Metal Properties and Destructive Testing: Module 6 - 1

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
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.
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
Module 6 - 5
Selection process of materials

 Kinds of materials
 Properties of materials
 Service requirement
 Economy
 Method preparation
 Method of testing and inspections
Module 6 - 6
Strength
“The ability of a material to bear an applied

load”
Module 6 - 7
Strength
Two common methods of expression:
 Ultimate tensile strength (UTS)

 Yield strength (or yield point)
Module 6 - 8
Metal Behavior Under Load

 Elastic - No permanent deformation
 Plastic - Permanent deformation
Module 6 - 9
Elastic
Behavior of
Steel
Module 6 - 10
Temperature Effects
As metal temperatures increase:
 Strength decreases
 Hardness decreases
 Ductility increases
Module 6 - 11
Ductility
The ability of a metal to deform without breaking

* Measurements
A- Elongation
B - Reduction
Module 6 - 12
Brittle vs Ductile Failure
Brittle Ductile
Module 6 - 13
Ductility Terms
 Percent elongation
 Percent reduction of area
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.
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
Module 6 - 16
Hardness
“Ability to resist indentation or scratch”

A-Indentation Hardness
B-Rebound Hardness
C-Scratch Hardness
D-Wear Hardness
E-Machinability
Module 6 - 17
Hardness test type

 Brinell
 Rockwell
 Vickers
 Micro
Module 6 - 18
Indenter Types
Module 6 - 19
Hardness Tester
Module 6 - 20
Indentation
Shapes
Module 6 - 21
Toughness
“The ability to absorb energy”
Module 6 - 22
Toughness Comparison
Modulus of toughness
Module 6 - 23
Notch Toughness
“Toughness in the presence of surface notches

and rapid loading”
(also referred to as “Impact Strength”)
Module 6 - 24
Stress Riser
“A surface condition, or geometric feature,

that increases the applied stress at the
condition or geometry”
Module 6 - 25
Stress Risers (Notch Effects)
Module 6 - 26
Notch Effects on Fatigue
Module 6 - 27
Surface Finish Effects on Fatigue
Module 6 - 28
Ductile - to - Brittle
Transition Temperature
“The temperature at which a metal fracture

mode changes from ductile to brittle”
Module 6 - 29
Fatigue Strength
“The strength of a metal when exposed to

repeated reversals of cyclic stresses”
Module 6 - 30
Endurance Limit
“The maximum stress at which no failure will

occur, regardless of cycles”
Module 6 - 31
Typical S-N Curves
Module 6 - 32
Soundness
“Freedom from discontinuities”
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
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

Module 6 - 35
Low Alloy Steels

 High strength, low alloy
 Automotive & machinery
 Low temperature
 Elevated temperature
Module 6 - 36
High Alloy Steels

 Corrosion resistant
 High temperature
 High strength
Module 6 - 37
Stainless Steels
Contain at least 12% Cr

 Austenitic
 Martensitic
 Ferritic
 Precipitation hardening
 Duplex
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
Module 6 - 39
Elements in Steels - 2 of 2
 Mo - Hardenability
 Ni - Toughness, Ductility
 Al - Deoxidizer
V - Hardenability
 Nb - Stabilizer
Module 6 - 40
Dissolved Gases
(Embrittle steels, cause porosity)
 Hydrogen
 Oxygen
 Nitrogen
Module 6 - 41
Aluminum Alloys
Heat treatable
Major Alloying Aluminum Association

Element Number
Cu 2XXX
Mg & Si 6XXX
Zn 7XXX
Module 6 - 42
Aluminum Alloys
Non-heat treatable
Major Alloying Aluminum Association

Element Number
Pure Al 1XXX
Mn 3XXX
Si 4XXX
Mg 5XXX
Module 6 - 43
Nickel Alloys
 Corrosionresistant
 Good low temperature properties
 Good high temperature properties
Module 6 - 44
Copper Alloys
 Electrical
conductivity
 Resistance to corrosion
 Resistance to erosion
 Resistance to water and salt water
Module 6 - 45
Destructive Testing
“Failing, or destroying, a part, or a portion

thereof, to determine its properties”
Module 6 - 46
Nondestructive Testing
“Does not affect the serviceability of the part

after testing is completed”
Module 6 - 47
Tensile Testing
Module 6 - 48
Typical Stress/Strain Curve - Steel
Module 6 - 49
Sample Preparation
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
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
Module 6 - 52
Calculation Shortcut
Area of Circle shortcut:
Area = 0.7854 x D2
because:
 ÷ 4 = 3.1416 ÷ 4 = 0.7854
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
Module 6 - 54
Offset
Method
Unit Strain e e
Module 6 - 55
Stress-Strain Diagram
High and Medium Strength Steels
High Strength Steel

