MEng8042 Materials Characterization and Testing

By: Fakada Dabalo Gurmesa

JIMMA UNIVERSITY, JIT

Faculty of Mechanical Engineering

August 7, 2022

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Presentation Outlines
1 Static Mechanical Testing methods
Hardness testing methods and relevant standards
Tensile test methods and standards; Stress-strain relations for different
materials
Torsion test methods and standards
Impact and fracture toughness tests
Codes and standards for testing metallic and composite materials
2 Dynamic Mechanical Testing-Fatigue
Stress cycle and the S-N curve
Low and high cycle fatigue
Fluid Velocity Measuring System
Fatigue tests: LCF and HCF tests, test methods and equipmen
Statistical nature of fatigue and strain-life equations.
3 Creep and stress rupture including examples of testing methods

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1. Static Mechanical Testing methods
a) Review of hardness testing methods and relevant standards
Definition: Hardness is the resistance of a material to permanent
deformation such as indentation, wear, abrasion, scratch.
Theory: Current practice divides hardness testing into two categories:
macro hardness and micro hardness.
1) Macro Hardness Testers (Applied Loads > 1 kg)
Rockwell
Brinell
Vickers
2) Micro Hardness Testers (Applied Loads < 1 kg)
Knoop diamond
Vickers diamond pyramid

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1) Macro-hardness testers (Applied loads > 1 kg)
(a) Rockwell Hardness Tester
Apparatus:
Rockwell hardness testing machine.
Diamond cone indentor, ball indentor.
Specimens (Hardened steel, Mild steel, Brass, Copper, Aluminium)
Indentor used is the cone having an angle of 120 degrees made of black
diamond.
The principle of Rockwell hardness test has to do with the application of
a standard load (Based on the type of material) through a standard
indentor (cone or ball indentor) for a standard duration of time.
Suitable Application:
- Rockwell hardness test is generally used for larger sample geometries.
- It is a ’quick test’ mainly used for metallic materials.
- It can also be used for advanced tests, such as the Jominy (end quench)
test (HRC).
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Rockwell hardness testing machine

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Brinell hardness testing machine
Apparatus:
Brinell hardness testing machine and Brinell Microscope.
Ball Indentor of diameter 2.5mm and 5mm
Specimens (Mild steel, Brass, Copper, Aluminum)
Theory: The Brinell Hardness Test is used to determine the Hardness
Number of hard, moderately hard, and soft material E.g.: Brass, Bronze,
Aluminum, Gold, and Copper.

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Brinell hardness testing machine Contd

Very hard material and Brittle material cannot be tested by Brinell

hardness tester.
Brinell hardness number (BHN) is obtained by the ratio of the calculated
load and the spherical area of the Indentation or Impression made on the
specimen by the corresponding Indentor Ball.
In Brinell hardness test, a steel ball of diameter (D) is forced under a
load (F) on to a surface of the test specimen.
Mean diameter (d) of indentation is measured after the removal of the
load (P).
The Brinell Hardness Number (BHN) is obtained by dividing the applied
force P, in kg-F; by the curved surface area of the indentation, which is
actually a segment of a sphere.

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Brinell hardness testing machine

UTS (in MPa) = 3.45 x BHN

Suitable Application:
Brinell hardness test is used for materials with a coarse or
inhomogeneous grain structure.
It is used for larger samples and also suitable for forgings and castings
where the structural elements are large.
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Brinell hardness testing machine Contd

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Vickers Hardness Testing
Apparatus:
Vickers Hardness Testing Machine.
Diamond cone indentor,
Specimen
Theory:
Very Hard materials (e.g. Mild steel, case hardened steel, etc,) can be
tested by the Vickers’ method.
If the moderately hard materials like Brass, Copper and Aluminum are
tested in this machine, the indentor makes a deep impression.
A proper indentation cannot be made on the specimen and correct value
of the hardness cannot be obtained for these materials by V. H. Test.
VHN = Load Sloping or pyramidal area of the indentation This test is
similar to the Brinell hardness test similar relationship and eliminates most
of the errors.

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Vickers Hardness Testing
Equipment Description:

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Vickers Hardness Testing Contd
Suitable Application:
Vickers hardness test is used for hardness testing of all solid materials,
including metallic materials.
It is suitable for a wide range of applications.
It can also be used for a sub-group of hardness testing of welds.

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Knoop diamond Hardness Testing
Suitable Application:

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Tensile test methods and standards
The tensile properties of the samples, strength and modulus were
measured using an Instron universal tester.
Tensile testing was performed according to ASTM D638, using an MTS
Extensometer.

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Impact Tests
Impact Testing
The impact testing was carried out in accordance with ASTM standard
D256.
Impact properties is tested using a Tinius Olsen Model Impact 104 Izod
impact tester with a pendulum energy.

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3) Creep and stress rupture including examples of
testing methods
Creep Testing Equipment
Loading device(s) or equipment
A furnace or heating chamber equipped with sensitive temperature
regulating controls with ASTM E633.
An accurate extensometer
Time measuring, recording, and supporting instrumentation, and software
Required test conditions

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END

Thank You!
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