OML751

TESTING OF MATERIALS

K. Senthilkumar
Associate Professor
Department of Mechanical Engineering
Google classroom code

xefqjy6
Test schedule (tentative)

 Internal assessment I - September 12 to 14, 2022

 Internal assessment II - October 12 to 14, 2022

 Internal assessment III - November 10 to 14, 2022

 Course outcomes

 Explain the overall view about materials and their importance in testing

 Select the mechanical characterization technique for a particular application

 Apply the appropriate nondestructive technique method to find the internal flaws in the

material

 Explain about different techniques available for structural characterization

 Analyze modern characterization methods for various material systems

 Introduction
 What is materials science?

Materials science is the study of materials

and their applications.

 Why should we know about it?

 Why should we know about it?

Almost every walk of our life is directly dependent on

them

Food
Shelter
Clothing
Transportation
Communication
Entertainment
 Human Civilization through Materials
 Stone age
 Bronze age
 Iron age
 Modern Materials Age
 Plastic Age
 Silicon Age (What’s next?)
 Designed materials
 Molecular self-assembly

 Hierarchical structures

 Smart materials

 Metamaterials
 Role of Materials
 Think of major challenges that we face today

 Clean energy

 Clean water

 Heath care

 Infrastructure

 Sustainable environment

Materials play a central role in solving these problems!

 Clean energy
 Efficient combustion processes

 New materials for solar energy with improve efficiency

 New composites for wind turbines with high durability and strength

 Batteries with high energy density and long life

 Structures with resistance to high temperatures and loads for next generation thermal
energy generation

 Hydrogen as a source of energy

Clean water
 Better materials for water purification

 Low cost materials such as membranes

 Carbon based filtering

 Sand filtering

 Ceramic filtering
Health care

 Biodegradable materials for implants

 Disposable materials after surgeries

 Minimize hazardous health care waste

 Methodologies to deal with new epidemics and new medical devices

 Time for decomposition
up to two years

18 months to 10 years

20 to 500 years
Infrastructure

 Better housing with durable and low-cost materials

 Buildings that consume less energy

 Carbon negative or green infrastructure

 Communication with reduced energy consumption

Materials that changed the History
 Material testing
 To ascertain both the physical (absorption, area, thickness, color, density, etc) and
mechanical properties (tensile, flexural, compressive, impact, etc)

 It also measures the characteristics and behaviour of substances such as metals,

ceramics, or plastics under various conditions
 Classification of Material Testing

Test may be classified based on

 Loading condition-static, dynamic or long time tests

 Temperature-normal or room temperature and elevated temperature,

 Special requirement on instrument-holdings, special atmosphere like salt spray,

corrosive etc
Materials testing classified into three major
categories

1. Mechanical testing (or) Destructive testing (DT)

2. Nondestructive testing

3. Material characterization testing

 Mechanical or Destructive Testing

 Involves applying a test to break down a particular material to determine its physical, and

mechanical properties of strength, toughness, flexibility, and hardness.

 In order to understand a specimen's performance or material behavior.

 Classification of Destructive Testing

1. Static testing

2. Impact testing

3. Cyclic testing
 Static Testing
 Where the load is applied gradually in static testing. Different material testing methods
available under static testing.

 Tension Test

 Compression Test

 Shear Test

 Hardness Test

 Bending test
 Impact (Dynamic) Testing

 When the given specimen is subjected to shock loads then it is known as the impact load
testing or the dynamic load testing.

 Charpy Test

 Izod Test

 Drop Ball

 Instrumented Puncture Testing

Cyclic Testing
 When the load is repeatedly varied in magnitude and the direction then this test is
called cyclic testing.

 Fatigue test
Advantages of destructive testing
 Identify the mechanical properties

 Properties of the bonding can be defined

 The costs of equipment for destructive testing are cheaper compare with the

certain equipment used in non - destructive testing.

 Disadvantages of destructive testing
 Cannot identify internal defectology (bubbles, delaminating, pores, wrong thickness etc.)

 Need to make large number of specimens

 Not directly identifies the status of the failure area

 NON-DESTRUCTIVE TESTING (NDT)

 Utilized to detect, characterize, or measure the presence of damage mechanisms

( e.g. corrosion or cracks).

 Many types of NDT techniques are capable of locating defects and determining the

features of the defects (porosity, cracks for welding) such as size, shape, and orientation.

 The purpose of NDT is to inspect a component in a safe, reliable, and cost

effective manner without causing damage to the equipment or shutting down plant

operations.
Major source of NDT test

 Liquids

 Radiation

 Sound

 Magnetism

 Infrared
Classification of Destructive Testing
 Acoustic Emission Testing (AET)

 Infrared Testing (IR)

 Leak Testing (LT)

 Liquid Penetrant Testing (PT)

 Electromagnetic Testing (ET)

 Magnetic Particle Testing (MPT)

 Radiographic Testing (RT)

 Film Radiography (FR)

 Ultrasonic Testing (UT)

 Visual Inspection (VI)

Advanced NDT Techniques
Advantages of NDT Test
 Most of the equipment in NDT test is portable.

 The obtaining of result is quick and reliable.

 Many properties are found in single specimen.

 Identify areas of concern before failure.

Disadvantages of NDT Test
 Result interpretation is difficult.

 Skilled labor is required.

 Components needing to be cleaned before and after inspection.

 Sensitivity of inspection can sometimes be affected by the finish of a

component.

 On some non-destructive test methods, only relatively non-porous surfaces

can be inspected.