MEE 098: Materials Science and Engineering for ME

Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Lesson Title: Fracture Toughness and Fatigue in Engineering Materials Materials:

Lesson Objectives: Module, Paper, Pen
At the end of this module you must be able to:
1. Identify what causes fracture and fatigue on materials References:
2. Identify different testing procedure that identifies fracture and Material Science and Engineering (8th
fatigue on materials edition) by William D. Callister Jr.

Productivity Tip:
”Create with the heart; build with the mind.” (Criss Jami)

A. LESSON PREVIEW/REVIEW
1) Introduction (2 mins)
Coming up into a good material doesn’t focus only on determining the material's property and characteristic.
In order to attain that, flaws on the material must also be considered. Pre-existing surface flaws and pre-existing
internal cracks play a central role in the failure of materials. In this module, we will be discussing about these
material flaws and on how to detect them.

2) Activity 1: What I Know Chart, part 1 (3 mins)

Before we start the topic answer the questions in column 2. Write your answers in the column 1. Leave
the third column blank (will be answered during Activity 4).

What I Know Questions: What I Learned (Activity 4)

1. How do you define fracture and
fatigue?

2. Enumerate ways to identify the

fracture and fatigue present on
engineering materials.

B. MAIN LESSON
1) Activity 2: Content Notes (13 mins)
The analysis of fractures of machine parts and structures has revealed that in most cases, their fracture is
due to material fatigue, which is known to be responsible for the initiation and propagation of fatigue cracks in the
course of cyclic loading. Such cracks ultimately lead to complete failure of a component. The terms, tough, ductile,
brittle, or fatigue are frequently used to describe the fracture behaviour of a material.

This document is the property of PHINMA EDUCATION 1

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

a) Tough or ductile fracture – failure is preceded by excessive plastic deformation often detectable.
b) Brittle or non-ductile fracture - involves little or no plastic deformation – often Catastrophic.

Figure 1: Ductile vs. Brittle Failure

Can you name some material that is ductile?

Can you name some material that is brittle?

The type of fracture which occurs is largely dependent upon the type and condition of the material. Other
factors include:
a) Type of stress applied.
b) Rate of stress application.
c) Temperature and environmental conditions.
d) Component geometry.
e) Size and nature of internal flaws.

Figure 2: Failure in Different Material Type

Fracture toughness describes the ability of a material containing a crack to resist fracture. To improve
fracture toughness there is a need to avoid excessive elastic deflections & plastic yielding. Fast fracture can occur
which causes catastrophic failure. In this module, we will be discussing about fracture and fatigue in materials and
how to identify them.

This document is the property of PHINMA EDUCATION 2

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Destructive Testing
In principle, material testing methods can be divided into two categories:
a) destructive testing
b) non-destructive testing.

With destructive testing, the material is damaged and the component can usually no longer be used. In
general, specially prepared and standardized samples are used for this type of testing. The destructive testing
procedures provide important parameters in order to determine not only the proper material but also geometry of
the component depending on the applied load. Destructive testing is used to determine specific material constants
or component constants.
The following test methods are considered destructive testing. Some of them were discussed on the past
module and others will be discussed in this module and on the following modules.
a) tensile test
b) compression test
c) hardness test
d) flexural test
e) impact test
f) fatigue test
g) creep rupture test
h) relaxation test
i) cupping test

For further demonstration refer to this link

https://www.youtube.com/watch?v=KWzrOvJzzlE
What have you learned about destructive testing after watching the video?

Due to the complexity and the interaction between the different loads, not all cases can be recorded in
material properties. This is always a problem when human lives are at risk due to component failure. For this reason,
safety-relevant components must be checked at regular intervals, as is the case with turbine blades of aircraft
engines. It is not economically viable to carry out a destructive material test at this point in order to subsequently
state that everything was in order. That is why non-destructive testing (NDT) was developed. This means that the
component can still be used, provided everything is fine. Non-Destructive Testing will bediscussed on the next
modules.

Can you differentiate destructive testing from non-destructive testing?

This document is the property of PHINMA EDUCATION 3

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Impact Testing

An impact test is used to observe the mechanics that a material will exhibit when it experiences a shock
loading that causes the specimen to immediately deform, fracture or rupture completely. To perform this test the
sample is placed into a holding fixture with the geometry and orientation determined by the type of test that isused
and then a known weight generally but not always in the shape of a pendulum is released from a known height so
that it collides with the specimen with a sudden force. This collision between the weight and specimen generally
results in the destruction of the specimen but the transfer of energy between the two is used to determine the fracture
mechanics of the material.

