Module 6 - 1

Module 6

Metal Properties
and
Destructive
Testing

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Module 6 - 2

Metal Properties
Physical

properties (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 - 3

Strength
The ability of a material to bear an
applied load

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Module 6 - 4

Strength
Two common methods of expression:
Ultimate

tensile strength (UTS)

Yield strength (or yield point)

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Metal Behavior Under

Load

Module 6 - 5

Elastic

- No permanent deformation
Plastic - Permanent deformation

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Module 6 - 6

Elastic
Behavior
of Steel

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Module 6 - 7

Temperature Effects
As metal temperatures increase:
Strength

decreases
Hardness decreases
Ductility increases

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Module 6 - 8

Ductility
The ability of a metal to deform without
breaking

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Module 6 - 9

Brittle vs Ductile Failure

Brittl
e

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Module 6 - 10

Ductility Terms
Percent

elongation
Percent reduction of area

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Module 6 - 11

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 - 12

Rolling Directions

X Direction

Best Strength & Ductility

Y Direction

10 - 30% Less Strength

20 - 50% Less Ductility

2 Direction

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Still Lower Strength & Ductility

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Module 6 - 13

Hardness
Ability to resist indentation

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Module 6 - 14

Indenter Types

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Module 6 - 15

Hardness Tester

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Module 6 - 16

Indentatio
n Shapes

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Module 6 - 17

Toughness
The ability to absorb energy

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Module 6 - 18

Toughness Comparison

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Module 6 - 19

Notch Toughness
Toughness in the presence of
surface notches and rapid loading
(also referred to as Impact
Strength)

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Module 6 - 20

Stress Riser
A surface condition, or geometric
feature, that increases the applied
stress at the condition or geometry

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Stress Risers (Notch

Effects)

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Module 6 - 21

o c i e t y

Module 6 - 22

Notch Effects on Fatigue

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Surface Finish Effects on

Fatigue

Module 6 - 23

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Module 6 - 24

Ductile - to - Brittle
Transition Temperature

The temperature at which a metal

fracture mode changes from ductile
to brittle

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Module 6 - 25

Fatigue Strength
The strength of a metal when
exposed to repeated reversals of
cyclic stresses

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Module 6 - 26

Endurance Limit
The maximum stress at which no
failure will occur, regardless of
cycles

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Module 6 - 27

Typical S-N Curves

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Module 6 - 28

Soundness
Freedom from discontinuities

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Module 6 - 29

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 - 30

Common Steel Alloys

Common Name
Weldability
Ingot iron
Low C
Mild Steel
Medium C
High C

C%

Typical Use

.03*
.15*

Deep drawing Excellent

Electrodes
Excellent
.15-.30
Structural
Good
.30-.50
Machinery
Fair
.50-1.0
Springs, dies
Poor

* Single values are maximums

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Module 6 - 31

Low Alloy Steels

High

strength, low alloy

Automotive & machinery
Low temperature
Elevated temperature

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Module 6 - 32

High Alloy Steels

Corrosion

resistant
High temperature
High strength

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Module 6 - 33

Stainless Steels
Contain at least 12% Cr
Austenitic
Martensitic
Ferritic
Precipitation

hardening

Duplex

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Module 6 - 34

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 - 35

Elements in Steels - 2 of 2
Mo

- Hardenability
Ni
- Toughness, Ductility
Al
- Deoxidizer
V
- Hardenability
Nb
- Stabilizer

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Dissolved Gases

(Embrittle steels, cause

porosity)

Module 6 - 36

Hydrogen
Oxygen
Nitrogen

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Aluminum Alloys

Module 6 - 37

Heat treatable

Major Alloying
Element
Cu
Mg & Si
Zn

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Aluminum Association
Number
2XXX
6XXX
7XXX

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Module 6 - 38

Aluminum Alloys
Non-heat treatable

Major Alloying
Element
Pure Al
Mn
Si
Mg

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Aluminum Association
Number
1XXX
3XXX
4XXX
5XXX

