ASM Lab Record Book

B.M.S.
COLLEGE OF ENGINEERING
BENGALURU – 19
(AUTONOMOUS INSTITUTE AFFILIATED TO VTU)
RECORD BOOK
for
AEROSAPCE MATERIAL TESTING LAB [19AE3DCASM]
4th Semester Aerospace Engineering
Student Name: USN:
Section: Batch: Staff in charge:

BMS COLLEGE OF ENGINEERING
BENGALURU-19
(Autonomous Institute under VTU)
DEPARTMENT OF AEROSPACE ENGINEERING
CERTIFICATE
This is to certify that Ms./Mr. bearing

USN is the student of IV Semester B.E.(Aerospace),
BMS College of Engineering, affiliated to Visvesvaraya
Technological University, Belgaum has successfully completed the
lab work connected with the AEROSPACE MATERIAL TESTING Lab
as prescribed by the college during the Academic year 2020-21.
Total Marks obtained
Staff In charge : Prof.& Head
Date : Dept. of Aerospace Engg.

Table of Contents
Introduction 1
Experiment 1: Tensile Test 2
Experiment 2: Compression Test 9
Experiment 3: Shear Test 16
Experiment 4: I-zod Impact Test 18
Experiment 5: Charpy Impact Test 20
Experiment 6: Brinell Hardness Test 22
Experiment 7: Rockwell Hardness Test 25
Experiment 8: Bending Test 26
Experiment 9: Torsion Test 32
iii
Dept. of Mechanical Engg., BMSCE MT Lab Observation Book
INTRODUCTION
Testing of materials is nothing but evaluation of material properties.
Knowledge of material properties is very essential in characterizing the same. There
are a variety of materials in the market which finds application in several
machines/equipments/general use/ engineering use etc. Materials can be classified as
metals and non metals.
Metals can be classified as ferrous (all iron containing metals such as cast iron,
steel, S.G. Iron) and non-ferrous (without iron such as aluminium, copper,
magnesium).
Examples for non-metals are glass, wood, plastic, ceramics etc. Metals are
characterized by their good electrical and thermal properties and non-metals are
characterized by poor thermal and electrical properties. Metals have good properties in
tension, compression, bending, ductility etc. Hence, they are used extensively in
practice. Ex. Automobile parts, Machine parts, general engineering applications. Non
metals also find application in industries and house hold use.
Metals are generally evaluated for mechanical properties such as Tensile
strength, compression strength, hardness etc. Various equipments such as Universal
Testing Machine, hardness tester are used for the purpose. Mechanical testing of
materials is required to assess the performance of a new material as compared with
available materials.
Metals are given heat treatment to enhance the properties as a result of
structural changes. Annealing, Normalizing, Tempering etc., are some of the heat
treatment methods.
In metallographic examination of metals micro aspects of metals are studied
under a microscope. Mainly grain structure and phases are studied. Each metal has its
own structure which distinguishes itself from others. This is used to characterize the
metal. Structure can be photographed and recorded for future reference. For this a
metallurgical microscope is used. In general metals are observed under a magnification
of 100X or 500X.
In this book test procedures for evaluating different mechanical properties and
metallographic examination is given. General guidelines regarding content for writing
lab record are:
1) Aim, 2) Apparatus required, 3) Theory, 4) Procedure, 5) Apparatus
sketch (unruled-page), 6) Specimen sketch (unruled-page), 7) Initial observations
(unruled-page), 8) Tabular column (unruled-page), 9) Specimen calculations
(unruled-page), 10) Result & 11) Learning outcomes.
1
EXPERIMENT NO - 1
TENSILE TEST
Objective:
The objective of this experiment is to conduct uniaxial tension test on different
materials and to determine their mechanical properties.
Experimental Procedure:
1. Measure the diameter of the specimen in three locations and determine the mean.
2. Mark the centre of the specimen and the gauge length using a steel rule and a
punch. Note: To accurately compare elongation values between tests, the gage lengths must
be the same.
3. Attach the extensometer to the specimen to record the extension during loading.
4. Fix the specimen in the shackles.
5. Fix the arrangement to UTM.
6. Apply the tensile load gradually.
7. Record the load for every one division (1.27 mm) of the specimen with reference
to the extensometer until the specimen breaks.
8. Carefully remove the specimen and inspect the shape near the failure surface.
Make notes about the appearance of the failure surface. If you have a digital
camera take picture of the failure surfaces and include it in your record.
9. Carefully put the two pieces of the specimen together and measure the final
length of the specimen.
10. Measure the diameter of the specimen at the failure location.
11. Plot the stress vs. strain graph and calculate the necessary parameters i.e., yield
point, yield stress, upper yield stress, lower yield stress, 0.2% offset yield stress,
Maximum Load, Ultimate tensile stress, Breaking load, Breaking stress, %
Elongation, Cross section area at fracture, %Reduction in area, Young's modulus.
Data Sheet:
Material Name Material Type
(ductile/brittle)
Initial Observations:
Sl. No. Particulars Value
1. Overall length of specimen _______________ mm
2. Shoulder length of specimen _______________ mm
3. Initial gage length of the specimen, Lo _______________ mm
4. Initial diameter of the specimen, Do _______________ mm
2
Sl. Load, F Extension Stress  Strain Young's Modulus

