VELAMMAL ENGINEERING
COLLEGE
Department
of
mechanical engineering
OML751
TESTING OF MATERIALS
BY
MR. SRIKANTH P
ASSISTANT PROFESSOR
OBJECTIVE
• To understand the various destructive and
non destructive testing methods of
materials and its industrial applications.
DESTRUCTIVE TESTING
• Destructive testing or Destructive physical
analysis, DPA tests are carried out to the
specimen's failure,
• to understand a specimen's performance
or material behavior under different loads.
• Tensile tests, Charpy impact tests, Pellini
drop weight testing, crush testing,
pressure and fracture testing.
Ballistic Impact tests
The characteristic features of the machine
are as follows:
• maximum velocity with the forced drive: 20 m/s;
• maximum simulated drop height: 20.4 m;
• impact energy range: from 4.5 to 1600 J;
• impact standard head: energy range from 4.5 to
940 J;
• impact heavy head: energy range from 25 to
1600 J;
• environmental test chamber: temperature range
from −51 ◦C to 177 ◦C
LAYOUT OF TEST DEVICES
VIEW OF THE HELMET AFTER FIRING
Nondestructive testing (NDT)
• Nondestructive testing (NDT) is a wide group
of analysis techniques used in science and
technology industry to evaluate the properties
of a material, component or system without
causing damage.
ERW Pipe Manufacturing Process
• Electric resistance welded (ERW) pipe is
manufactured by cold-forming a sheet of steel
into a cylindrical shape. Current is then passed
between the two edges of the steel to heat
the steel to a point at which the edges are
forced together to form a bond without the
use of welding filler material.
OUTCOMES
• Identify suitable testing technique to
inspect industrial component
• Ability to use the different technique and
know its applications and limitations
Manufacturing industries
• Automotive industry •Shipbuilding industry
• Electronics industry •Food industry
• Semiconductor industry •Textile industry
• Computer industry •Mining
• Aerospace industry •Water industry
• Chemical industry •Construction industry
• Pharmaceutical •Energy industry
industry •Electrical power industry
• Industrial robot •Petroleum industry
industry •Pulp and paper industry
• Defense industry •Steel industry
Food packaging
• Foods categories such as fresh produce, frozen
foods, irradiated foods, fresh fish, canned
foods, etc. have regulatory requirements and
special packaging needs.
Package testing
• Materials testing •Package Insulation
• Conditioning, testing •Vacuum testing
atmosphere •Shock and impact
• Degradation of •Thermal shock
product •Vibration
•Compression
• Barrier Properties
•Large loads
• Degradation of •Test Protocols for Shipping
Packages Containers
UNIT- I
INTRODUCTION TO MATERIALS TESTING
• Overview Of Materials
• Classification Of Material Testing
• Purpose Of Testing,
• Selection Of Material
• Development Of Testing
• Testing Organizations And Its Committee
• Testing Standards
• Result Analysis
UNIT -II
MECHANICAL TESTING
• Introduction to mechanical testing
• Hardness test (Vickers, Brinell, Rockwell)
• Tensile test,Impact test
• (Izod, Charpy) – PrinciplesTechniques, Methods, Advantages and
Limitations, Applications
• Bend test
• Shear test
• Creep and Fatigue test - Principles, Techniques, Methods, Advantages
and Limitations, Applications
UNIT- III
NON DESTRUCTIVE TESTING
• Visual inspection
• Liquid penetrant test
• Magnetic particle test
• Thermography test – Principles Techniques, Advantages and
Limitations, Applications
• Radiographic test, Eddy current test
• Ultrasonic test Acoustic emission- Principles, Techniques,
Methods, Advantages and Limitations, Applications.
UNIT- IV
MATERIAL CHARACTERIZATION TESTING
• Macroscopic and Microscopic observations
• Optical and Electron microscopy (SEM and TEM) -
Principles, Types, Advantages and Limitations, Applications
• Diffraction techniques
• Spectroscopic Techniques
• Electrical and Magnetic Techniques- Principles, Types, Advantages and
Limitations, Applications
UNIT -V
OTHER TESTING
• Thermal Testing
• Differential scanning calorimetry, Differential thermal analysis
• Thermo-mechanical and Dynamic mechanical analysis:
Principles, Advantages, Applications
• Chemical Testing: X-Ray, Fluorescence
• Elemental Analysis by Inductively Coupled Plasma-Optical
Emission Spectroscopy and Plasma-Mass Spectrometry
TEXT BOOKS
1. Baldev Raj, [Link], [Link] “Practical Non-
Destructive Testing”, Narosa
Publishing House, 2009.
