Material Science and Testing Lab

Experiment No. 1
Aim : To compare the Charpy Toughness of the specimen Before and after Heat Treatment. Impact Testing Machine, Muffle furnace. Toughness, Impact test methods, stress concentration, stress riser, Notch Sensitivity, Fracture.

Apparatus : Theory :

Procedure : 1. Place the specimen on the supports or anvil so that the blow of hammer be opposite to the V-notch for Charpy test . 2. Rise the pendulum to the standard height (H) and make the loose pointer in contact with the fixed pointer. 3. Release the pendulum which will strike the specimen through its momentum. 4. Stop the pendulum and note down the reading as indicated by the loose pointer on the scale (h). 5. Stop the hammer by applying brake.

Observation:

Type of heat treatment done:

Before Heat Treatment:
Specimen No. UI = Energy loss (H-h) without specimen Energy Us (H-h) with Specimen Nett energy Un = ( Us-Ui) Mean Energy Jouls

1. 2.

After Heat Treatment:

Specimen No. UI = Energy loss (H-h) without specimen Energy Us (H-h) with Specimen Nett energy Un = ( Us-Ui) Mean Energy Jouls

1. 2. Result: Charpy toughness before heat treatment:... Charpy toughness after heat treatment:.. Conclusion: Precautions: 1. Nobody should stand within the range of swing of the pendulum. 2. Release the pendulum lever carefully. 3. Specimen should be placed carefully, considering the correct position of the Vnotch. 4. Pendulum brakes should not be applied while the pendulum is returning. 5. Adjust the loose pointer in contact with the fixed pointer after setting the pendulum. Viva Questions : 1. What is meant by toughness? 2. What is the purpose of V-notch in impact testing and what is its dimension? 3. What is resilience? 4. How does tempering changes the toughness of a material? 5. Define Notch Impact Strength & Modulus of Rupture. 6. Differentiate between Izod & Charpy impact testing techniques?

Material Science and Testing Lab

Experiment No. 2
Aim : Hardness testing of given specimen using Brinell Hardness testing machine.

Apparatus :Brinell hardness testing machine , Ball indenter, Brinell Microscope, Tongs, Muffle furnace. : Hardness, BHN, indenter, Hardness test types.

Theory

Procedure : 1. Select the ball Indenter and fix the indenter into the indenter holder. 2. Place the specimen on the anvil. By rotating the hand wheel raise the anvil so that the testing specimen touches the indenter. 3. Press the specimen against indenter for the small movement of the needle, in this position the minor load is applied. 4. Select the Load to be applied. 5. The major load is applied slowly by the movement of the lever. 6. Slowly move back the lever and rotate the anvil in opposite direction in order to lower the anvil in down ward direction. 7. Measure the diameter of the dent or impression on the specimen d by Brinell Microscope. 8. Calculate the hardness number.

Observation and Tabular Column: Type of heat treatment done: BHN = 2P ------------------------ D ( D - (D - d )) Where, P = Load applied D = Diameter of the ball d = Diameter of the indentation or impression. Observation table: S.NO 1. 2. 3. 4. 5. Load applied ( kg.) Dia of the Ball (mm) Dia of the indentation ( mm) BHN Remarks

Result: BHN of the specimen:

Conclusion:

Precautions: 1. Apply the minor load carefully. 2. Release the lever gently while applying the major load. 3. Observation should be made at a sufficient distance from previous indentation. 4. Handle the Brinnel microscope carefully. 5. Care must be taken to set the anvil and indenter firmly.

Viva Questions: 1. List different types of hardness testing methods? 2. What is meant by BHN? 3. Differentiate between hardenability and hardness? 4. What are the different types of indenters used in hardness testing? 5. What are the factors which effect the hardness of steels? 6. Why is the minor load applied before applying the major load? 7. Derive the formula to calculate BHN.