No kg N L (mm) (N/mm2)  E (N/mm2)
3
Slope of the
4 linear portion of
5 the Stress vs.
Strain curve
6
10
11
12
13
14
15
16
17
18
Final Observations:
Sl.No. Particulars Value
1. Final gage (or shoulder) length of the specimen, Lf
_______________ mm
2. Final diameter of the specimen, Df
_______________ mm
3
==================================================
Material Name Material Type (ductile/brittle)
1. Overall length of specimen
_______________ mm
2. Shoulder length of specimen
_______________ mm
3. Gage length of the specimen, L0
_______________ mm
4. Initial diameter of the specimen, D0
_______________ mm
Sl. Load, F Extension Stress Strain Young's Modulus

No kg N L mm  (N/mm2)  E (N/mm2)
1
7
Slope of the
8 linear portion
9 of the Stress
vs. Strain curve
10
11
12
13
14
15
16
17
4
18
Final Observations:
Sl. Particulars Value
No.
_______________ mm
_______________ mm
Formulae:
D 2
Area of Cross Section, A = mm 2
4
P
Stress,  = N / mm 2
Ao
;
L
Strain,  =
Lo
L f − Lo
% Elongation in length =  100
Lo
;
Ao − A f
% Reduction in Cross section area =  100
Ao
5
Worksheet
6
Worksheet
7
Worksheet
Faculty Signature Date Remarks
8
EXPERIMENT NO - 2
COMPRESSION TEST
Objective:
The objective of the experiment is to conduct compression test on different materials
and to determine their mechanical properties.
1. Determine the mean length and mean diameter of the specimen.
2. Fix the compression shackles to the upper and lower cross heads of the UTM.
3. Place the specimen axially on the bottom shackles.
4. Fix the specimen between the shackles by adjusting the upper cross-head.
5. Adjust the dial indicator to zero.
6. Apply the load gradually. Record the load at different intervals. Continue the
experiment until the specimen breaks.
7. Record the corresponding load for decrease in length of 0.5mm for M.S. and Al
and 0.25mm for C.I.
8. Measure the final length and diameter of the specimen.
9. Plot the stress vs. strain graph and calculate the necessary parameters.
Data Sheet:
1. Initial length of the specimen, Lo
_______________ mm
2. Initial diameter of the specimen, Do
_______________ mm
Sl Load, P Decrease in Stress,  (N/mm2) Strain, 

No kg N length l (mm)
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
10
Final Observations:
1. Final length of the specimen, Lf
_______________ mm
_______________ mm
==================================================
1. Initial length of the specimen, Lo
_______________ mm
2. Initial diameter of the specimen, Do
_______________ mm
Sl Load, P Decrease in Stress,  (N/mm2) Strain, 

