MODULE-6

MATERIALS AND HARDWARES

CAR66 Ref::M 6.1

DURATION : 15 HRS

Aim of the Exercise : Identification of Ferrous Metals. (Spark Test)

Tools/Equipment Required: Grinding Machine , Steel Samples, Protective

Goggles , Spark analysis/ Comparison Diagram.

Safety precaution:
1..All observers should be kept at a safe distance away from the work area.

2.Be sure to keep good footing and maintain good balance.

3..The proper apparel should be worn. Loose clothing, ties, or jewelry can become
caught in moving parts.

4. Gloves and safety footwear are recommended during use of electric tools.

5. use proper eye protection.

Procedure:

1. Place all the materials to be tested on a safe place,

2. Switch on the bench grinder machine.
3. Firmly hold the metals to be tested with a proper gripping tools.
4. Bring the metal to be tested near the grinder with a required pressure.
5. The spark testing should be done carefully so that the metal piece
should not get loosened while carrying out spark testing.
Step:1 Spark testing is a common means of identifying various ferrous metals. In
this test the piece of iron or steel is held against a revolving grinding stone and the
metal is identified by the sparks thrown off. Each ferrous metal has its own
peculiar spark characteristics. The spark streams vary from a few tiny shafts to a
shower of sparks several feet in length.
Step:2 Wrought iron produces long shafts that are straw colored as they leave the
stone and white at the end.

Step:3 Cast iron sparks are red as they leave the stone and turn to a straw color.

Step:4 Low carbon steels give off long, straight shafts having a few white sprigs. As
the carbon content of the steel increases, the number of sprigs along each shaft
increases and the stream becomes whiter in color.

Step:5 Nickel steel causes the spark stream to contain small white blocks of light
With in the main burst.

Drawing/Diagram
 Aim of the Exercise : Familirisation of Testing of ferrous metals

Tools/Equipment Required:

1.Breinell hardness tester

2.Rockwell hardness tester

3.Charpy tester

4.Tensile testing machine

5.Compression tester

6.Torsion tester
7.Operating manuals for various testing machine

8.Test specimen

Procedure:
HARDNESS TESTING

a. Brinell Hardness

- Pressing a hardened steel ball under a known pressure, into a flat

surface of the specimen to be tested.
- For testing steel a ball of 10 mm in dia under a pressure of 3000kg is
used.
- For softer metal like Al and bronze 500 kg load is used.
- The load should be applied for at least 10 second before release.
- The area of impression made by the ball is measured by a calibrated
microscope that read accurately to 0.05mm.
- The brinell no is the load in kg divided by the area of spherical surface
of the impression in square mm.

1.In the Brinell hardness test, an optical method, the size of indentation left
by the indenter is measured. In contrast to the likewise optical Vickers
method,which involves a pyramid-shaped indenter being pressed into a
specimen, the Brinell method uses a spherical indenter.

2.The larger the indent left in the surface of a workpiece (specimen) by the
Brinell indenter with a defined ball diameter and a defined test force, the
softer the tested material.

3.In order to determine the Brinell hardness (HBW) according to ISO 6506,
the spherical, hard metal (tungsten carbide) indenter is pressed into a
specimen (workpiece) with a defined test load (between 1 kgf and 3000 kgf).

4.The Brinell hardness (HBW) results from the quotient of the applied test
force (F in newtons (N)) and the surface area of the residual indent on the
specimen (the projection of the indent) after withdrawing the test force (see
formula below). To calculate the surface area of the residual spherical
indentation, the arithmetic mean (d) of the two perpendicular diagonals
(d1 and d2 in mm) is used, because the base area of Brinell indents is
frequently not exactly round.

4.Brinell hardness (HB) testing shall be performed in accordance with the latest revision of
ASTM E10. Deviations to this procedure are permissible so long as the client
requests an alternative method or procedure. Alternative methods or
procedures shall be noted on the Lab worksheet.

5.Brinell testing is done with the calibrated Brinell machine that applies a
predetermined indenting load to a ball in contact with the specimen. The
ball is a 10 mm ball used to apply load of 3000, 1000, or 500 kgf depending
on the material for 10 to 15 seconds.