2. Cullity, B. D., “Elements of X-ray diffraction”, 3rd Edition,
Addison-Wesley Company Inc., New
York, 2000.
3. P. Field Foster, “The Mechanical Testing of Metals and Alloys”
7th Edition, Cousens Press, 2007.
REFERENCES
1. Metals Handbook: Mechanical testing, (Volume 8) ASM Handbook
Committee, 9th Edition, American Society for Metals, 1978.
2. ASM Metals Handbook, “Non-Destructive Evaluation and Quality
Control”, American Society of Metals, Metals Park, Ohio, USA.
3. Brandon D.G., “Modern Techniques in Metallography”, Von
Nostrand Inc. NJ, USA, 1986.
Why Material Testing is important in the industry
• Material testing has become an integral phase in almost all
types of industries for ensuring its quality and safety.
• In manufacturing, quality is a measure of excellence or a state
of being free from defects, deficiencies and significant
variations.
• Safety is the condition of being protected from harm or other
non-desirable outcomes
El Al disaster 747 boieng failure 1992
netherlands
(Summary)
Soon after the take-off of a Boeing 747 cargo air
transport of El-Al Israel Airlines, the two engines on
the right wing dropped off, and the air transport went
out of control, finally colliding into the apartment
building.
Thirty-nine apartment habitants were killed in this
accident. The cause of engine separation during take-
off phase was fatigue failure of the pylon fuse pin.
• High Rise Catastrophe _ El Al Flight 1862.mp4
• Component
• Pylon fuse pin (Pylon is the structural
component connecting the jet engine to the
main wing. The role of the fuse pin is to allow
the engine to separate from the wing under
the strong impact load that occurs in the
event of a crash or hard landing in order to
protect the fuselage from engine fire.)
Cause
• A fuse pin of the No.3 engine fractured as a result of
corrosion fatigue. (The engine is sustained by four fuse
pins.) As a result, the engine became unstable and began
to vibrate. The vibration caused fuel to leak. The leaking
fuel caught fire, and then the other fuse pins were torn
off by overload and heating, and the engines finally
dropped off.
• When the two engines dropped off during the critical
phase of the initial climb, the cockpit crew could not put
the fail-safe mechanism into operation, and they lost
control of the aircraft.
Social Impact
• The cargo also caused a large impact to society.
• The transport was carrying depleted uranium and
also chemical raw materials for producing sarin,
highly poisonous lethal gas.
• Thousands of people, not only the inhabitants of
the apartment building but also those who
participated in the rescue or who were otherwise
involved in the accident, suffered long after from
the after effects from exposure to these materials.
TITANIC CASE STUDY
• On April 14, 1912, the R.M.S. Titanic collided with a
massive iceberg and sank in less than three hours.
• At the time, more than 2,200 passengers and crew were
aboard the Titanic for her maiden voyage to the United
States.
• Only 705 survived. According to the builders of the
Titanic, even in the worst possible accident at sea, the
ship should have stayed afloat for two to three days.
• This article discusses the material failures and design
flaws that contributed to the rapid sinking of the Titanic.
About TITANIC
• At the time of her construction, the Titanic was the largest ship
ever built.
• She was nearly 900 feet long, stood 25 stories high, and weighed
an incredible 46,000 tons. With turn-of the-century design and
technology, including sixteen major watertight compartments in
her lower section that could easily be sealed off in the event of a
punctured hull, the Titanic was deemed an unsinkable ship.
• According to her builders, even in the worst possible accident at
sea, two ships colliding, the Titanic would stay afloat for two to
three days, which would provide enough time for nearby ships
to help.
• Material Failures When the Titanic collided
with the iceberg, the hull steel and the
wrought iron rivets failed because of brittle
fracture.
• A type of catastrophic failure in structural
materials, brittle fracture occurs without prior
plastic deformation and at extremely high
speeds.
• The causes of brittle fracture
• The water temperature was below freezing,
• the Titanic was travelling at a high speed on
impact with the iceberg,
• and the hull steel contained high levels of
sulphur.
