most common mechanical properties measured by torsion testing are:
modulus of elasticity in shear, yield shear strength, ultimate shear strength, modulus of rupture in shear,
and ductility. Many products and components are subjected to torsional forces during their
operation. Torsion testing is necessary when engineers wish to change or update the materials used in
these products. For example, the metal used in vehicle drive trains experiences a complex combined
loading when in use, with torsion being the main component. An engineer trying to design a more fuel-
efficient vehicle may need to change the material of the driveshaft to reduce vehicle weight. Torsional
testing can help the engineer identify an appropriate material that will possess the required torsional
strength while also contributing to the goal of light weighting.
Many finished products are also subjected to torsional forces during their operation. Products
such as biomedical tubing, switches, and fasteners are just a few devices subjected to torsional stresses
in their everyday use. By testing their products in torsion, manufacturers can simulate real life service
conditions, check product quality, verify designs, and ensure proper manufacturing techniques.

Beam deflection test

Bend testing, sometimes called flexure testing or transverse beam testing, measures the behavior
of materials subjected to simple beam loading. It is commonly performed on relatively flexible materials
such as polymers, wood, and composites. At its most basic level a bend test is performed by placing a
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specimen on two support anvils, which is bent through applied force on 1 or 2 loading anvils. The force is
applied with either a single upper anvil at the midpoint, which is a 3-point bend test, or two upper anvils
equidistant from the center, a 4-point bend test. n a 3-point test the area of uniform stress is quite small
and concentrated under the center loading point. In a 4-point test, the area of uniform stress exists
between the inner span loading points (typically half the length of the outer span). Depending on the type
of material being tested, there are many different flex fixtures that may be appropriate. Engineers often
want to understand various aspects of material’s behavior, but a simple uniaxial tension or compression
test may not provide all necessary information. As the specimen bends or flexes, it is subjected to a
complex combination of forces including tension, compression, and shear. For this reason, bend testing is
commonly used to evaluate the reaction of materials to realistic loading situations. Flexural test data can
be particularly useful when a material is to be used as a support structure. For example, a plastic chair
needs to give support in many directions. While the legs are in compression when in use, the seat will
need to withstand flexural forces applied from the person seated. Not only do manufacturers want to
provide a product that can hold expected loads, but the material also needs to return to its original shape
if any bending occurs.

Sample Activity 1
Name the type of material testing which is being conducted by the following:

1.1 Universal testing machine (UTS)

1.2 Extensometer
1.3 Osmometer
1.4 Brinell test

IN-TEXT ACTIVITY

1.Get another material testing concept through this link: https://www.youtube.com/watch?v=gmmj-Cn-

HUo

SESSION SUMMARY

The integrity of the buildings, equipment, machines, and instruments must always be considered
before and during the time these are actively used. It is therefore a requirement for them to be
subjected to the different material testing to ensure the quality of their services alongside to
predict their lifespan.
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SELF ASSESSMENT

ACTIVITY 3
Material Testing

Name: ________________ Score: ______________

Date: ________________

Critical Thinking:
1.Which among the different material testing procedure do you think will be the most expensive
if being done? Can you rank them from the most to the least expensive?

2.What parameters are generated during the conduct of the material testing? Cite all the
parameters for each material testing.

REFERENCES

1.Ashby, M.F. Materials Selection in Mechanical Design, 2011

2.https://www.instron.us/our-company/library/test-types/tensile-test

3.https://thermtest.com/testing-services/thermal-expansion#

4.https://mechanicalc.com/reference/engineering-materials