MSE 332 Inspection and Testing of Materials

(October 20, 2014)

Abdul Wadood (PhD), Assistant Professor

Department of Materials Science and
Engineering
Room# 211 (MSE)
Visiting Hours: 11:00 13:00

Attendance: 80% as per Institute policy

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 MSE 332 Inspection and Testing of Materials
Grading Policy:

Quizes: 5 (20%)

3 OHTs: 30%

Final: 50%

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 Type of Materials
Metallic Materials
Polymeric Materials Performance Goal

Ceramic Materials
Composite Materials Properties

Inter-related
Intermetallic
Electronic Materials
Structure
Aerospace Materials
Biomaterials Processing
Nano materials
Smart Materials Material

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 Materials Properties

1. Physical properties

2. Mechanical properties

3. Chemical properties

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 MSE 332 Inspection and Testing of Materials
Any organization , big or small must look for quality of its
products.

For quality, organization establishes ways to control the materials

by having a check system on quality, precision and accuracy.

Control on incoming/outgoing materials is exercised through

Inspection.

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 Management Issues
Management must:
Understand and support the objectives of the
inspection process.

Be willing to commit the resources necessary to train

inspectors.

Be willing to include inspections in project schedules.

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MSE 332 Inspection and Testing of Materials
Management
Find problems at the earliest possible point in the
development process.

Provide data on product quality and process

effectiveness.

Build technical knowledge among team members.

Follow the standard of excellence for product and

company.

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 Development Process Issues
There must be:
Support for inspections within the engineering
organization.

An identification of potential obstacles to the inspection

process.

Resources available for training in the inspection process

Commitment to train new employees as they are hired.

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 Inspection---Team Work
Moderator Coordinates the inspection and
leads the discussion.

Inspector Inspects the product.

Recorder Records problems discussed.

Manager Supervises the producer.

Identify and rectify errors and defects in the work product being inspected
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 Hardness Research Papers

Ti-xCr-3Sn Titanium alloys

350
Vickers Hardness / HV

/ Metastable Stable +

Young Modulus
martensite
300 /

250 // Slip
//
200
x=4 x=5 x=6 x=7 x=8 x=9 stabilizing

elements
A. Wadood, T. Inamura, H. Hosoda, S. Collings EW, in Physical
Miyazaki, Materials Transactions metallurgy of titanium alloys
52 (2011) 1787-1793 (Metals Park, OH: ASM; 1984)

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 Responsibilities of the Moderator
Understand the information being inspected.

Lead the team in an effective discussion.

Recognize key issues and keep the team focused.

Maintain an unbiased view of the information being

presented.

Assign responsibilities.

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 Responsibilities of the Inspector
Be familiar with the product being inspected as well as the
required documents and standards for the product.

Identify discrepancies between the work product and applicable

documents and standards.

Focus on identifying problems.

Remain objective.

Criticize the product not the producer.

Support the moderator

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 Responsibilities of the Recorder

Be thoroughly familiar with the product being

inspected.

Record all issues raised by the team and ensure

that they are recorded correctly.

Record additional information as requested by

the moderator.

Support the moderator.

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 Responsibilities of the Manager
To decide what to inspect.

Include inspections in project schedules.

Allocate resources for inspections.

Support inspection training.

Support the moderator in completing any required

rework.
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 Objective of the Inspection Meeting
Identify errors and defects in the work product
being inspected and ways to overcome them
Standard Procedures---followed or not

Defects/Errors??, How to get rid of such defects?

Customers complaints/demands

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 Objective of Overview Meeting
Educate the inspection team on the work product
being inspected and discuss the review material.

Objective of the Inspection Meeting

Identify errors and defects in the work product
being inspected, ways to solve them.
Objective of the Follow-Up
Assure that appropriate action has been taken to
correct problems found during an inspection.
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 Inspection Process
Planning

Overview Meeting

Inspection Process

Inspection Meeting

Follow-up

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 Objectives of Planning
Which products need to be inspected?

Identify the inspection team.

Determine whether an overview meeting is

necessary.