Material Science and Testing Lab

Experiment No. 3
Aim : To find the value of E for a simply supported beam subjected to point load due to deflection. Supporting stand, mirror stand, scale, beam, weight. Beam, Bending moment equation, center of gravity, Youngs Modulus. Place the beam on the support as a simply supported, check for its straightness. Select the loading point on the beam, place the load. By using mirror measure the deflection of the beam at that point. Measure the distance of load acting point. Repeat the procedure for different beam, different load and for different position of load.

Apparatus : Theory :

Procedure :1. 2. 3. 4. 5.

Observation and Tabular column. W = weight on the beam a = distance measured from first support = ______________kg = ___________ mm

b = distance measured from second support = ___________ mm I = moment of inertia of the beam y = deflection at the point of loading L = length of beam E = Youngs Modulus
=

= ____________ mm 4 = ___________ mm = ____________ mm W. a b

_______________

= _________ Kg / mm2

3. I. y. L

Trial no: 1 Type of Sl.no. Beam Square 1. beam Square 2. beam Rectangular 3. beam Rectangular 4. beam Wooden 5. beam Wooden 6. beam Load (Kg) a (mm) b (mm) Deflection y (mm) Youngs modulus E1

Trial no: 2 Type of Sl.no. Beam Square 1. beam Square 2. beam Rectangular 3. beam Rectangular 4. beam Wooden 5. beam Wooden 6. beam Load (Kg) a (mm) b (mm) Deflection y (mm) Youngs modulus E2

Trial no: 3 Type of Sl.no. Beam Square 1. beam Square 2. beam Rectangular 3. beam Rectangular 4. beam Wooden 5. beam Wooden 6. beam Load (Kg) a (mm) b (mm) Deflection y (mm) Youngs modulus E3

Result: Average Youngs Modulus of the square beam = E1+ E2+ E3

-----------------------------=

Kg/mm2

Average Youngs Modulus of the Rectangular beam =

E1+ E2+ E3
---------------------------- =

Kg/mm2

Average Youngs Modulus of the Wooden beam

=
____

E1+ E2+ E3
---------------------

Kg/mm2

Conclusion: Precautions: 1. While taking the readings in the mirror, the needle pointer should coincide with its image in the mirror. 2. The supports of the beam should be leveled before taking the readings. 3. The load should be applied carefully.

Viva Questions : 1. What is Youngs Modulus? 2. What is meant by Moment of Inertia? 3. How to find out the least count of vernier caliper. 4. What is the effect of temperature on Youngs Modulus? 5. How will you define a beam? 6. What is the difference between a simple supported beam & cantilever beam? 7. What is the formula used to calculate the Moment of Inertia of a Square section beam; Rectangular section beam and a circular beam about the axis. 8. What is meant by Polar Moment of Inertia & how is it calculated? 9. Derive the relationship between Youngs Modulus, Modulus of Rigidity & Bulk Modulus. 10. Describe different types of loads on beam with the help of sketches.

Material Science and Testing Lab

Experiment No. 4

Aim

: To find the strength of the given specimen of mild steel on UTM with full details. UTM, Dial gauge, vernier caliper. Stress, strain, True stress, True strain, Fracture.

Apparatus : :

Theory

Procedure : 1. 2. 3. 4. 5. 6. 7. 8. 9. Measure the original gauge length and diameter of the specimen. Set up the UTM machine for conducting Tensile test. Fix the specimen ends in the upper and lower jaw of the UTM platen. Gradually apply load and for each equal increment of the load note down the corresponding dial gauge reading. After taking eight to ten reading, remove the dial gauge. Test is carried out till failure of the specimen. Remove the specimen from the jaw. Measure the fracture length and diameter of the specimen. Draw Stress vs Strain graph.

