UNIVERSITY OF ENGINEERING & TECNOLOGY, LAHORE.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF MATERIAL TESTING

PRESENTED TO SIR SYED SAQIB GROUP MEMBERS
MADNI IJAZ GHULAM AHMAD MUZAMMIL ARIF AHMAD SHAIKH 2009-ME-154 2009-ME-190 2009-ME-192 2009-ME-170

OUTLINE
WHAT IS MATERIAL TESTING? WHY ARE MATERIALS TESTED? TYPES OF MATERIAL TESTING DESTRUCTIVE TESTING NON-DISTRUCTIVE TESTING ADVANTAGES AND DISADVANTAGES

WHAT IS MATERIAL TESTING?

MATERIALS ARE TESTED FOR:

PYSICAL PROPERTIES CHEMICAL PROPERTIES MAGNETIC PROPERTIES ELECTRICAL PROPERTIES

TESTING FOR PHYSICAL & CHEMICAL PROPERTIES:

WHY ARE MATERIALS TESTED?

OPTIMIZE COST & PERFORMANCE ENSURE QUALITY PREVENT FAILURE IN USE MAKE INFORMED CHOICES IN USING MATERIALS

PHASES OF MATERIAL TESTING

BEFORE THE MANUFACTURING PROCESS

DURING THE WORKING CYCLE OF THE COMPONENT

DESTRUCTIVE TESTING
It is used to determine the material properties and the behaviour under loading until failure.

TYPES
Tensile Test. Impact Test. Hardness Test.

Tensile Test
Tensile testing, also known as tension testing, is a fundamental materials science test in which a sample is subjected to uniaxial tension until failure. Youngs modulus, poisons ratio, yield strength, strain hardening can be determined. Apparatus such as hounsfield tensometer is used. Stress strain curve is plotted.

Impact Testing
Impact testing is testing an object's ability to resist highrate loading Measure of service life. Ductile materials need more energy to initate the crack. Brittle materials are less tough.

Hardness Testing
Hardness is resistance upto plastic deformation. Rockwell Hardness Test. Brinell Hardness Test. Vickers Hardness Test.

Hardness Test

Non Destructive Testing

It is a techniques used in science and industry to evaluate the properties of a material, without causing damage.

Six Most Common NDT Methods Visual Inspection

Dye Penetrant Inspection Magnetic Inspection Ultrasonic Inspection Eddy Current Inspection X-ray Inspection

Visual Inspection
Most basic and common inspection method. Human eye. Optical aid such as mirrors, magnifying glass and microscopes. Tools include fiberscope, borescopes.

Visual Inspection
Portable video inspection units are also used. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines Independant of size and shape.

Advantages and Disadvantages

Simple and easy to use. Inexpensive. Inspector skill is required. Limited to detection of surface flaws only.

Dye Penetrant Inspections

Used to detect surface defect in metal or other non porous material. STEPS:

1. PRE-CLEANING:
Cleaning preparation is very important on this method. Usually solvent removal is been used

2. APPLICATION OF PENETRANT:
Brightly coloured dyes or flourescent material. Dipping ,Spraying or Brushing . Capillary action.

Dye Penetrant Inspections

3. EXCESS PENETRANT REMOVAL:
Wiping, water wash or solvent.

4. APPLICATION OF DEVELOPER:
Contrasting background.

5. INSPECTION:
Ultraviolet light or radioactive material.

6. POST CLEANING:
Solvent, water To prevent corrosion.

7. LIMITATION:
Only limited to detect surface defects.

DPI

Magnetic Particle Inspection

Magnetizing of the part to be inspected Application of the finely milled iron particles Accumulation of the iron particles. Photographs and videotapes can be used to save the record.

Magnetic Particle Inspection

Electromagnet (yolk) DC or AC Collection of ink particles due to leakage field

Prods DC or AC

Crack like indicatio n

Crack like indicatio n

Magnetic Particle Crack Indications

Advantages
Simple and fast. Low cost Surface and subsurface cracks. Portable inspection method. Independent of size and geometry.

Disadvantages
Cannot inspect non-ferrous materials. Performed on ferromagnetic materials. Post cleaning, and post demagnetization. High current source.

Ultrasonic Inspection Uses high frequency sound

typically 2MHz

Pulsed oscillator and transducer:

Piezo electric crystal to transmit and receive ultrasonic pulses

Acoustic coupling medium:

Air is not good conductor of ultrasonic waves so a medium is required to transmit waves

Receiving transducer:
Receives the signal back

Ultrasonic Inspection
Pulse echo signals A scan Display

probe

Ultrasonic Inspection
Amplifies, filter and processes the signal. Comparison of both signal.

Radiographic (X-ray) testing:

Inspecting materials for hidden flaws. Pre visual inspection. Specimen is placed between source and the screen. Costly method. Operator skills required.

Eddy current testing is particularly well suited for detecting surface cracks

EDDY CURRENT TESTING

Eddy Current Testing

PRINCIPLE:
Changing magnetic field due to the eddy current.

Advantage:
Can detect both surface and near surface irregularities. Applicable to both ferrous and non ferrous metals. High speed and low cost test. No final cleanup is required.

Limitation:
Only applicable to conductive material. Depth of penetration is limited. Constant distance between coils and specimen is required

Acoustic Emission Testing

Principle:
Material emit high frequency sound when stressed.

Advantages:
Entire structure can be monitored. Defects in inacessible to other methods can be detected. Inspection can be in harsh environment.

Acoustic Emission Testing

LIMITATION:
growing or active flaws can be detected. Background signals may cause difficulty. No indication of size and shape of the flaw. Require sound transmitting path between sound and the detector

Some other non destructive tests

Leak Testing. Thermal Methods. Advanced Optical Method. Resistivity Methods.

Advantages and Disadvantages of Destructive and Non-Destructive Testing:

Advantages of Destructive Testing:

Provides reliable measurement of how material will act under service conditions Provides quantitative results Mediocre skill level for operator is acceptable Determines quality of welds Ensures compliance with regulations

Disadvantages of Destructive Testing:

Applied only to sample Tested parts are destroyed during tests New part is required for different test Cannot be used for costly and few-in-number parts Combined effect of different tests is hard to predict Hard to be applied on in use parts Extensive machining is required High capital is required for machining and labor

Advantages of Nondestructive Testing:

Not affected by cost and quantity of parts Can be performed on 100% of the production lot Different tests can be applied on the same items Can be done on parts that are in service Test equipment is portable Low labor cost

Disadvantages of Nondestructive Testing:

Results require interpretation by skilled worker Different observers may interpret results differently Misinterpretation of scratches Results are comparative or qualitative not quantitative Some test equipments require a large initial investment Complex set ups required