No kg N length l (mm)
1
2
10
11
12
11
13
14
15
16
17
18
19
20
21
22
23
24
Final Observations:
Sl. Particulars Value
No.
_______________ mm
_______________ mm
Formulae:
D 2 P L
Area of Cross Section, A = mm 2 Stress,  = N / mm 2 Strain,  =
4 ; Ao Lo
;
Lo − L f A f − Ao
% Reduction in length =  100 % Increase in Cross section area =  100
Lo Ao
;
12
Worksheet
13
Worksheet
14
Worksheet
15
EXPERIMENT NO - 3
SHEAR TEST
Objective:
The objective of this experiment is to conduct shear test on different materials and to
determine the shear strength of the materials.
1. Determine the mean diameter of the specimen.
2. Fix the top and the bottom shackles in position.
3. Insert the specimen into the holes of the top and bottom shackles.
4. Grip the specimen in position and close the release valve.
5. Apply the tensile load to the specimen perpendicular to its axis gradually until
breaking.
6. Note the breaking load or shear load when the specimen breaks.
7. Determine the shear-strengths of all the materials and compare them using a
histogram.
Data Sheet:
Diameter, D Shear Load F Shear strength,
Sl. No. Material
(mm) in kgf N s (N/mm2)
1. MILD STEEL
2. CAST – IRON
3. ALUMINIUM
4. COPPER
5. BRASS
Formulae:
D 2
Area of Cross Section, A = mm 2
4
P
Stress,  s = N / mm 2
2A
16
Worksheet
17
EXPERIMENT NO - 4
IZOD IMPACT TEST
Objective:
The objective of this experiment is to determine the impact strength of different
materials through Izod test.
Caution: Be extra careful while operating the machine. Avoid being in the path of
swinging hammer.
1. Measure the dimensions of the specimen and the notch.
2. Insert the specimen in the shackles.
3. Fix the shackles with the specimen in the vice provided at the bottom using the
gripper and the gauge. The notch should face the pendulum i.e. tension side.
4. Lift the swinging weight of the pendulum manually to a fixed length i.e. up to the
lever and lock it.
5. Bring the pointer to the zero position.
6. Release the pendulum by operating the lever provided at that place.
7. As the specimen is broken and the pendulum returns back, hold it in position
manually.
8. Note down the impact energy of the specimen as recorded by the pointer in kg-m
on the graduated scale.
Data Sheet:
1. Weight of the hammer
_______________ kg
2. Height of the initial position of the hammer
_______________
3. Swinging angle of the hammer
_______________ deg
Notch Impact Energy Cross-sectional Impact

Sl. Diameter
Material Depth, d E Area at Impact Strength
No. D (mm)
(mm) kgf-m J Point, AI(m2) J/m2
MILD
1.
STEEL
CAST –
2.
IRON
ALUMINI
3.
UM
18
Formulae:
 D2   
  − cos −1  D − d    +  D − d  Dd − d 2   10 −6 m 2
 
