UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

Tensile Testing
Laboratory-01
Introduction
Figure below shows the typical tensile instrument for mechanical testing. The mechanical
properties of materials are determined by performing carefully designed laboratory
experiments that replicate as nearly as possible the service conditions. In real life, there
are many factors involved in the nature in which loads are applied on a material. The
following are some common examples of modes in which loads might be applied: tensile,
compressive, and shear. These properties are important in materials selections for
mechanical design. Other factors that often complicate the design process include
temperature and time factors. The topic of this lab is confined to the tensile property of
metal samples.

Figure 1:TypicalInstron load frame used for tensile testing.

Objective
1. To learn how to use Inston Universal Material Testing Machine for tensile testing.
2. To determine modulus of elasticity, tensile strength and fracture strength of test

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

specimen.
Materials/Apparatus
1. Mild steel rod
2. Aluminium rod
3. Inston 5582 Tensile Machine
4. Extensometer
5. Ruler
6. Vernier caliper.
Procedures:
1.

The diameter and lengths (gage length) of all the specimens were measured and
recorded.

2.

Fast equipment calibration was performed. The load cell was calibrated and the
reading was set to be zero after having gripping the specimen at the upper size. The
strain was set to zero.

3.

The sample was gripped firmly at the bottom.

4.

Bluehill 2 software was used to setup the test program and saved it with an
identifiable file name. The procedures were create for a method of tension test,
measurement unit(SI) was selected and the criteria was define.

5.

The test was run.

6.

The experiment was repeated with other specimen rods (aluminium, & mild steel).

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

Mild Steel
Table 1: Average initial and final diameter of mild steel
Reading

Initial diameter Final

1st
2nd
3rd
Average

(mm)
4.54
4.48
4.50
4.51

diameter Initial length Final

(mm)
3.06
3.10
3.24
3.13

(cm)
4.0
4.0
4.0
4.0

length

(cm)
4.3
4.3
4.3
4.3

1. Youngs modulus
From the Figure 2, when tensile strain = 0.2%, tensile stress = =425 MPa .
Youngs modulus =graph gradient
=

Tensile Stress
Tensile strain

2 1
21
6

42510 0
0.0020

=212.5 GPa
Percentage error =

value
|CalculatedTruevalueTrue
|
value
GPa
|212.5GPa180
|
180 GPa

x 100%

x 100%

= 18.06%
2. Proportional limit
Maximum tensile stress along proportional limit line = 525MPa
Maximum tensile strain along proportional limit line = 0.25%
3. No upper and lower yield stress can be observed from the Figure 2.

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

4. 0.2% yield strength

2
Cross-sectional area: A = r 0

do

=
2

( )

4.51 x 103

= 1.597507718 x 10-5 m2
Load at yield point = 10137.57654 N
Yield stress at 0.2% plastic strain,

F
Ao

10137.57654 N
1.597507718 x 105 m2

= 634.5870149MPa
5. Ultimate strength
Maximum load = 10331.76929 N
Ultimate tensile stress,

F
Ao

10331.76929 N
1.597507718 x 105 m2

= 646.7429968MPa

Percentage error =

value
|CalculatedTruevalueTrue
|
value
MPa860 MPa
|646.74 860
|
MPa

= 24.80%

x 100%

x 100%

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

6. % elongation at fracture
l f l o
lo

( )

% EL =

x 100%

( 4.3 x 1024.0 x 102 )

4.0 x 10

x 100

=7.50%
7. % reduction in area
% RA =

A f A o
Ao

x 100%

3 2

3 2

3.13 x 10
2

) (

4.51 x 10
2

4.51 x 10
2

3 2

= -51.83455342%
8. True stress and true strain
Cross-sectional area:
=

Af

2
= rf

3.13 x 103
2

=7.694467267 x 10-6m2
Load at yield point = 10137.57654 N

True stress

t=

F
Af

x 100%

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

10137.57654 N
7.694467267 x 106 m

= 1.317515065 GPa
True strain

= ln (
=ln (

AO
Af

1.604599864 x 105 m2
7.694467267 x 106 m 2

= 0.7349579787
=73.49579787%

Aluminium
Table 2: Average initial and final diameter of aluminium
Reading
Initial diameter Final
diameter
(mm)
(mm)
1st
4.50
4.20
nd
2
4.48
4.06
3rd
4.58
3.94
Average
4.52
4.07

Initial length Final

(cm)
(cm)
4.0
4.4
4.0
4.4
4.0
4.4
4.0
4.4

length

Table 3: Data for stress-strain curve of aluminium.

