Module 6 - 1

Module 6

Metal Properties
and
Destructive Testing
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Classification of materials
 All engineering materials can be classified
due to physical properties in to 4 type
 Elastic material
 Plastic material
 Ductile material
 Brittle material

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Metal Properties
 Physicalproperties (density)
 Mechanical properties *
 Alloy chemistry
 Alloy heat treatment

* Mechanical properties depend on alloy

chemistry, heat treatment and cold work.

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Terminology
 Elasticity
 Stress a- tensile b- compressive
stress = load / area
 Strain ε = δl / l
δl= change of length after removal the
external load
 Elastic limit
 Yielding strength : stress at which slip
becomes noticeable a- upper b- lower
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Selection process of materials

 Kinds of materials
 Properties of materials
 Service requirement
 Economy
 Method preparation
 Method of testing and inspections

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Strength

“The ability of a material to bear an applied

load”

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Strength
Two common methods of expression:

 Ultimate tensile strength (UTS)

 Yield strength (or yield point)

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Metal Behavior Under Load

 Elastic - No permanent deformation
 Plastic - Permanent deformation

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Elastic
Behavior of
Steel

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Temperature Effects
As metal temperatures increase:

 Strength decreases
 Hardness decreases
 Ductility increases

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Ductility

The ability of a metal to deform without breaking

* Measurements
A- Elongation
B - Reduction

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Brittle vs Ductile Failure

Brittle Ductile

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Ductility Terms
 Percent elongation
 Percent reduction of area

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Directional Properties

Both strength and ductility are affected by the

rolling direction of the metal. The three axes
of rolling direction are referred to as the X, Y,
and Z directions.

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Rolling Directions

X Direction Best Strength & Ductility

Y Direction 10 - 30% Less Strength
20 - 50% Less Ductility
2 Direction Still Lower Strength & Ductility

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Hardness

“Ability to resist indentation or scratch”

A-Indentation Hardness
B-Rebound Hardness
C-Scratch Hardness
D-Wear Hardness
E-Machinability

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Hardness test type

 Brinell
 Rockwell
 Vickers
 Micro

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Indenter Types

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Hardness Tester

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Indentation
Shapes

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Toughness

“The ability to absorb energy”

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Toughness Comparison

Modulus of toughness

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Notch Toughness

“Toughness in the presence of surface notches

and rapid loading”

(also referred to as “Impact Strength”)

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Stress Riser

“A surface condition, or geometric feature,

that increases the applied stress at the
condition or geometry”

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Stress Risers (Notch Effects)

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Notch Effects on Fatigue

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Surface Finish Effects on Fatigue

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Ductile - to - Brittle
Transition Temperature

“The temperature at which a metal fracture

mode changes from ductile to brittle”

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Fatigue Strength

“The strength of a metal when exposed to

repeated reversals of cyclic stresses”

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Endurance Limit

“The maximum stress at which no failure will

occur, regardless of cycles”

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Typical S-N Curves

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Soundness

“Freedom from discontinuities”

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Chemical Properties
 Metals are mixtures of elements, and are
referred to as alloys
 Minor changes in alloy composition can
have major effects on alloy properties such
as mechanical strength, corrosion resistance

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Common Steel Alloys

Common Name C% Typical Use Weldability

Ingot iron .03* Deep drawing Excellent

Low C .15* Electrodes Excellent
Mild Steel .15-.30 Structural Good
Medium C .30-.50 Machinery Fair
High C .50-1.0 Springs, dies Poor

* Single values are maximums

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Low Alloy Steels

 High strength, low alloy
 Automotive & machinery
 Low temperature
 Elevated temperature

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High Alloy Steels

 Corrosion resistant
 High temperature
 High strength

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Stainless Steels

Contain at least 12% Cr

 Austenitic
 Martensitic
 Ferritic
 Precipitation hardening
 Duplex

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Elements in Steels - 1 of 2
C - Most important
S - Undesirable
P - Undesirable
 Si - Deoxidizer
 Mn - Combines with S
 Cr - Hardenability, Corrosion Resistance

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Elements in Steels - 2 of 2
 Mo - Hardenability
 Ni - Toughness, Ductility
 Al - Deoxidizer
V - Hardenability
 Nb - Stabilizer

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Dissolved Gases
(Embrittle steels, cause porosity)
 Hydrogen
 Oxygen
 Nitrogen

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Aluminum Alloys
Heat treatable

Major Alloying Aluminum Association

Element Number
Cu 2XXX
Mg & Si 6XXX
Zn 7XXX

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Aluminum Alloys
Non-heat treatable

Major Alloying Aluminum Association

Element Number
Pure Al 1XXX
Mn 3XXX
Si 4XXX
Mg 5XXX

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Nickel Alloys
 Corrosionresistant
 Good low temperature properties
 Good high temperature properties

