Module 6 - 1
Module 6
Metal Properties
and
Destructive Testing
Am e r i c a n We l d i n g So c i e t y
Module 6 - 2
Classification of materials
All engineering materials can be classified
due to physical properties in to 4 type
Elastic material
Plastic material
Ductile material
Brittle material
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Module 6 - 3
Metal Properties
Physicalproperties (density)
Mechanical properties *
Alloy chemistry
Alloy heat treatment
* Mechanical properties depend on alloy
chemistry, heat treatment and cold work.
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Module 6 - 4
Terminology
Elasticity
Stress a- tensile b- compressive
stress = load / area
Strain ε = δl / l
δl= change of length after removal the
external load
Elastic limit
Yielding strength : stress at which slip
becomes noticeable a- upper b- lower
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Module 6 - 5
Selection process of materials
Kinds of materials
Properties of materials
Service requirement
Economy
Method preparation
Method of testing and inspections
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Module 6 - 6
Strength
“The ability of a material to bear an applied
load”
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Module 6 - 7
Strength
Two common methods of expression:
Ultimate tensile strength (UTS)
Yield strength (or yield point)
Am e r i c a n We l d i n g So c i e t y
Module 6 - 8
Metal Behavior Under Load
Elastic - No permanent deformation
Plastic - Permanent deformation
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Module 6 - 9
Elastic
Behavior of
Steel
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Module 6 - 10
Temperature Effects
As metal temperatures increase:
Strength decreases
Hardness decreases
Ductility increases
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Module 6 - 11
Ductility
The ability of a metal to deform without breaking
* Measurements
A- Elongation
B - Reduction
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Module 6 - 12
Brittle vs Ductile Failure
Brittle Ductile
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Module 6 - 13
Ductility Terms
Percent elongation
Percent reduction of area
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Module 6 - 14
Directional Properties
Both strength and ductility are affected by the
rolling direction of the metal. The three axes
of rolling direction are referred to as the X, Y,
and Z directions.
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Module 6 - 15
Rolling Directions
X Direction Best Strength & Ductility
Y Direction 10 - 30% Less Strength
20 - 50% Less Ductility
2 Direction Still Lower Strength & Ductility
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Module 6 - 16
Hardness
“Ability to resist indentation or scratch”
A-Indentation Hardness
B-Rebound Hardness
C-Scratch Hardness
D-Wear Hardness
E-Machinability
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Module 6 - 17
Hardness test type
Brinell
Rockwell
Vickers
Micro
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Module 6 - 18
Indenter Types
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Module 6 - 19
Hardness Tester
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Module 6 - 20
Indentation
Shapes
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Module 6 - 21
Toughness
“The ability to absorb energy”
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Module 6 - 22
Toughness Comparison
Modulus of toughness
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Module 6 - 23
Notch Toughness
“Toughness in the presence of surface notches
and rapid loading”
(also referred to as “Impact Strength”)
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Module 6 - 24
Stress Riser
“A surface condition, or geometric feature,
that increases the applied stress at the
condition or geometry”
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Module 6 - 25
Stress Risers (Notch Effects)
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Module 6 - 26
Notch Effects on Fatigue
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Module 6 - 27
Surface Finish Effects on Fatigue
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Module 6 - 28
Ductile - to - Brittle
Transition Temperature
“The temperature at which a metal fracture
mode changes from ductile to brittle”
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Module 6 - 29
Fatigue Strength
“The strength of a metal when exposed to
repeated reversals of cyclic stresses”
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Module 6 - 30
Endurance Limit
“The maximum stress at which no failure will
occur, regardless of cycles”
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Module 6 - 31
Typical S-N Curves
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Module 6 - 32
Soundness
“Freedom from discontinuities”
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Module 6 - 33
Chemical Properties
Metals are mixtures of elements, and are
referred to as alloys
Minor changes in alloy composition can
have major effects on alloy properties such
as mechanical strength, corrosion resistance
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Module 6 - 34
Common Steel Alloys
Common Name C% Typical Use Weldability
Ingot iron .03* Deep drawing Excellent
Low C .15* Electrodes Excellent
Mild Steel .15-.30 Structural Good
Medium C .30-.50 Machinery Fair
High C .50-1.0 Springs, dies Poor
* Single values are maximums
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Module 6 - 35
Low Alloy Steels
High strength, low alloy
Automotive & machinery
Low temperature
Elevated temperature
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Module 6 - 36
High Alloy Steels
Corrosion resistant
High temperature
High strength
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Module 6 - 37
Stainless Steels
Contain at least 12% Cr
Austenitic
Martensitic
Ferritic
Precipitation hardening
Duplex
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Module 6 - 38
Elements in Steels - 1 of 2
C - Most important
S - Undesirable
P - Undesirable
Si - Deoxidizer
Mn - Combines with S
Cr - Hardenability, Corrosion Resistance
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Module 6 - 39
Elements in Steels - 2 of 2
Mo - Hardenability
Ni - Toughness, Ductility
Al - Deoxidizer
V - Hardenability
Nb - Stabilizer
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Module 6 - 40
Dissolved Gases
(Embrittle steels, cause porosity)
Hydrogen
Oxygen
Nitrogen
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Module 6 - 41
Aluminum Alloys
Heat treatable
Major Alloying Aluminum Association
Element Number
Cu 2XXX
Mg & Si 6XXX
Zn 7XXX
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Module 6 - 42
Aluminum Alloys
Non-heat treatable
Major Alloying Aluminum Association
Element Number
Pure Al 1XXX
Mn 3XXX
Si 4XXX
Mg 5XXX
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Module 6 - 43
Nickel Alloys
Corrosionresistant
Good low temperature properties
Good high temperature properties
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Module 6 - 44
Copper Alloys
Electrical
conductivity
Resistance to corrosion
Resistance to erosion
Resistance to water and salt water
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Module 6 - 45
Destructive Testing
“Failing, or destroying, a part, or a portion
thereof, to determine its properties”
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Module 6 - 46
Nondestructive Testing
“Does not affect the serviceability of the part
after testing is completed”
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Module 6 - 47
Tensile Testing
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Module 6 - 48
Typical Stress/Strain Curve - Steel
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Module 6 - 49
Sample Preparation
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Module 6 - 50
Area of a Circular Cross Section
Example 1
Area (circle)= x Radius2 = R2
= x Diameter2 = D2
4 4
Sample Diameter, D = 0.505 in.