6.Calibration of Brinell tester shall be done prior to any test run for the day.
Each block for calibration will have NIST traceability. The full load shall be
applied for a full 15 seconds during the calibration process.
7.The specimen submitted for testing should be flat and parallel. The
thickness should be that no bulge or other marking showing the effect of the
load appears on the side of the piece opposite the impression. The surface of
specimen shall be filed, ground, machined or polished so that the edge of
the impression shall be clearly enough defined to permit measurement of
the diameter.

8.Place the test piece on the base of the Wilson Brinell tester.  Raise the
sample to bring in contact with the 10mm ball, apply the specified load and
hold for 10 to 15 seconds.  Release load, remove test piece and measure the
impression with the B & L 20X scope to the nearest .5mm.  Use the Brinell
hardness number table on ASTM E10 to find the proper Brinell value
according to the load used.  When permissible report an average of 3
readings.  Report the Brinell hardness number, load used and ball size.

Test Method Illustration 

D = Ball diameter 
d = impression diameter 
F = load 
HB = Brinell result 

b.Rockwell Hardness

- It is determined by measuring the penetration of a diamond cone or

hardness steel ball under definite load.

- First applied a minor load of 10 kg, the direct reading dial is set to
zero, and the major load is applied.

- The force that penetrates into the metal and after removal of load, the
Rockwell hardness can be read from the dial.
c. Charpy impact Testing

The test consist of breaking by one below from a swinging pendulum, under
conditions defines by standards, a test piece notched in the middle and
supported at each end.

The energy absorbed is determined in joules.

This absorbed energy is a measure of the impact strength of a material.

The test bar, notched in the center, is located on two supports.

The hammer will fracture the test bar and the absorbed energy is an indication
for the resistance of material to shock loads

d. Tensile Testing

Objective:

Tension test is carried out to obtain the stress strain diagram, to determine the
tensile properties and hence to get valuable information about the mechanical
behavior and the engineering performance of the material.

Before the test:

1.put gage marks on the specimen

2.Measure the initial gage length and diameter

3.Select a load scale to deform and fracture the specimen. Note that tensile
strength of the material used has to be known approximately.

During the test:

1.Record the maximum load

2.Conduct the test until fracture

After the test:

1.Measure the final gage length and diameter should be measured from the
neck

e. Compression Testing

Procedure
 The original dimensions of the specimen like original diameter,
gauge length etc. is to be measured.

 The specimen is mounted on the Universal Testing machine

between the fixed and movable jaws.

 The load range in the machine is adjusted to its maximum capacity

 The dial gauge is mounted on the machine at the appropriate

positions and adjusted to zero.

 The machine is switched on and the compression load is applied

gradually.

 For every 5 KN of load, the readings of dial gauge is noted and

tabulated.

 Remove the dial gauge at slightly below the expected load at yield
point.

 Record the load at yield point, at the yield point the pointer on load
scale will remain stationary for small interval of time and blue needle
will come back by 2 or 3 divisions that point is lower yield point.

 The specimen is loaded continuously up to the ultimate load (red

needle will stops) where there is formation of cup and cone at neck
in the specimen, which is to be noted.

 With further loading the specimen breaks, and breaking load is

noted.

 The specimen is removed and final dimensions are measured.

f. Torsion test

1. Measure the overall length and test diameter of the specimen.

2. Draw a line down the length of the test section of the specimen with a pencil
this serves as a visual aid to the degree of twist being put on the specimen
during loading.
3. Mount the specimen firmly in the torsion testing machine as indicated in the
operating instructions.

For each increment of strain record the following:

1. angle of twist of the specimen in degrees

2.Applied torque(T)

3. Angle of twist over the 50 mm (or 2.0 in )gauge length in radians, as

recorded by dial gauge indicator radians.

4.when the elastic limit has been passed, continue to test destruction with
increasing increments of strain, recording for each strain increment,

(1)Angle of twist in degrees;

(2)Applied torque

Checked by: Verified by

Practical assessor Chief Practical Assessor