MATERIAL TESTING (TEVETA NOTES)
1. Introduction to Material Testing
Definition
Material testing is the process of determining the physical, mechanical and chemical properties of a
material by applying controlled conditions and observing its behaviour.
Purpose of Material Testing
To determine strength and suitability of materials
To ensure quality control
To prevent failure in service
To compare materials for selection
To comply with standards and specifications
Types of Material Testing
Mechanical testing
Non-destructive testing (NDT)
Physical testing
Chemical testing
2. Mechanical Testing of Materials
Mechanical tests determine how a material behaves under forces or loads.
2.1 Tensile Test
Definition
A tensile test is a test in which a material is subjected to a pulling force until it fractures.
Purpose
To determine tensile strength
To determine yield strength
To measure elongation and ductility
Test Method
A standard test piece is fixed in a Universal Testing Machine (UTM)
Load is applied gradually
Extension is measured until failure occurs
Properties Determined
Ultimate tensile strength
Yield point
Percentage elongation
Reduction in area
Example
Testing mild steel rods used in construction
2.2 Compression Test
Definition
A compression test determines how a material behaves when subjected to a pushing or crushing force.
Materials Tested
Concrete
Bricks
Cast iron
Method
Load is applied to a specimen between compression plates until failure
Example
Testing concrete blocks for building strength
2.3 Hardness Test
Definition
Hardness is the resistance of a material to indentation, scratching or wear.
Common Hardness Tests
Brinell hardness test
Rockwell hardness test
Vickers hardness test
Example
Testing gear wheels for wear resistance
2.4 Impact Test
Definition
An impact test measures the ability of a material to absorb shock energy before fracture.
Types
Charpy test
Izod test
Example
Testing materials used in axles and railway components
2.5 Bending (Flexural) Test
Definition
A bending test determines the resistance of a material to bending.
Method
Load is applied at the centre of a supported specimen
Example
Testing wooden beams or metal bars
2.6 Torsion Test
Definition
A torsion test determines the behaviour of a material under twisting forces.
Example
Testing shafts and drive rods
3. Non-Destructive Testing (NDT)
Definition
Non-destructive testing is testing carried out without damaging the material.
Advantages
Material can still be used
Detects internal and surface defects
Saves cost
Common NDT Methods
3.1 Visual Inspection
Checking for cracks, corrosion, and surface defects
Example: Weld inspection
3.2 Dye Penetrant Test
Uses coloured dye to detect surface cracks
Common in welding inspections
3.3 Magnetic Particle Testing
Used on ferrous materials
Detects surface and near-surface defects
3.4 Ultrasonic Testing
Uses sound waves to detect internal flaws
Used in pipelines and pressure vessels
3.5 Radiographic Testing (X-ray)
Detects internal defects using radiation
4. Physical Testing of Materials
Common Physical Properties Tested
Density
Porosity
Moisture content
Thermal conductivity
Example
Testing timber moisture content
5. Chemical Testing of Materials
Definition
Chemical testing determines the chemical composition of materials.
Purpose
To confirm material grade
To detect impurities
Example
Determining carbon content in steel
6. Importance of Material Testing in Industry
Ensures safety
Improves product quality
Reduces failure and accidents
Ensures standard compliance
POSSIBLE TEVETA EXAM QUESTIONS AND MODEL ANSWERS
Question 1
Define material testing.
Answer:
Material testing is the process of determining the physical, mechanical and chemical properties of a
material to assess its suitability for use.
Question 2
State four purposes of material testing.
Answer:
To determine material strength
To ensure quality control
To prevent failure
To select suitable materials
Question 3
Describe a tensile test.
Answer:
A tensile test involves subjecting a material to a gradually increasing pulling force until it fractures, in
order to determine tensile strength, yield strength and elongation.
Question 4
Mention three hardness testing methods.
Answer:
Brinell
Rockwell
Vickers
Question 5
What is non-destructive testing? State two advantages.
Answer:
Non-destructive testing is testing carried out on a material without causing damage.
Advantages:
The material can still be used
Internal defects can be detected
Question 6
Differentiate between destructive and non-destructive testing.
Answer:
Destructive testing damages or breaks the material during testing, while non-destructive testing does
not damage the material.
Question 7
State two materials suitable for compression testing.
Answer:
Concrete
Bricks
Question 8
Give two examples of materials tested using impact testing.
Answer:
Axles
Railway components