Cross Sectional Area at impact pt , AI =   
 4    D  180   2  
E
Impact Strength = J / m2
AI
Worksheet
19
EXPERIMENT NO - 5
CHARPY IMPACT TEST
Objective:
The objective of this experiment is to determine the impact strength of different
materials through Charpy test.
Caution: Be extra careful while operating the machine. Avoid being in the path of
swinging hammer.
1. Measure the dimensions of the specimen & the notch.
2. Lift the pendulum and fix it in its highest position. Secure it in that position by
using the hook.
3. Place the specimen in the provided shackles/support in such a way that, the notch
should face away from the pendulum.
4. Bring the pointer to the maximum position.
5. Release the pendulum by operating the lever provided at that place.
6. As the specimen is broken and the pendulum returns back, stop its swing by
periodically pressing the side brake.
7. Note down the impact energy of the specimen as recorded by the pointer in Joules
on the graduated scale.
Data Sheet:
1. Weight of the hammer
_______________ kg
2. Height of the initial position of the hammer
_______________
3. Swinging angle of the hammer
_______________ deg
Cross-
sectional
Width, Thick Notch Impact Impact
Sl. Area at
Material w ness, t Depth, d Energy, Strength
No. Impact
(mm) (mm) (mm) E (J) J/m2
Point,
AI(m2)
1. MILD STEEL
2. ALUMINIUM
3. BRASS
4. COPPER
20
Formulae:
Cross Sectional Area at impact pt , AI = w  (t − d ) 10 −6 m 2
E
Impact Strength = J / m2
AI
Worksheet
21
EXPERIMENT NO - 6
BRINELL HARDNESS TEST
Objective:
The objective of this experiment is to determine the Brinell hardness number (BHN)
of different materials.
1. Identify the given material by inspection.
2. Calculate the load to be applied using the formula P/D2 = K.
K - constant - depending on the material (5 - 30 ) whether it is soft or hard. For
soft metals like Al = 5 , Cu = 10 , For hard metals like Steel = 30 , Cast Iron =
30.
D - diameter of the indentor ball.
P - Load required for indentation.
If the thickness of the material being tested is T > 6 mm then D = 10mm ,
if T = 3 - 6 mm then D= 5mm and T < 3mm then D = 2.5 mm.
3. Adjust the load in the pan of the machine as per the calculation.
4. Insert the indentor ball into the shackles and fix it into the loading arm.
5. Adjust the time of loading from the scale provided in the machine by operating
the lever up and down.
6. Lift the specimen kept on the table of the machine up using a round plate, until it
makes contact with the indentor ball.
7. Initial adjustment of the table is to be made such that prior to applying the load
the specimen surface just touches the surface of the indentor.
8. Now apply the load by operating the lever in the machine.
9. The duration of the load that is applied is a function of the material
t=15 sec for 3000 kg for cast iron, mild steel etc.
t=30 sec for 1000 kg for Brass, copper etc.
t=30 sec for 500 kg for Aluminium etc.
10. Take out the specimen and measure the diameter of indentation by using a
microscope.
11. Calculate the BHN using the below formula and tabulate the results:
2P
BHN =
D D − D 2 − d 2 
 
Data sheet:
1. Dead weight (equivalent) of the load pan
_______________ kg
2. Weight (equivalent) of load billet
_______________ kg
3. Machine time (constant)
_______________ s
4. Least count of travelling microscope
_______________ mm
22
Sl Material Diameter Diameter Applied Time of BHN

No used for of of load testing
testing indentor indentation (kg) (sec) t
D (mm) d (mm)
1 Mild steel
2 Cast Iron
3 Aluminium
4 Brass
5 Copper
Vickers Hardness Testing:

A diamond pyramid indenter (136 o ) is used here. Loads in the range of 1gm to 120
kg. is applied gradually on to the specimen through the indenter. The dimensions
(diagonal) of the resulting impression is measured accurately using the inbuilt
micrometer microscope attachment. Hardness is calculated by using the formula
VHN = 1.8544 P/d2 or directly read from the chart.
Worksheet
23
Worksheet
24
EXPERIMENT NO - 7
ROCKWELL HARDNESS TEST
Objective:
The objective of this experiment is to determine the Rockwell Hardness of different
materials.
1. Insert the ball-indentor of required diameter in the holder.
2. Clean the surface of the specimen by removing dirt / dust / oil / grease.
3. Rotate the lever such that, the indentor just makes the contact with the surface of
the specimen.
4. Set the load to the required value by turning the load selector dial.
5. Wait for 15 seconds and then release the load by pulling the lever.
6. The needle in the hardness-indicator starts to rotate back. Note down the reading
once the needle stabilizes.
7. Tabulate the values and compare.
Data sheet:
Sl Material used Diameter of Applied Scale Rockwell
No for testing indentor load Hardness
D (inch) (kg) number
1 Mild steel
2 Cast Iron
3 Aluminium
4 Brass
5 Copper
25
EXPERIMENT NO - 8
BENDING TEST
Objective:
The objective of this experiment is to conduct bending test on different materials and
to determine Young's modulus, Maximum bending stress and Radius of bending.
1. Measure the dimensions of the specimen.
2. Mark the center and the gauge length of the specimen.
3. Fix the specimen is on the two supports such that the two supports coincide with
the end markings of the specimen [the supports are movable within the slot]
4. Apply the load on to the specimen gradually. (normal to the axis of the specimen)
5. Record the applied load for each one division deflection of the specimen.
6. Continue the experiment up to 20 divisions of deflection.
7. Draw a graph of load v/s deflection and calculate the necessary parameters.
Data Sheet:
Ductile Material
1. Length of specimen between the supports, L _______________ m
2. Breadth of the specimen, b _______________ m
3. Depth of the specimen, d _______________ m
Sl. Load in Load in Deflection in Bending stress in

