Material testing , and phase

diagram

Nada Ibrahim El Kafrawy

Dr. Tarek Al-Mahdy

Eng. Khaled Hamed

Mechatronics- Y2

SEC 2
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Engineering material selection

Introduction Steel is one of the most widely used engineering materials, due to its versatility,
durability, and affordability. However, steel also has some limitations, such as corrosion, fatigue, and
brittleness. Therefore, it is important to understand the mechanical properties of steel and how they
can be modified by alloying, heat treatment, and processing. One of the methods to evaluate the
mechanical properties of steel is the tension test, which measures the stress and strain behavior of a
material under axial loading. The tension test can provide information about the strength, ductility,
elasticity, resilience, and toughness of a material. In this report, a steel alloy with a modulus of elasticity
between 190-210 GPa was selected and tested using a universal testing machine. The results of the
tension test were analyzed and compared with other tests, such as hardness tests. The report also
discusses the importance of the phase diagram, which shows the phases of a material at different
temperatures and pressures.

The importance of the tension test and the methodology of the test.
I select the cast iron to do the test on it .certainly! Tension testing is a critical method used to evaluate
the mechanical properties of materials, including strength, toughness, and hardness. For cast iron
specifically, this test helps determine its behavior under tensile stress, which is vital to understanding its
suitability for various applications.

Strength: Tensile testing helps determine the maximum stress a material can withstand before
breaking. For cast iron, this test reveals its ability to withstand pulling forces without breaking.

Toughness: This test determines the maximum value of the material’s resistance to deformation
before breaking. This property is essential in applications where impact resistance and flexibility are
essential.

Hardness: Refers to the ability of a material to resist deformation or scratching. It expresses the
hardness of the material and its ability to resist external mechanical influences.

Stress test methodology:

1: Sample preparation: Select representative samples of cast iron, and ensure that they meet the
required standards in terms of size and shape. Manufacturing samples to ASTM or other standards is
critical for accurate testing.

2: Test setup: Secure the specimen in the tensile testing machine, usually using specialized grips,
ensuring uniform distribution of force along its axis.````

3: Apply load: Gradually apply an increasing tensile load to the specimen while measuring the
corresponding deformation (strain) and applied force (strain). This is done until the sample breaks.

4: Data collection and analysis: Record stress-strain curves to analyze the behavior of the material
under tension. Key parameters include ultimate tensile strength (UTS), yield strength, elongation at
failure, and Young's modulus of elasticity.

5: Interpretation: Analyze the results to understand the performance of the material under tension.
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Engineering material selection
6: Reports and Recommendations: Compile the results into a comprehensive report detailing the
tensile properties of the material. Provide recommendations based on observed behavior regarding suit

the different results of the previous test and if there is any possibility to have
the results from different tests.
Tensile testing, also known as tensile testing, is a common method for evaluating mechanical properties.
The properties of materials, especially metals. During testing, samples of materials are tested Increase
tension until failure. Voltage test results provide information on Strength, ductility, and other
mechanical properties of materials. Here I discuss some of the key findings and investigate the
possibility of obtaining different results from other tests.

stress-strain curve: The main result of the tensile test is the stress-strain curve. This curve illustrates
the connection he relationship between stress (force per unit area) and strain (deformation) when a
material is subjected to increasing amounts of stress load.

The curve usually has different regions: elastic deformation, yield point, plastic deformation ,Shrink
and eventually break. The slope of the initial linear portion of the curve corresponds to the elastic
modulus of the material. Provides information about its stiffness.

Yield Strength: Yield strength is a key parameter determined from the stress-strain curve. it represents
this point In which the material deforms from elastic to plastic deformation.

Ultimate Tensile Strength (UTS): UTS is the maximum load a material can withstand before failure. It
is a crucial parameter indicating The strength of a material under tension. High UTS materials are ideal
for applications where strength is a priority.

Ductility: Ductility is the ability of a material to undergo significant plastic deformation before fracture.
This is This is usually assessed by measuring the strain and area reduction of the specimen after failure.
Ductile materials deform significantly before breaking, whereas brittle materials break easily Have little
or no plastic deformation.

Breakpoint: The point at which a material breaks indicates its brittleness or ductility. It is important
to remember that tensile testing is only used to evaluate tensile properties Results may vary from test
to test. Various mechanical tests including impact, compression and Hardness testing provides different
insights into the behavior of materials under different loading conditions.

Compression test: Measure the response of a material to compressive force. Yield strength and
elastic modulus in compression may differ from those in tension

Impact test: Evaluate the ability of a material to withstand sudden impacts or shock loads Provides
toughness and elasticity information that may not be fully captured in tensile testing.