Force
(N)

2
Area ( m

0
100
110
1250
2600
4000
4800

1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5

Tensile stress (MPa)

Extension, l

(mm)
0.000000000
6.259750665
6.885725731
78.24688331
162.7535173
250.3900266
300.4680319

0.00
0.25
0.50
0.75
1.00
1.25
1.50

Initial
l
length, o
(cm)
4.00
4.00
4.00
4.00
4.00
4.00
4.00

Tens
strain

0.000
0.625
1.250
1.875
2.500
3.125
3.750

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

5000
5100
5200
5300
5500
5600
5700
5500
5350
0

1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5
1.597507718 x 10-5

312.9875332
319.2472839
325.5070346
331.7667852
344.2862866
350.5460372
356.8057879
344.2862866
334.8966606
0.000000000

1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
3.75
4.00

4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00

4.375
5.000
5.625
6.250
6.875
7.500
8.125
8.750
9.375
10.00

Tensile stress (MPa)

400
350
300
250
200
150
100
50
0
0

Figure 3: Tensile stress-strain curve of aluminium.

1. Youngs modulus
From the Figure 3,

10

12

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

when tensile strain = 1.25%, tensile stress 6.885725731 MPa .

when tensile strain = 3.125%,tensile stress 250.3900266 MPa .

Youngs modulus = graph gradient

=

Tensile Stress
Tensile strain

2 1
21

250.3900266 x 1066.885725731 x 106

0.031250.0125

=12.98689605GPa
value
|CalculatedTruevalueTrue
|
value

Percentage error =

G Pa
|12.99GPa69
|
69 GPa

x 100%

x 100%

= 81.17%

2. Proportional limit
Maximum tensile stress along proportional limit line = 300.4680319MPa
Maximum tensile strain along proportional limit line = 3.75%
3. No upper and lower yield stress can be observed from the Figure 3.
4. 0.2% yield strength
Cross-sectional area:

Ao

2
= r0

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

d
o
2

( )

=
=

4.52 x 103
2

= 1.6046 x 10-5 m2
Load at yield point = 4970.62380 N
Yield stress at 0.2% plastic strain,

F
Ao

4970.62380 N
1.6046 x 105 m2

= 309.773389MPa

Percentage error =

value
|CalculatedTruevalueTrue
|
value
MPa
|309.77 MPa95
|
95 MPa

x 100%

= 226.07%

5. Ultimate strength
Maximum load = 5223.65645 N
Ultimate tensile stress,

F
Ao
5223.65645 N

= 1.6046 x 105 m2
= 325.425932MPa

x 100%

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

value
|CalculatedTruevalueTrue
|
value

Percentage error =

MPa110 MPa
|325.43 110
|
MPa

x 100%

x 100%

= 195.85%

6. % elongation at fracture
% EL =

l f l o
lo

( )

x 100%

( 4.4 x 1024.0 x 102)

4.0 x 102

x 100

=10.00%
7. % reduction in area
% RA =

A f A o
Ao

x 100%
2

) (

4.07 x 103
4.52 x 103

2
2

4.52 x 103

= -18.9203344%
8. True stress and true strain
Af

Cross-sectional area:

2
= rf

4.07 x 103
=
2

5
=1.301004204 x 10 m2

x 100%

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

Load at yield point = 4970.62380 N

True stress

t=

F
Af
4970.62380 N

= 1.301004204 x 105 m2
= 382.0605487GPa
True strain

AO
= ln ( A f )
5

1.604599864 x 10 m
= ln ( 1.301004204 x 105 m2 )