Sample Radius, R = 0.2525 in.
Area = 3.1416 x 0.25252
Area = 0.20 in2
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Module 6 - 51
Alternate Calculation
Example 2 (using diameter directly)
Area = ∏ D2
4
Area = 3.1416 x (0.505) 2
4
Area = 0.20 in2
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Module 6 - 52
Calculation Shortcut
Area of Circle shortcut:
Area = 0.7854 x D2
because:
÷ 4 = 3.1416 ÷ 4 = 0.7854
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Module 6 - 53
Calculation of Tensile Strength
Example 3
Load to break = 12,500 lbs
Area of sample = 0.20 in. 2
Tensile strength = load area
Tensile strength = 12,500 0.20
Tensile strength = 62,500 psi
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Module 6 - 54
Offset
Method
Unit Strain e e
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Module 6 - 55
Stress-Strain Diagram
High and Medium Strength Steels
High Strength Steel
High Carbon Spring Steel
Structural Steel
Medium Strength Steel
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Module 6 - 56
Percent Elongation
Original gage length = 2.0 in.
Final gage length = 2.6 in.
%Elongation = final length - original length x 100
original length
%Elongation = 2.6 - 2.0 x 100 = 30%
2.0
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Module 6 - 57
Percent Reduction of Area
Original area = 0.2 in.2
Final area = 0.1 in. 2
%Reduction of area (%RA) = ?
%RA = original area - final area x 100
original area
%RA = 0.2 - 0.1 x 100 = 50%
A m e0.2
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Module 6 - 58
Hardness Tests
Brinell
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Module 6 - 59
Hardness Tests
Rockwell
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Module 6 - 60
Hardness Tests
Microhardness
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Module 6 - 61
Hardness Testing Steps
Preparesurface
Make indentation
‘Measure’ indentation
Determine hardness
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Module 6 - 62
Toughness Testing
Impact testing a- pendulum b- drop weight
* charpy and Izod
Notch toughness
Transition temperature
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Module 6 - 63
Charpy Test
Prepare notched specimens (sets of 3)
Test each specimen set at a specific
temperature
Impact sample
Plot results
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Module 6 - 64
Charpy Specimens
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Module 6 - 65
Typical
Charpy
Testing
Machine
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Module 6 - 66
Charpy Test Results
Energy absorption - Ft. lbs.
Percent shear - %
Lateral expansion - Mils
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Module 6 - 67
Transition
Temperature
Determinations
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Module 6 - 68
Transition Temperature Samples
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Module 6 - 69
Soundness Testing
Bend testing
Nick-break
Fillet break
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Bend Test Samples Module 6 - 70
Transverse Weld Bend Specimens
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Module 6 - 71
Bend Test Samples
Longitudinal Weld Bend Specimens
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Module 6 - 72
Guided Bend Test Jig
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Module 6 - 73
Wrap-around
Bend Test Jig
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Module 6 - 74
Bend Test Procedure
Prepare sample
Orient in jig
Bend sample (weld and HAZ in bend)
Evaluate bend to Code
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Module 6 - 75
Nick Break Test
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Module 6 - 76
Evaluation of Nick-Break Test
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Module 6 - 77
Fillet Break Test
Prepare sample
Break sample
Evaluate fracture
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Module 6 - 78
Fillet Break - Sample Fracture
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Module 6 - 79
Fillet Break Specimen - T-Joint
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Module 6 - 80
Fatigue Testing
Prepare samples
Test series of various loads
Test to failure, record cycles
Test at maximum load vs no failure
Plot data
Determine endurance limit
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Module 6 - 81
Chemical Testing
Determines Chemistry of Metals
Spectrographic
Combustion (CO, CO2 determination)
Wet chemistry (titration)
X-Ray fluorescence (XRF)
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Module 6 - 82
Corrosion Testing
“Evaluates metals in corrosive environments”
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Metallographic Testing
Shows structure of metal
Macroscopic - less than 10X
Microscopic - typically more than 100X
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Module 6 - 84
Photomacrograph
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Module 6 - 85
Photomicrograph
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Module 6 - 86
Heat Treatment - 1 of 3
Mechanical properties are often very
dependent upon heat treat condition
Many types of heat treatment
Determine heat treat condition prior to
welding on base metal or mech. testing
Consider effects of welding on heat treat
condition and mechanical properties
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Module 6 - 87
Heat Treatment - 2 of 3
Heat Treatments For Steels:
Preheating
Stress Relieving
Normalizing
Annealing
Quenching and Tempering
Others
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Module 6 - 88
Heat Treatment - 3 of 3
Heat Treatments For Stainless Steels:
Preheating
Stress Relieving
Solution Annealing, Water Quench
(Solution Treatment)
Quenching and Tempering
Others
More on heat treating in Module 8
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