Schedule overview and inspection meetings.

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 Incoming Materials Control
There are several ways of carrying out inspection.

Pre Dispatch Inspection

This is inspection before dispatch of material. Usually specified in the

Purchase Order (PO).

The inspection is carried out at suppliers area (works).

After internal clearance of the material in all respect & internal

checking, the supplier gives the final Inspection Request (IR) to the
inspection agency mentioned in the PO.

After receiving IR, the inspecting officer visits the suppliers side along
with documents necessary for inspecting such as copy of PO, drawing,
specification etc.
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MSE 332 Inspection and Testing of Materials
On receiving test results, they are conformed
that specification is verified & clearance is given
to the supplier for further processing of the item.

In some critical cases, joint inspection by

Indenter & Inspection is carried out.

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MSE 332 Inspection and Testing of Materials
Document Inspection :

Sometimes and usually for very standard

requirements, inspection can be carried out through
the verification of supplier given certificates such as
Material Test Certificate , Manufacturing Certificate,
Guarantee Certificate etc.

After ensuring conformance of materials to the

ordered specification, in all respect, Inspection
Certificate (IC) is issued by the inspecting officer to
the supplier.
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MSE 332 Inspection and Testing of Materials
Stores / Receiving Items Inspection :

Majority of items are inspected through this route.

Materials are received in Stores.

Such items are usually accepted based on visual

examination & verification of documents.

Materials in the store are separated into several

categories, based on their quality control status and
destination. 22
 Materials in the Receiving Bay
Awaiting inspection This category consists of material that has been
received and is awaiting inspection before being moved into stock.

Acceptance upon certification This category consists of material that

may be accepted pending certification.

Rework In this category are materials that are defective and must be
reworked.

Return This category contains materials that are defective and will be
returned to the supplier for credit or replacement.

Materials to be tested This category consists of materials which have

been received and are awaiting delivery to the using/testing
department

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 MSE 332 Inspection and Testing of Materials
Quality Complaint Issues:
If materials after issue to the user department is found to be having
defects such as dimensional deviation, fitness problem etc, the
supplier is asked to supply free replacement against such defects.

If there is a pre-mature failure of the material, joint investigation is

carried out by the indenter & inspection agency.

If it is established that, the pre-mature failure has occurred due to

use of wrong material or faulty material, the supplier is asked to
either rectify the defects (if feasible) or supply free replacement.

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 Materials Testing--Objectives
Ensure quality
Material properties e.g. brittle, ductile
Prevent failure in use
Choice of materials
Factor of Safety
Interpretation of results
Phase constitution, phase transformation
Structural stability
Thermal stability
Mode of deformation
Strength of material
Physical and chemical properties
Dimensional accuracy
Defects free structures/components
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MSE 332 Inspection and Testing of Materials
Documentation
Inspection and test results must be documented on a
company form with letterhead.

Inspection and test results must clearly indicate:

the type and number of inspections or tests performed

the results of the inspection or test
the signature/date of personnel performing the test
Defects/defective parts %age

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MSE 332 Inspection and Testing of Materials
Documentation
When required by the Purchase Order, the
Inspection and Test Reports shall be provided

Inspection and Test Reports shall not contain

any qualifying statements, such as to the best
of our knowledge, approximately, etc.

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MSE 332 Inspection and Testing of Materials

All instruments, gages, and tools used to perform official

inspections and tests must be calibrated in accordance
with a documented calibration program.

Actual instruments, gages, and tools used to perform

official inspections and tests should be identified and
listed in the inspection or test report:

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MSE 332 Inspection and Testing of Materials
Documentation (continued)
Inspection Records and Test Reports shall be
traceable back to the product being tested or
inspected and the applicable procedures or
instruction being used.

Corrections of errors on Inspection Records or

Test Reports shall be in accordance with the
requirements/Specifications.

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MSE 332 Inspection and Testing of Materials

To better ensure the integrity of the inspection

system :
Implement an over-check program that periodically
confirms inspector results.

Implement a refresher training and qualification

program for inspectors (similar to NDT, welding, etc.)

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