High Carbon Spring Steel
Structural Steel
Medium Strength Steel
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
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
r i c a n We l d i n g So c i e t y
Module 6 - 58
Hardness Tests
Brinell
Module 6 - 59
Hardness Tests
Rockwell
Module 6 - 60
Hardness Tests
Microhardness
Module 6 - 61
Hardness Testing Steps

 Preparesurface
 Make indentation
 ‘Measure’ indentation
 Determine hardness
Module 6 - 62
Toughness Testing
 Impact testing a- pendulum b- drop weight
* charpy and Izod
 Notch toughness
 Transition temperature
Module 6 - 63
Charpy Test
 Prepare notched specimens (sets of 3)
 Test each specimen set at a specific
temperature
 Impact sample
 Plot results
Module 6 - 64
Charpy Specimens
Module 6 - 65
Typical
Charpy
Testing
Machine
Module 6 - 66
Charpy Test Results

 Energy absorption - Ft. lbs.
 Percent shear - %
 Lateral expansion - Mils
Module 6 - 67
Transition
Temperature
Determinations
Module 6 - 68
Transition Temperature Samples
Module 6 - 69
Soundness Testing
 Bend testing
 Nick-break
 Fillet break
Bend Test Samples Module 6 - 70
Transverse Weld Bend Specimens
Module 6 - 71
Bend Test Samples
Longitudinal Weld Bend Specimens
Module 6 - 72
Guided Bend Test Jig
Module 6 - 73
Wrap-around
Bend Test Jig
Module 6 - 74
Bend Test Procedure

 Prepare sample
 Orient in jig
 Bend sample (weld and HAZ in bend)
 Evaluate bend to Code
Module 6 - 75
Nick Break Test
Module 6 - 76
Evaluation of Nick-Break Test
Module 6 - 77
Fillet Break Test

 Prepare sample
 Break sample
 Evaluate fracture
Module 6 - 78
Fillet Break - Sample Fracture
Module 6 - 79
Fillet Break Specimen - T-Joint
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
Module 6 - 81
Chemical Testing
Determines Chemistry of Metals
 Spectrographic
 Combustion (CO, CO2 determination)
 Wet chemistry (titration)
 X-Ray fluorescence (XRF)
Module 6 - 82
Corrosion Testing
“Evaluates metals in corrosive environments”
Module 6 - 83
Metallographic Testing
 Shows structure of metal
 Macroscopic - less than 10X
 Microscopic - typically more than 100X
Module 6 - 84
Photomacrograph
Module 6 - 85
Photomicrograph
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
Module 6 - 87
Heat Treatments For Steels:
 Preheating
 Stress Relieving
 Normalizing
 Annealing
 Quenching and Tempering
 Others
Module 6 - 88
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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Module 6 - 1

* Mechanical properties depend on alloy

Selection process of materials

“The ability of a material to bear an applied

 Ultimate tensile strength (UTS)

Metal Behavior Under Load

The ability of a metal to deform without breaking

Brittle vs Ductile Failure

Both strength and ductility are affected by the

X Direction Best Strength & Ductility

“Ability to resist indentation or scratch”

Hardness test type

“The ability to absorb energy”

“Toughness in the presence of surface notches

(also referred to as “Impact Strength”)

“A surface condition, or geometric feature,

Stress Risers (Notch Effects)

Notch Effects on Fatigue

Surface Finish Effects on Fatigue

“The temperature at which a metal fracture

“The strength of a metal when exposed to

“The maximum stress at which no failure will

Typical S-N Curves

“Freedom from discontinuities”

Common Steel Alloys

Ingot iron .03* Deep drawing Excellent

* Single values are maximums

Low Alloy Steels

High Alloy Steels

Contain at least 12% Cr

Major Alloying Aluminum Association

Major Alloying Aluminum Association

“Failing, or destroying, a part, or a portion

“Does not affect the serviceability of the part

Typical Stress/Strain Curve - Steel

Area of a Circular Cross Section

Area = 3.1416 x 0.25252

Area = 3.1416 x (0.505) 2

Area = 0.20 in2

Calculation of Tensile Strength

Tensile strength = load  area

High Strength Steel

%Elongation = final length - original length x 100

%Elongation = 2.6 - 2.0 x 100 = 30%

Percent Reduction of Area

%RA = 0.2 - 0.1 x 100 = 50%

Hardness Testing Steps

Charpy Test Results

Transition Temperature Samples

Transverse Weld Bend Specimens

Guided Bend Test Jig

Bend Test Procedure

Nick Break Test

Evaluation of Nick-Break Test

Fillet Break Test

Fillet Break - Sample Fracture

Fillet Break Specimen - T-Joint

“Evaluates metals in corrosive environments”