Hardness Testing: Measure a material's resistance to deformation, penetration or scratching

relates to strength but does not provide a complete stress-strain curve ability for specific applications.
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Engineering material selection

The tension test using universal testing machine for a mild steel specimenof
14 mm diameter and length of 50 mm.

Proportional Limit: 260.49 MPa

Yield Tensile Strength: 340.39 MPa

Ultimate Stress: 441.74 MPa

Elongation Percentage: 15%

Modulus of Elasticity: 204950 Pa

Modulus of Resilience: 0.18069 J/m^3

Modulus of Toughness: 10.2901 J/m^3

Modulus of Rigidity: 78826.9231 Pa

Summarize the different types of Hardness tests (Vickers - Rockwell-Brinell).

1: Vickers Hardness Test: The size of an indentation left by an indenter shaped like a diamond is used
to determine the hardness of a material.
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Engineering material selection
Method: A diamond indenter with a pyramidal form is pressed into the material for a predetermined
amount of time and at a predetermined force.
Measurement: The diagonals of the indentation are measured, and the surface area of the indentation
and the applied load are used to compute the Vickers hardness number (HV).
Advantages: high accuracy, compatibility with a variety of materials, and the ability to examine thin or
small samples.

2: Rockwell hardness test: Hardness is determined by measuring the depth of penetration of the
indenter underneath Small and large loads.

Method: A spherical or conical diamond tip indenter is used. The small load is applied, followed by the
larger load, and then the larger load is removed while maintaining the smaller load.
Measurement: The difference in depth between the two loads determines the hardness value (for
example, HRC for Rockwell C scale).
Advantages: Fast and straightforward, suitable for various materials, and provides different
measurements for specific material types.

3: Brinell hardness Test: Measures hardness based on the diameter of the indentation made by a
spherical indenter.

Method: A spherical indenter is pressed into the material with a specific load for a set time, creating an
indentation.
Measurement: The diameter of the indentation is measured and used, along with the applied load, to
calculate the Brinell hardness number (HB).
Advantages: Suitable for softer materials and provides an average hardness over a larger area.

Plain the importance of the phase diagram, Discuss its stages

1. Solid phase the equilibrium line between the solid and liquid phases: It represents the
boundary between the solid and liquid phases. At certain combinations of temperature and pressure
below this line, the substance exists as a solid.
2. Liquid phase: Liquid-gas equilibrium line: This line indicates the boundary between the liquid
and gas phases. Under conditions outside this line, the substance exists as a gas.
3. Critical point: This is the point beyond which the distinction between the liquid and gaseous phases
becomes blurred, and the substance exists as a supercritical fluid. The temperature and pressure at this
point are critical values
4. Gas phase Triple Point: This represents the unique combination of pressure and temperature in
which the three phases (solid, liquid, and gas) coexist in equilibrium. It is a crucial point in the stage
diagram.

Importance of stage diagrams:

1: Predicting phase transformations: Phase diagrams allow us to predict the state of a substance
under different temperature and pressure conditions, which helps in industrial processes and materials
design.
2: Understanding the behavior of materials: It helps to understand the behavior of materials under
different conditions to design materials with specific properties.
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Engineering material selection
3: Critical conditions: Identifying critical points helps in understanding the behavior of materials
under extreme conditions.
4: Process optimization: Industries use phase diagrams to optimize processes such as heating, cooling
and pressure changes to efficiently obtain the required materials or products.
5: Quality Control: For materials with specific applications, phase charts assist in quality control by
ensuring that materials are within the desired phase limits for optimal performance.
6: Research and development: Scientists use phase diagrams as a guide to explore new materials and
materials with properties required for various applications

Water on the phase diagram under temperature and pressure

The Water behaves differently depending on the temperature and pressure, so knowing its phase
diagram is essential to comprehending its different states. This paper offers a succinct synopsis of the
phase diagram of water, highlighting the significance of temperature and pressure

Notice one key difference between the general phase diagram and the phase diagram for water. In
water’s diagram, the slope of the line between the solid and liquid states is negative rather than
positive. The reason is that water is an unusual substance in that its solid state is less dense than the
liquid state. Ice floats in liquid water. Therefore, a pressure change has the opposite effect on those two
phases. If ice is relatively near its melting point, it can be changed into liquid water by the application of
pressure. The water molecules are actually closer together in the liquid phase than they are in the solid
phase .Notice point E, labeled the critical point. What does that mean? At 373.99°C, particles of water in
the gas phase are moving very, very rapidly. At any temperature higher than that, the gas phase cannot
be made to liquefy, no matter how much pressure is applied to the gas. The critical pressure (Pc) is the
pressure that must be applied to the gas at the critical temperature in order to turn it into a liquid. For
water, the critical pressure is very high, 217.75 atm. The critical point is the intersection point of the
critical temperature and the critical pressure.