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Copper Alloys
 Electrical
conductivity
 Resistance to corrosion
 Resistance to erosion
 Resistance to water and salt water

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Destructive Testing

“Failing, or destroying, a part, or a portion

thereof, to determine its properties”

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Nondestructive Testing

“Does not affect the serviceability of the part

after testing is completed”

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Tensile Testing

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Typical Stress/Strain Curve - Steel

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Sample Preparation

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Area of a Circular Cross Section

Example 1
Area (circle)=  x Radius2 = R2
=  x Diameter2 = D2
4 4
Sample Diameter, D = 0.505 in.
Sample Radius, R = 0.2525 in.

Area = 3.1416 x 0.25252

Area = 0.20 in2
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Alternate Calculation
Example 2 (using diameter directly)
Area = ∏ D2
4

Area = 3.1416 x (0.505) 2

4

Area = 0.20 in2

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Calculation Shortcut
Area of Circle shortcut:

Area = 0.7854 x D2

because:
 ÷ 4 = 3.1416 ÷ 4 = 0.7854

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Calculation of Tensile Strength

Example 3
Load to break = 12,500 lbs
Area of sample = 0.20 in. 2

Tensile strength = load  area

Tensile strength = 12,500  0.20
Tensile strength = 62,500 psi

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Offset
Method

Unit Strain e e

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Stress-Strain Diagram
High and Medium Strength Steels

High Strength Steel

High Carbon Spring Steel

Structural Steel
Medium Strength Steel

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Percent Elongation
Original gage length = 2.0 in.
Final gage length = 2.6 in.

%Elongation = final length - original length x 100

original length

%Elongation = 2.6 - 2.0 x 100 = 30%

2.0
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Percent Reduction of Area

Original area = 0.2 in.2
Final area = 0.1 in. 2
%Reduction of area (%RA) = ?
%RA = original area - final area x 100
original area

%RA = 0.2 - 0.1 x 100 = 50%

A m e0.2
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Hardness Tests
Brinell

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Hardness Tests
Rockwell

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Hardness Tests
Microhardness

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Hardness Testing Steps

 Preparesurface
 Make indentation
 ‘Measure’ indentation
 Determine hardness

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Toughness Testing
 Impact testing a- pendulum b- drop weight
* charpy and Izod
 Notch toughness
 Transition temperature

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Charpy Test
 Prepare notched specimens (sets of 3)
 Test each specimen set at a specific
temperature
 Impact sample
 Plot results

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Charpy Specimens

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Typical
Charpy
Testing
Machine

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Charpy Test Results

 Energy absorption - Ft. lbs.
 Percent shear - %
 Lateral expansion - Mils

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Transition
Temperature
Determinations

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Transition Temperature Samples

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Soundness Testing
 Bend testing
 Nick-break
 Fillet break

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Transverse Weld Bend Specimens

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Bend Test Samples
Longitudinal Weld Bend Specimens

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Guided Bend Test Jig

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Wrap-around
Bend Test Jig

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Bend Test Procedure

 Prepare sample
 Orient in jig
 Bend sample (weld and HAZ in bend)
 Evaluate bend to Code

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Nick Break Test

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Evaluation of Nick-Break Test

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Fillet Break Test

 Prepare sample
 Break sample
 Evaluate fracture

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Fillet Break - Sample Fracture

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Fillet Break Specimen - T-Joint

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Fatigue Testing
 Prepare samples
 Test series of various loads
 Test to failure, record cycles
 Test at maximum load vs no failure
 Plot data
 Determine endurance limit

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Chemical Testing
Determines Chemistry of Metals
 Spectrographic
 Combustion (CO, CO2 determination)
 Wet chemistry (titration)
 X-Ray fluorescence (XRF)

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Corrosion Testing

“Evaluates metals in corrosive environments”

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Metallographic Testing
 Shows structure of metal
 Macroscopic - less than 10X
 Microscopic - typically more than 100X

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Photomacrograph

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Photomicrograph

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Heat Treatment - 1 of 3
 Mechanical properties are often very
dependent upon heat treat condition
 Many types of heat treatment
 Determine heat treat condition prior to
welding on base metal or mech. testing
 Consider effects of welding on heat treat
condition and mechanical properties

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Heat Treatment - 2 of 3
Heat Treatments For Steels:
 Preheating
 Stress Relieving
 Normalizing
 Annealing
 Quenching and Tempering
 Others

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Heat Treatment - 3 of 3
Heat Treatments For Stainless Steels:
 Preheating
 Stress Relieving
 Solution Annealing, Water Quench
(Solution Treatment)
 Quenching and Tempering
 Others
More on heat treating in Module 8
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