National Institute of Technology Karnataka, Surathkal

Department of Metallurgical and Materials Engineering

Testing of Materials Lab

IV Sem BTech, Code: MT299

CYCLE-2

Group D Instructors

Mohit Gupta (15MT22) Subray R. Hegde

Nikhil Shanta Naik (15MT24)
Udaya Bhat. K
Nitya Singh (15MT25)
Pattipati Yeswanth (15MT27)
Poorvi (15MT28)
Prajwal (15MT29)

2017

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 CYCLE II

Contents

Serial No. Experiment Page No.

4. Impact Test 3

5. Cupping Test & Spark Test 6

6. Non-Destructive Tests (NDT) 11

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 4. IMPACT TEST
4.1 Objective
To generate ductile to brittle transition temperature (DBTT) curve for mild steel sample using a
Charpy impact tester.

4.2 Equipment and Materials

Charpy impact tester, ice, Common salt, flasks, furnace, mercury thermometer, Charpy impact
o
testing specimens (Bar of 10 x 10mm size, 45 V-notch of 2mm depth, 0.25mm root radius)

4.3Procedure
 Fix the hammer at its maximum height on the impact testing machine and set the pointer
to its maximum value (300J).
o
 Maintain the furnace temperature at 500 C and boil water and keep a specimen in it.
o
 Prepare a salt and ice mixture in a beaker and keep a specimen in it to get 0 C.
 Without loss of time, remove the specimen from the furnace/beaker, keep it on the impact
tester such that notch faces away from the hammer and break it by releasing the hammer.
 Note down the energy absorbed from the calibrated dial on the tester.
o o o o
 Repeat the experiment with other specimens at 400 C, 300 C, 200 C, 100 C and
o o
room temperature, -5 C, -10 C.

4.4 Experimental Setup

Figure 4.2 Fracture surfaces of Charpy

specimens tested at different temperatures.
Figure 4.1 Charpy impact tester
o o
A) 400 C, B) 500 C

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4.5 Observations
Table 4.1 Measured values of energy absorbed by
the specimen at various temperatures
o
Sl No. Temperature ( C) Energy Absorbed (Joules)
1 500 26
2 400 42
3 300 81
4 200 100
5 100 105
6 30 111
7 0 86
8 -5 84
9 -10 80

120

100
Energy Absorbed (Joules)

80

60

40

20

0
- 0 100 200 300 400 500 600
100 o
Temperature ( C)

Figure 4.3 Ductile to brittle transition curve for mild steel

4.6 Results
o
 Ductile to brittle transition for mild steel takes place below 0 C.
 Mild steel exhibits the phenomenon of blue brittleness in the temperature
o o
range of 230 C to 370 C where impact energy is decreased due to an
accelerated form of strain aging.
 The surface of ductile fractured specimen is dull and fibrous.
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4.7 Conclusions

 The amount of energy required to break a ductile material is greater than that required for
brittle material.

 Tri-axial state of stress, low temperature and high strain rate (rapid rate of loading) are the
basic factors that lead to brittle fracture.
 Mild steel is ductile in normal operating conditions and can be used in structural applications.

4.8 References
 Dieter G.E. Mechanical Metallurgy, McGraw Hill 1988

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 5. CUPPING TEST & SPARK TEST

5.1 ERICHSEN CUPPING TEST

5.1.1 Objective
To determine the Erichsen cupping number for the given metal sheet specimen
5.1.2 Equipment and Materials
Erichsen cupping equipment, Metal sheet specimens, Vernier calipers

5.1.3 Procedure
 Find the thickness of the metal sheet specimens using vernier calipers.
 Fix the sheet between the dies of the cupping equipment by the use of
blank holding force of 100kgf.
 Start applying the punch load slowly using the wheel handle provided
and observe the increasing pressure in the Bourden gauge.
 Continue the rotation of wheel for application of punch load until the
bottom of the cup formed is cracked. This can be observed from a mirror
fixed opposite to the operator.
 After the cup being formed just starts to crack, the pressure in the Bourden
gauge also starts to decrease. Hence, note down the maximum pressure
attained in the gauge.
 Now, remove the sample from the dies and measure the total depth of
the cup formed using vernier calipers.
 Subtract the initial thickness of the sheet from the total depth of cup to
gives the Erichsen cupping number.

5.1.4 Observations

Figure 5.1 Cupped specimens of Brass, Copper, Galvanised Iron and

Aluminium (clockwise from top left)

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5.1.5 Results
Table 5.1 – Observations and inferences from the cupping test.
Specimen Maximum
pressure applied Initial Total depth of
before the thickness of the cup formed Erichsen Index
cracking of specimen (D mm) (EI = (D-d)mm)
specimen (d mm)
2
( kg/cm )
Brass 290 0.9 10.7 9.8
Copper 180 1.2 8.3 7.1
Galvanised Iron 290 1.0 10.0 9.0
Aluminium 90 1.0 7.2 6.2

5.1.6 Conclusion
The ease of deep drawability of given materials is as follows,
Aluminium > Copper > Galvanised Iron > Brass.