Figure 3: Impact Tester

The purpose of an impact test is to determine the ability of the material to absorb energy during a collision.
This energy may be used to determine the toughness, impact strength, fracture resistance, impact resistance or
fracture resistance of the material depending on the test that was performed and the characteristic that is to be
determined. These values are important for the selection of materials that will be used in applications that require
the material to undergo very rapid loading processes such as in vehicular collisions.
Nearly all materials may benefit from impact testing, but the most common types used are metals, plastics,
woods, composites, ceramics, and polymers. Generally these materials take the form of sheets of varying
thicknesses or short rods depending on the test. However, most materials will experience either ductile or brittle
failure depending of the type of test, the rate of loading and the temperature of the sample. Brittle failure of a
material requires a small amount of energy to begin the crack or to cause the crack to grow until the sample fails.
On the other hand, ductile failure of a material requires a much higher load to initiate and propagate the crack until
failure.
For a single impact test the three most popular types of test are the Charpy V-notch test, the Izod test and
the Tensile Impact test. These three tests all essentially determine the same characteristics of the material but differ
in the orientation of the test sample which causes the sample to be stressed in different directions and involve a
known weight released from a known height colliding with the specimen in its test fixture. All of these tests are
useful in determining the impact mechanics of the test specimen.

Charpy Impact Test

The Charpy impact test, also known as the Charpy V-notch test, is a high strain-rate test that involves
striking a standard notched specimen with a controlled weight pendulum swung from a set height. The impact test
helps measure the amount of energy absorbed by the specimen during fracture. The standard Charpy-V notch
specimen is 55mm long, 10mm square and has a 2mm deep notch with a tip radius of 0.25mm machined on one
face.

This document is the property of PHINMA EDUCATION 4

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Figure 4: Standard Charpy V-notch Specimen

In some circumstances, sub-size Charpy specimens can be tested with thickness less than 10mm. The
specimen is supported at its two ends on an anvil and struck on the opposite face to the notch by the pendulum. The
amount of energy absorbed in fracturing the test-piece is measured and this gives an indication of the notch
toughness of the test material. The pendulum swings through during the test, the height of the swing being a measure
of the amount of energy absorbed in fracturing the specimen. Conventionally, three specimens are tested at any one
temperature and the results averaged. Alternatively, tests are carried out at a range of temperatures in order to
generate a ductile to brittle transition curve.
Charpy tests show whether a metal can be classified as being either brittle or ductile. This is particularly
useful for ferritic steels that show a ductile to brittle transition with decreasing temperature. A brittle metal will
absorb a small amount of energy when impact tested; a tough ductile metal absorbs a large amount of energy. The
appearance of a fracture surface also gives information about the type of fracture that has occurred; a brittle fracture
is bright and crystalline, a ductile fracture is dull and fibrous. The percentage crystallinity is determined by making
a judgement of the amount of crystalline or brittle fracture on the surface of the broken specimen, and is a measure
of the amount of brittle fracture.
Lateral expansion is a measure of the ductility of the specimen. When a ductile metal is broken, the test-
piece deforms before breaking, and material is squeezed out on the sides of the compression face. The amount by
which the specimen deforms in this way is measured and expressed as millimetres of lateral expansion.

For further demonstration refer to this link

https://www.youtube.com/watch?v=tpGhqQvftAo
What have you learned about charpy impact test after watching the video?

Izod Impact Test

Izod impact testing is a method of determining the impact resistance of materials. A pivoting arm is raised
to a specific height (constant potential energy) and then released. The arm swings down hitting a notched sample,
breaking the specimen. The energy absorbed by the sample is calculated from the height the arm swings to after
hitting the sample. A notched sample is generally used to determine impact energy and notch sensitivity.
The test is similar to the Charpy impact test but uses a different arrangement of the specimen under test.
The Izod impact test differs from the Charpy impact test in that the sample is held in a cantilevered beam
configuration as opposed to a three-point bending configuration.

This document is the property of PHINMA EDUCATION 5

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Figure 5: Notched Izod Impact Test

In this test, a specimen is machined to a square or round section, with either one, two, or three notches that
have a dimension of 70 mm × 15 mm × 3 mm. The Izod impact test consists of a pendulum with a determined weight
at the end of its arm swinging down and striking the specimen while it is held securely in a vertical position. The
impact strength is determined by the loss of energy of the pendulum as determined by precisely measuring the loss
of height in the pendulum's swing.

For further demonstration refer to this link

https://www.youtube.com/watch?v=l20kF6fhScA
What have you learned about izod impact test after watching the video?

Tensile Impact Test

The tensile impact test measures the amount of force needed to break a specimen under a high
speed tensile load introduced through a swinging pendulum. There are two types of test specimens which can be
used, long (L) and short (S). Both are 63.5mm (2.5") long, but gauge length areas vary. Type L specimens, with a
gauge length of 9.53mm (0.375") provide a greater differentiation between materials. Type S specimens, which
have no true gauge length.
In Tensile Impact Test, the thickness and width of the test specimen is recorded. The specimen is then
clamped to the crosshead and placed into the pendulum. The pendulum is released and allowed to strike the anvil
breaking the specimen. The tensile impact energy is recorded and then corrected impact energy is calculated.

This document is the property of PHINMA EDUCATION 6

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Figure 6: Tensile Impact Test

For further demonstration refer to this link

https://www.youtube.com/watch?v=NC63y6OWAxc
What have you learned about tensile impact test after watching the video?

Can you name some impact testing procedures that weren’t mention above?

