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Presented By: S.Rajesh Kumar PSG Tech
Presented By: S.Rajesh Kumar PSG Tech
S.Rajesh kumar
PSG TECH
INTRODUCTION
Composite materials are being used in an ever-
increasing variety of products and applications, as
more and more industries realize the benefits that
these materials offer.
As the demands for light-weight composite structures
for aerospace, ground transportation, and
environmentally sustainable energy systems develop,
so do the mechanical testing requirements for
composite materials, components and structures.
TYPES OF TESTING
This Mechanical & Non-Destructive
Testing program explores Both mechanical and non-
destructive tests used to gage the quality of materials
and parts throughout the manufacturing process.
Mechanical tests are used to gather specific
performance or property values of materials for part
design purposes and quality control.
Non-destructive tests examine an object or material in
a manner that does not impair it's future usefulness.
MECHANICAL TESTING
The brinell hardness test,
Rockwell hardness test,
Tensile tests,
Compression tests,
The charpy impact test,
The izod impact test,
Fracture-toughness tests,
Fatigue tests, and
Creep tests.
NON DESTRUCTIVE TESTING
Visual inspection,
Liquid penetrant testing,
Magnetic particle inspection,
Eddy-current testing,
Ultrasonic testing and
Radiographic testing.
TYPES OF DEFECTS
TYPES OF DEFECTS Cont…
MECHANICAL TESTING
BRINELL HARDNESS TESTING
BRINELL HARDNESS TEST Cont…
Brinell hardness is determined by forcing a hard steel
or carbide sphere of a specified diameter under a
specified load into the surface of a material and
measuring the diameter of the indentation left after
the test.
The Brinell hardness number, or simply the Brinell
number, is obtained by dividing the load used, in
kilograms, by the actual surface area of the
indentation, in square millimeters.
The result is a pressure measurement.
BRINELL HARDNESS TEST Cont…
Brinell Hardness Testing Machine is used.
The specimen size used here is a circular rod of length
of 65mm and the diameter of 35mm.
The specifications of the machine are ball intender of
diameter 20mm and the maximum load of 4000N.
The load is usually applied for 10 to 15 seconds
The formula used to determine the BHN of the
specimen is given below,
BHN = P/A
BRINELL HARDNESS TEST Cont…
where
BHN = the Brinell hardness number
F = the imposed load in kg
D = the diameter of the spherical indenter in mm
Di = diameter of the resulting indenter impression
in mm
BHN is usually quoted as a range of values (e.g. 210 to
245, or 210-245)
TENSILE TESTING
ASTM D3039 tensile testing is used to measure the
force required to break a polymer composite specimen
and the extent to which the specimen stretches or
elongates to that breaking point.
Tensile tests produce a stress-strain diagram, which is
used to determine tensile modulus.
SPECIMEN SIZE
The most common specimen for ASTM D3039 is a
constant rectangular cross section, 25 mm (1 in) wide
and 250 mm (10 mm) long.
TENSILE TESTING Cont…
TESTING PROCEDURE:
Specimens are placed in the grips of a Universal Test
Machine at a specified grip separation and pulled until
failure.
For ASTM D3039 the test speed can be determined by
the material specification or time to failure (1 to 10
minutes).
A typical test speed for standard test specimens is 2
mm/min (0.05 in/min).
An extensometer or strain gauge is used to determine
elongation and tensile modulus.
TENSILE TESTING INSTRUMENT
COMPRESSIVE STRENGTH
COMPRESSIVE PROPERTIES ASTM D6641
This test method determines compressive properties
of polymer composite materials by applying combined
end-loading and shear-loading using a combined
loading compression (CLC) fixture.
ASTM D6641 is designed for polymer matrix
composite laminates which contain at least one 0˚ ply,
but other materials can also be tested.
The test fixture is designed to provide a combined
loading to the unsupported center 12 mm (0.5 inch)
gauge length of the specimen.
COMPRESSIVE STRENGTH Cont….
TESTING PROCEDURE
The test specimen is inserted into the two halves of the
test fixture so that the ends of the specimen are flush
with the top and bottom of the test fixture, and the
bolts in the fixture are tightened to a specified torque
to capture the test specimen.
The fixture is placed between the platens of a
Universal Testing Machine, and if a strain measuring
device is being used, it is attached to the specimen.
The specimen is compressed to failure.
COMPRESSION TESTING
INSTRUMENT
CHARPY IMPACT TEST
For a typical fiber reinforced polymer Charpy
specimen, L = 126 ± 1 mm, D = 12.7 ± 0.15 mm, and 3.00
mm < w < 12.7 mm.
The specimen is then placed in a vacuum to remove
excess resin, and allowed to cure (with or without
external pressure and heat).
The resultant plate can then be cut into small
rectangles which will be used as Charpy impact
specimens.
The final step is to cut the notch into the specimen.
CHARPY IMPACT TEST Cont…
CHARPY IMPACT TEST Cont…
The specimen that fits into the Charpy impact tester is
rectangular with a notch cut in one side.
The notch allows for a predetermined crack initiation
location.
CHARPY IMPACT TEST Cont…
TESTING PROCEDURE
The Charpy impact test method works by placing a
notched specimen (with the notch facing away from
the point of contact) into a large machine with a
pendulum of a known weight.
The pendulum is raised to a known height and allowed
to fall.
As the pendulum swings, it impacts and breaks the
specimen, rising to a measured height.
CHARPY IMPACT TEST Cont…
CHARPY IMPACT TEST Cont…
The difference in the initial and final heights is directly
proportional to the amount of energy lost due to fracturing
the specimen.
The total energy of fracture is determined by
where
total is the total energy,
m is the mass,
g is gravitational acceleration,
ho is the original height, and
hf is the final height.
PICTURE OF FAILED COMPOSITES
CHARPY IMPACT TEST Cont…
Specimens were tested with lay-up angles of 0, 10, 22.5,
30, 45, 67.5, and 90 degrees.
It is possible to see that specimen 1 failed from fiber
breakage and pull-out.
Specimen 2 failed from a combination of fiber pull-out
and fiber-matrix separation.
Specimens 3-7 failed at the fiber-matrix interface.
Composites therefore may need to be tested in different
fiber directions due to the anisotropy of the material.
The failure type is important when characterizing
composites.
FRACTURE TOUGHNESS TEST
Fracture toughness by using a mixed-mode bending test.
Understand susceptibility to delamination by determining the
interlaminar fracture toughness of a polymer composite with an
initiated delamination.
SCOPE