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Module 6 - 39

Nickel Alloys
Corrosion

resistant
Good low temperature properties
Good high temperature properties

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Module 6 - 40

Copper Alloys
Electrical

conductivity
Resistance to corrosion
Resistance to erosion
Resistance to water and salt water

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Module 6 - 41

Destructive Testing
Failing, or destroying, a part, or a
portion thereof, to determine its
properties

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Module 6 - 42

Nondestructive Testing
Does not affect the serviceability of
the part after testing is completed

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Module 6 - 43

Tensile Testing

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Typical Stress/Strain Curve

- Steel

Module 6 - 44

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Module 6 - 45

Sample Preparation

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Area of a Circular Cross

Section

Module 6 - 46

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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Alternate Calculation

Module 6 - 47

Example 2 (using diameter

directly)
Area = D2
4
Area = 3.1416 x (0.505)
4

Area = 0.20 in2

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Module 6 - 48

Calculation Shortcut
Area of Circle shortcut:
Area = 0.7854 x D2
because:
4 = 3.1416 4 = 0.7854

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Calculation of Tensile
Strength

Module 6 - 49

Example 3

Load to break =
Area of sample =

12,500 lbs
0.20 in. 2

Tensile
Tensile
Tensile

=
=
=

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Module 6 - 50

Offset
Method

Unit Strain e e

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Stress-Strain Diagram

Module 6 - 51

High and Medium Strength

Steels
High Strength Steel
High Carbon Spring Steel
Structural Steel
Medium Strength Steel

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Module 6 - 52

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
2.0

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= 30%

o c i e t y

Module 6 - 53

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%
0.2

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Hardness Tests

Module 6 - 54

Brinell

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Module 6 - 55

Hardness
Tests
Rockwell

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Module 6 - 56

Hardness
Tests

Microhardness

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Module 6 - 57

Hardness Testing Steps

Prepare

surface
Make indentation
Measure indentation
Determine hardness

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Module 6 - 58

Toughness Testing
Impact

testing
Notch toughness
Transition temperature

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Module 6 - 59

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 - 60

Charpy Specimens

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Module 6 - 61

Typical
Charpy
Testing
Machine

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Module 6 - 62

Charpy Test Results

Energy

absorption - Ft. lbs.

Percent shear - %
Lateral expansion - Mils

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Module 6 - 63

Transition
Temperature
Determination
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Transition Temperature
Samples

Module 6 - 64

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Module 6 - 65

Soundness Testing
Bend

testing
Nick-break
Fillet break

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Bend Test Samples

Transverse Weld Bend
Specimens

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Module 6 - 66

o c i e t y

Bend Test Samples

Longitudinal Weld Bend

Specimens

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Module 6 - 67

o c i e t y

Module 6 - 68

Guided Bend Test Jig

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Module 6 - 69

Wraparound
Bend Test
Jig

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Module 6 - 70

Bend Test Procedure

Prepare

sample
Orient in jig
Bend sample (weld and HAZ in
bend)
Evaluate bend to Code

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Nick Break Test

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Module 6 - 71

o c i e t y

Evaluation of Nick-Break
Test

Module 6 - 72

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Module 6 - 73

Fillet Break Test

Prepare

sample
Break sample
Evaluate fracture

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Fillet Break - Sample

Fracture

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Module 6 - 74

o c i e t y

Fillet Break Specimen - TJoint

Module 6 - 75

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Module 6 - 76

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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Chemical Testing

Module 6 - 77

Determines Chemistry of Metals

Spectrographic
Combustion

(CO, CO2
determination)
Wet chemistry (titration)
X-Ray fluorescence (XRF)

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Module 6 - 78

Corrosion Testing
Evaluates metals in corrosive
environments

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Module 6 - 79

Metallographic Testing
Shows

structure of metal
Macroscopic - less than 10X
Microscopic - typically more than
100X

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Module 6 - 80

Photomacrograph

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Module 6 - 81

Photomicrograph

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Module 6 - 82

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 - 83

Heat Treatment - 2 of 3
Heat Treatments For Steels:
Preheating
Stress Relieving
Normalizing
Annealing
Quenching and Tempering
Others

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Module 6 - 84

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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