Fatigue Testing
A fatigue test helps determine a material’s ability to withstand cyclic fatigue loading conditions. By design,
a material is selected to meet or exceed service loads that are anticipated in fatigue testing applications. Cyclic
fatigue tests produce repeated loading and unloading in tension, compression, bending, torsion or combinations of
these stresses. Fatigue tests are commonly loaded in tension – tension, compression – compression and tension into
compression and reverse.
To perform a fatigue test a sample is loaded into a fatigue tester or fatigue test machine and loaded using
the pre-determined test stress, then unloaded to either zero load or an opposite load. This cycle of loading and
unloading is then repeated until the end of the test is reached. The test may be run to a pre-determined number of
cycles or until the sample has failed depending on the parameters of the test.
Usually the purpose of a fatigue test is to determine the lifespan that may be expected from a material
subjected to cyclic loading, however fatigue strength and crack resistance are commonly sought values as well. The
fatigue life of a material is the total number of cycles that a material can be subjected to under a single loading
scheme. A fatigue test is also used for the determination of the maximum load that a sample can withstand for a
specified number of cycles. All of these characteristics are extremely important in any industry where a material is
subject to fluctuating instead of constant forces.

This document is the property of PHINMA EDUCATION 7

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

Figure 7: Fatigue Tester

There are several common types of fatigue testing as well as two common forms: load controlled high cycle
and strain controlled low cycle fatigue. A high cycle test tends to be associated with loads in the elastic regime and
low cycle fatigue tests generally involve plastic deformations.
Nearly all materials may experience fatigue in one way or another during the lifespan of their application.
However, in applications where fatigue is a factor it is common to find components made from metals or
composites. These materials have a higher fatigue limit than others because of the rigidity and ductility, which are
characteristics that tend to increase fatigue strength. Other materials, such as, polymers, ceramics and wood may
experience fatigue and also need to be tested to understand how they will respond to these unique stress
combinations.

For further demonstration refer to this link

https://www.youtube.com/watch?v=LhUclxBUV_E
What have you learned about fatigue testing after watching the video?

Can you name some fatigue testing procedures that weren’t mention above?

This document is the property of PHINMA EDUCATION 8

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

2) Activity 3: Skill-building Activities (with answer key) (18 mins + 2 mins checking)

LET'S DO THIS!!!
Answer the following activities. Write your answers on the space provided.
“For the following activities, check your answers against the Key to
Corrections found at the end of this module. Write your score on your paper.”

A4-1: Complete the table below according to what you have learned during the discussion. Write your answer on
the space provided.

Material Testing Equipment Used Different Types Material Properties Obtained

Impact Testing

Fatigue Testing

A4-2: Enumerate what is asked. Write your answer on the space provided.
1-2) Two Types of Fracture

3-7) Five Factors that affects the Fracture of Material

8-9) Two Types of Material Testing

This document is the property of PHINMA EDUCATION 9

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

10-18) Nine Examples of Destructive Testing

19-20) Two Types of Impact Testing

3) Activity 4: What I Know Chart, part 2 (2 mins)

After the lesson, answer the questions on column 2 based on your learning. Write your answers on the
third column.

What I Know Questions: What I Learned (Activity 4)

1. How do you define fracture and
fatigue?

2. Enumerate ways to identify the

fracture and fatigue present on
engineering materials.

This document is the property of PHINMA EDUCATION 10

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

4) Activity 5: Check for Understanding (5 mins)

LET ME HEAR FROM YOU…

In your opinion, why is it important to detect flaws within the material?
Write your opinion on the space provided below.

C. LESSON WRAP-UP
1) Activity 6: Thinking about Learning (5 mins)

How is your learning experience? Which part of the lessons do you find to be difficult?

This document is the property of PHINMA EDUCATION 11

 MEE 098: Materials Science and Engineering for ME
Student Activity Sheet #4

Name: Class number:

Section: Schedule: Date:

FAQs
Why impact testing is important?
Impact test determines the amount of energy absorbed by a material during fracture. This absorbed
energy is a measure of a given material's toughness and acts as a tool to study temperature-dependent brittle-
ductile transition. It is to determine whether the material is brittle or ductile in nature.

Why do we use notch in impact test?

Impact energy is a measure of the work done to fracture a test specimen. When the striker impacts
the specimen, the specimen will absorb energy until it yields. The test specimen continues to absorb energy
and work hardens at the plastic zone at the notch. When the specimen can absorb no more energy, fracture
occurs.

What is a Fatigue Testing Machine?

A fatigue testing machine works to replicate the kind of stress and strain that the material will
encounter when out in use. It takes into account weight or pressure that the material will come into contact
with under, along with temperatures (both high and low) and strain that would cause it to deform.

Does Fatigue also exist on flexible material like rubber?

Yes, fatigue is not only present on hard materials like metals but also on soft materials like rubber.
Rubber fatigue refers to the wear and eventual failure of a rubber component. This is due to the material
being worn down over a period of time which can cause catastrophic problems. It can cause machine failure,
unforeseen downtime and can even compromise the safety of your workforce.

This document is the property of PHINMA EDUCATION 12