Observation and calculation. Lo = original gauge length. Lf = fracture length Do = original diameter of the specimen Df = diameter at the point of fracture Ao = original cross sectional area Af = cross sectional area at the point of Fracture Percentage Elongation % EL = = .mm = ..mm = .mm = ..mm = . ..mm2 = ..mm2

Lf - Lo = Lo Ao - Af Ao

X 100 = X 100 =
Strain g / Lo

Percentage Reduction in Area % RA =

S. N.

Load (kgf)

Stress (kgf/mm2)

Dial gauge reading (g mm)

1 2 3 4 5 6 7 8 9 10

Result:

Ultimate Tensile Strength:.. Percentage Elongation: Percentage Reduction in Area: .. Conclusion:

Precautions: 1. The specimen should be prepared in uniform cross-sectional area. 2. Load should be applied gradually. 3. The test specimen should be free from stress raisers like scratch marks in the gauge length portion. 4. The specimen should be fixed firmly in the vise on the UTM. 5. The readings for stress and strain should be taken simultaneously, during the test. 6. The dial indicator should be fixed firmly on the moving arm of the UTM and the indicator needle should be set to zero before starting the experiment.

Viva Questions: 1. Differentiate between Engineering Stress/Strain and True Stress/Strain. 2. What is meant by Plastic & Elastic Deformation? 3. Define Upper Yield Point; Lower Yield Point; Ultimate Strength; Fracture Strength. 4. What is meant by Gauge Length. 5. What are the various types of fractures? 6. Differentiate between Brittleness and ductility? 7. Define the term Malleability? 8. What is Strain hardening?

Material Science and Testing Lab

Experiment No. 5
Aim: Preparation of specimen for micro structural examination Cutting, Grinding & Rough (dry) Polishing. Apparatus: Cutting saw/hand saw, grinding machine, dry belt grinder, four grades of emery papers, MS specimen. Theory: Grain boundaries are not visible in an ordinary piece of metal owing to deformed layer or corroded surface. Their removal is essential for preparation of the specimen to be viewed under a microscope. Therefore, grinding (rough and fine), polishing and etching are done on them . Rough polishing (dry polishing) is done by abrasive papers having silicon carbide (SiC) powder bonded to it. Abrasive grades of 320, 400, 600 grits and particle sizes of 33, 23, 17 microns are generally used. Test Set-up and Specifications of Machines: The experiment is carried out on a series of machines which are: Cut-off machine: (Fig. 1) This is an open type abrasive cut-off machine capable of cutting up to 60 mm, 80 mm, 100 mm round bar and square. It is equipped with a heavy duty vice, coolant circulation system along with a coolant tank and pump. Belt grinder (Fig. 2). This is used for initial rough grinding of specimen. It is mounted with hp, 200 V, 1-phase motor, endless belt of 100 mm width and 915 mm length on dynamically well balanced roller. It is also equipped with a water faucet for intermediate rinsing of specimen to avoid heating and burn formation.

Procedure: The experiment is conducted in the following sequential steps. 1. Cut a cylindrical or square piece of MS of any size between 10 mm to 25 mm diameter/side as specimen. 2. Do its grinding on grinding machine . 3. Do its fine grinding on dry belt grinder. Continue grinding till the major scratches disappear. 4. Do the rough polishing by placing emery papers on a flat surface and moving the specimen along it in one direction. 5. Emery papers of various grades are used step wise, starting from the coarser one to the finer one. 6. Rough polishing is to be done in one direction, and the specimen has to be rotated by 90 when changing from one grade of emery paper to the next.

Observations:

1. Grade and size of Emery Papers used:

S. No. 1. Emery Paper 1 Emery Paper 2 Emery Paper 3 Emery Paper 4

Particles size (microns) Emery paper (grade)

2.

Precautions: 1. Work carefully on cut-off machine & dry belt grinder. 2. Keep the emery paper on a flat surface, and do the polishing in one direction, holding the specimen firmly. 3. Rotate the specimen by 90, while changing from one grade of emery paper to another. 4. Polish the specimen on the emery paper until all the scratch marks are predominant in the direction of polishing.

Viva Questions: 1. What are the specifications of grinding and polishing machines? 2. What is lapping? Which degree of accuracy can be achieved in metals by polishing? 3. Why is grinding performed before polishing? 4. What is the need of polishing on four grades of emery paper? 5. Why is the specimen rotated by 90, while changing from one grade of emery paper to another? 6. Why is dry polishing done before wet polishing?