5.1.7 References
http://me.aut.ac.ir/staff/solidmechanics/alizadeh/Erichsen%20Cupping%20Test.htm

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5.2 SPARK TEST
5.2.1 Objective
To conduct spark tests in order to identify the Fe-C alloys (steels and cast irons)

5.2.2 Equipment and Materials

Grinding wheel, A metre scale, Specimens of wrought iron, machine steel, 0.8%C
steel, 1%C steel, cast iron, stainless steel, high speed steel preferably in the form of
rods of atleast 10cm in length.

5.2.3 Procedure
 Switch on the grinding wheel and maintain its speed between 3600-5000rpm.
 Hold on the specimen pressed against the wheel such that the spark stream is at
right angles to the line of vision of operator and is approx. 30cms in length.
 Observe the colour of sparks produced both close to the wheel and near its
end, nature of the sparks, length of the stream, volume of sparks produced.
 Repeat the experiment with other specimens.
 From the characteristics of the sparks produced, identify the material from
the given standard chart.

5.2.4 Standard Chart

Given below are standard charts to recognize the type of Fe-C alloy using spark test.

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5.2.5 Observations
After the spark test, with the standard chart as reference, the specimens were identified.

Table 5.2.1 Characteristics of specimen 1

Color of stream Straw near the wheel,
White near the end.
Stream Volume Large
Spurts Very few in quantity
Forked in nature
Material Identified Wrought Iron
b) Specimen 2

Figure 5.2.1 Spark test of specimen 1

Table 5.2.2 Characteristics of specimen 2

Color of stream Red near the wheel,
Straw near the end.
Stream Volume Small
Spurts Many in quantity
Fine repeating in nature
Material Identified Grey cast iron

Figure 5.2.2 Spark test of specimen 2

Table 5.2.3 Characteristics of specimen 3

Color of stream Red near the wheel,
Straw near the end.
Stream Volume Small
Spurts Very few in quantity
Forked in nature
Material Identified Carbon Tool steel

Figure 5.2.3 Spark test of specimen 3

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 Table 5.2.4 Characteristics of specimen 4
Color of stream White
Stream Volume Medium-Large
Spurts Small in quantity
Fine repeating in nature
Material Identified High Carbon Steel

Figure 5.2.4 Spark test of specimen 4

Table 5.2.5 Characteristics of specimen 5

Color of stream
Stream Volume No sparks
Spurts
Material Identified Aluminium

Figure 5.2.5 Spark test of specimen 5

5.2.6 Results
Hence, this spark test allows us to find out the type of Fe-C alloy when its
characteristic sparks are produced.

5.2.7 References
 http://islandblacksmith.ca/2016/12/testing-reclaimed-steel-for-knife-making/
 http://www.weldingwire.com/Images/Interior/documentlibrary/metal%20id.pdf

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 6. NON-DESTRUCTIVE TESTS (NDT)

6.1Objective
To find surface defects and cracks through dye penetration test and magnetic particle inspection.

6.2 Equipment and Materials

 Dye Penetration Test
Coloured Dye penetrant, Cleaner, Developer, sample to be inspected for
defects, Cleaning cloth, safety gloves
 Magnetic Particle Inspection
Magnetic Probes, Magnetic Powder, Welded part

6.3 Procedure
6.3.1 Dye penetration test
 Clean the surface with a rag cloth and spray a cleaning agent on it and dry the surface.
o
 Apply the liquid penetrant by spraying on to the surface at an angle of 45 .
 Allow sufficient time for the dye to seep into the surface defects.
 Wipe the surface with a clean textile to remove excess residues.

 Apply developer spray at a distance of about 30 cm from the surface. The developer will
absorb the penetrant that infiltrated to the surface features such as cracks, splits.
 Observe the surface for flaws seen as red coloured on the background of the developer.

6.3.2 Magnetic Particle Inspection

 The surface of the specimen will be roughly cleaned by wiping with a piece of textile.
 Magnetic field will be applied with magnetic probes to the location of interest.
 The magnetic powder is poured on the specimen such that it is uniformly distributed.

 Gently tap on the surface to remove excess powder. The magnetic particles will be
accumulated in the cracks and defects of the material.

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6.4 Experimental Setup

Figure
6.1 Figure
Develop 6.2
er, Portaflu
Cleaner x
and (Magnet
Penetran ic
t used in Probe)
Dye used in
Penetran Magneti
t test c
Particle
Inspecti
on

6.5 Observations
Figure 6.3 Surface flaws observed Figure 6.4 Crack detected by magnetic
after dye penetration test particle inspection

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6.6 Results
Table 6.1 Summary of flaws detected during the test
Techniques Flaws Capabilities Limitations
detected
Dye penetrant test 3 Surface flaws No subsurface flaws,
Not for porous material.
Magnetic Particle 1 Surface/ near surface Only for ferromagnetic
Inspection and layer flaws materials. Limited
subsurface capability

 The red stain on the surface indicates that there is a surface defect at that location.
The dye on the other parts is due to insufficient cleaning and not due to defects.

6.7 Conclusions
 Dye penetrant test is more effective in finding small round defects, deeper flaws
and flaws on smooth surfaces.

 Magnetic particle inspection is used for detection of sub surface cracks of

ferrous materials.

6.8 References
 https://www.slideshare.net/ShyamPatel83/material-testing-71745258 accessed on
14.03.2017

 https://eis.hu.edu.jo/upload/38000000/Liquid%20Penetrant%20Testing.pdf
accessed on 14.03.2017
 www.ndt-ed.org accessed on 14.03.2017

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