No Kg KN mm N / mm2
w w  b max
1
26
10
11
12
13
14
15
16
17
18
Brittle Material
1. Length of specimen between the supports, L
_______________ m
2. Breadth of the specimen, b
_______________ m
3. Depth of the specimen, d
_______________ m
Sl. Load in Load in Deflection in Bending stress in

No Kg KN mm N / mm2
w w  b max
1
27
10
11
12
13
14
15
16
17
18
Formulae:
bd 3 4 wL
Moment of Inertia, I = m Max Bending Moment , M b max = N .m
12 4
M bmax  y M bmax  d 2
Maximum Bending Stress,  bmax = = N / m2
I bd 3 12
L3  w  EI
Young' s Modulus, E =   N / m2 Radius of Curvature, R = m
48I    slope M bmax
28
Worksheet
29
Worksheet
30
Worksheet
31
EXPERIMENT NO - 9
TORSION TEST
Objective:
The object of this experiment is to conduct torsion test on different materials and to
determine the mechanical properties of materials in torsion.
1. Measure the dimensions of the specimen.
2. Insert the specimen in torsion shackles, and fix this to the torsion testing machine.
3. Set the reading of torsion testing machine to zero manually.
4. Attach a graph sheet and a graph plotter (or pencils) to the circumference of the
drum.
5. Apply the load gradually by operating the motor, which rotates the worm.
6. Once the specimen breaks, using the plotted graph calculate the necessary
parameters. (machine constant -545.5 kg-cm)
Note: Draw coloured chalk line marks parallel to the axis of the specimen and
observe the same after the test.
Data Sheet:
1. Machine constant (x - axis)
_______________
2. Machine constant (y - axis)
_______________
Sl. Material Gage Diameter, Slope of Rigidity Shear

No Length, L d (mm) Linear Modulus, Strength,
(mm) Portion of G τmax
Graph, (N/mm2) (N/mm2)
dT/dq
1 Mild Steel
2 Aluminium
Formulae:
d 4 L  dT 
Polar Moment of Inertia, J = mm 4 Rigidity Modulus, G =   N / mm 2
32 J  dq  slope
Tmax  d 2
Shear Strength, max = N / mm 2
J
32
Worksheet
33

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B.M.S.

AEROSAPCE MATERIAL TESTING LAB [19AE3DCASM]

4th Semester Aerospace Engineering

Student Name: USN:

Section: Batch: Staff in charge:

DEPARTMENT OF AEROSPACE ENGINEERING

This is to certify that Ms./Mr. bearing

Total Marks obtained

Staff In charge : Prof.& Head

Date : Dept. of Aerospace Engg.

Experiment 1: Tensile Test 2

Experiment 2: Compression Test 9

Experiment 3: Shear Test 16

Experiment 4: I-zod Impact Test 18

Experiment 5: Charpy Impact Test 20

Experiment 6: Brinell Hardness Test 22

Experiment 7: Rockwell Hardness Test 25

Experiment 8: Bending Test 26

Experiment 9: Torsion Test 32

Sl. Load, F Extension Stress  Strain Young's Modulus

Sl. Load, F Extension Stress Strain Young's Modulus

Faculty Signature Date Remarks

Sl Load, P Decrease in Stress,  (N/mm2) Strain, 

Material Name Material Type (ductile/brittle)

Sl Load, P Decrease in Stress,  (N/mm2) Strain, 

Faculty Signature Date Remarks

Faculty Signature Date Remarks

Notch Impact Energy Cross-sectional Impact

Faculty Signature Date Remarks

Faculty Signature Date Remarks

Sl Material Diameter Diameter Applied Time of BHN

Vickers Hardness Testing:

Faculty Signature Date Remarks

Faculty Signature Date Remarks

Sl. Load in Load in Deflection in Bending stress in

Sl. Load in Load in Deflection in Bending stress in

Faculty Signature Date Remarks

Sl. Material Gage Diameter, Slope of Rigidity Shear

Faculty Signature Date Remarks

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