Material Science and Testing Lab

Experiment No. 6

Aim:

Grain size determination of a given specimen. A polished and etched metallic specimen, metallurgical microscope. Materials are composed of crystals (or grains) of various sizes. The grain sizes are specified by ASTM (American Society for Testing of Materials) numbers which specifies the grain sizes in materials from ASTM 1 to ASTM 12 of which ASTM 1 to ASTM 8 are the normal range in metals. The number of grains N observed in an area of one square inch (645 mm2) on a micrograph at a magnification of 100X is given by N = 2(n-1), where n is the ASTM number of the grain size. Based on their sizes, the grains are called coarse grain (for ASTM 3 or less), medium grain (for ASTM 4 to 6), fine grain (for ASTM 7 to 9) and ultrafine grain (for ASTM 10 or more). The grain size affects various properties of materials as given below:

Apparatus:

Theory:

Fine Property Ductility Yield Strength Hardness Resilience Toughness Tensile Strength Fatigue Resistance Surface Finish Corrosion Resistance Creep Resistance Hardenability Machinability Strain Hardening grained structure more more more more more more more more less less less less more

Coarse grained structure less less less less less less less less more more more more less

Procedure: 1. Take a thoroughly polished and etched specimen, and view it through a microscope. 2. View and area of one square inch (i.e. 645 mm2) on a photomicrograph at a magnification of 100X. 3. If the number of observed grains is N, then N=2(n-1) Where n is ASTM number of the grain size. Thus log N n= log 2 +1

Observation: Number of grains observed in one square inch area = ASTM No.(n):.

Viva Questions: 1. What is the effect of grain size on mechanical properties of steel? 2. What are the factors which affect the grain size? 3. How is grain size determined? 4. What is the significance of ASTM no. in grain size determination?

Material Science and Testing Lab

Experiment No. 7
Aim: Comparative study of microstructures of different given specimens (mild steel, gray C.I., brass, copper etc.) Apparatus: Properly polished and etched specimen, metallurgical microscopes of 1500X to 2400X, an air drier (optional) to dry the specimen. Theory: Levels of material structure may be both macro/micro. Whereas the macro structure can be seen with naked eye or with an optical microscope of low magnification, the microstructures can be observed with high magnification metallurgical microscopes. In this experiment one can visualize the crystals, grain boundaries and solid solution phases in the material. In steel and gray C.I. different microstructures can be seen, these are due to presence of carbon in different forms that is ferrite, cementite, pearlite, ludeburite etc. In brass, the two components , copper and zinc can be seen in random mixing. In copper, different solid phases like phase, - phase, - phase and their combination will be visible.

Procedure: 1. Polish and etch the specimen, make it dry. Put it on the microscope base. 2. Make the power supply ON to microscope. Select an appropriate objective lens for vision. 3. Focus the microscope, first by using general knob and then by fine tuning knob. See the surface of specimen through eyepiece lens.

Observation: 1. Sketch the visible structures. Measure their dimensions on horizontal and vertical scales, if provided on microscope. 2. The probable microstructures of some metals and alloys are illustrated in figures below. Find out as to which metals / alloys they belong top: copper, nodular CI and HSS. Precautions: 1. The specimen must be completely dry, otherwise the microstructure will not be clearly visible. 2. Focus the specimen clearly, before drawing the microstructures. 3. Handle the specimens carefully

Viva Questions: 1. Why are microstructures of metals are different from each other? 2. What are the effects of microstructure of steel and CI on their mechanical properties? 3. In which way is the microstructure of copper different from the microstructure of brass? 4. Define Pearlite, Austenite, Ferrite, Cementite, Martensite, Bainite, and Ledeburite. 5. What is the purpose of alloying. Describe few alloys of Copper and Aluminium. 6. How are steels classified based on their alloying (carbon) content? 7. What is Cast Iron? What are its types? 8. What are stainless steels? Give its composition. 9. Discuss in brief, the steel manufacturing process. 10. Discuss the properties and manufacturing process of the following: Composites; Ceramics; Plastics and Glass.