= 0.2097379887
=20.97379887%

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

Discussion
Youngs modulus or modulus of elasticity is used to measure the stiffness of certain
material. Modulus of elasticity has to do with bonding strength between the atoms in the
material.The gradient of the straight line of the curve in elastic region is used to trace
Youngs Modulus. Under elastic region, materials might experience elastic deformation
show linear relationship between tensile stress and tensile strain that can be described by
Hookes law. Elastic deformation is temporary.When the applied stress is removed, the
sample returns to its original shape Based on the calculation, the calculated Youngs
Modulus of mild steel is greater than Youngs Modulus of aluminium, which are 212.5
GPa and 12.99 GPa respectively. Usually, materials that possess high modulus elasticity
has high stiffness As such, mild steel is said to be more elastic and stiffer than aluminium.
Besides that, the proportional limit of mild steel is greater than aluminium. Often,
many mixed up proportional limit with elastic limit. Proportional limit is used to show to
linearity between tensile stress and strain whereas elastic limit is the maximum stress and
strain that the material can bear, so that it able to return to original shape once the applied
load is removed. From the observation, Figure 2 and 3 show no indication regarding
upper and lower yield stress. This type of yielding is due to discontinuous dislocation that
caused by plastic deformation. Referring to Figure 4, upper yield strength is higher and
the yield drops greatly to lower yield point after reaching upper yield point. This kind of
phenomenon depends upon many variables, they are alloy composition, presence of
impurities and cold working. It happens commonly in mild steel mainly because of the
presence of interstitial atoms like carbon and nitrogen as the alloying elements. Lower
yield strength is useful in structural engineering design.
Overall, the yield strength of mild steel is much greater than aluminium. Meaning,

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

mild steel has better resistivity prior to plastic deformation, more stress is required for the
conversion of elastic to plastic transition state. In real life application, it is tedious to find
out elastic-to-plastic point precisely. Hence, 0.002 offset straight line is drawn parallel to
elastic region. The intersection of the line constructed with the stress-strain curve is
known as the yield strength. Ultimate tensile strength is the highest stress value

Figure 4 Upper and lower yield points in stress-strain curve

that the material can sustain when it is pulled apart before result in fracture. Based on the
result, it can be concluded that mild steel capable to withstand heavier load than
aluminium do. Type of fracture can be identified via macroscopic examination like naked
eye observation. As shown in Figure 5, there is presence of necking and cup-and-cone
fracture formation. Hence, it is predicted to be ductile fracture. However, chevron

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

patterns and remnant of microvoid can be seen on the aluminium. Aluminium is likely
underwent brittle fracture. Elongation percentage of steel is comparatively lower than
aluminium by 2.5%. The reduction area percentage of mild steel and aluminium are
51.83% and 18.92%.
Percentage error of different values of mild steel and aluminium are compared and
calculated using Table 4. The percentage error of Youngs Modulus, yield strength and
ultimate strength for mild steel Youngs Modulus are 18.06%, 26.41, 24.80%
respectively, which are within acceptable range. However the estimated Youngs
Modulus, yield strength and ultimate strength of aluminium deviated significantly from
the standard values, which are corresponding to 81.17% 226.07% and 195.85%. The high
percentage errors might be due to insufficient use of points to represent the trend and
correlation between tensile stress and tensile strain of aluminium during the conversion of
load-extension curve to stress-strain curve. There are several factors that might contribute
to the cause of

the high pencentage errors. The examples are test environment

temperature, surface and microstructure defects and non-standard compositions. The

extensometer that attached to the machine should be handled with care as it is very fragile
and sensitive.
Conclusion
The Youngs Modulus, tensile strength and ultimate strength of mild steel are
212.5 GPa, 634.59 MPa and 646.74 MPa. They are all witin the acceptable range. The
Youngs Modulus, tensile strength and ultimate strength of aluminium are 12.99 GPa,
309.77 MPa and 325.43 MPa, which are out of satisfactory range. From the experiment,
Mild steel experienced ductile fracture whereas aluminium was likely underwent brittle
fracture Different materials have different mechanical properties. Mild steel has better
mechanical properties than aluminium.

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

Figure 5: Fracture surface of mild steel Figure 6: Fracture surface of aluminium.

Table 4: Comparison between Youngs Modulus, yield strength and ultimate tensile
strength of mild steel and aluminium.
Material

Youngs

Mild Steel
Aluminium

(GPa)
180
69

Modulus Yield

Strength Ultimate Tensile Strength

(MPa)
502
95

(MPa)
860
110

References
Books
1. Charles

Brooks,

2001.

Failure

Analysis

of

Engineering

Materials.1

Edition.McGraw-Hill Professional.Internet, pp.106-108.

2. William D. Callister, 2011. Materials Science and Engineering.8th Edition. John
Wiley & Sons Ltd, pp. 250-254.
3. William F. Smith, 2009. Foundations of Materials Science and Engineering.
Student international of 5th revised Edition. Mcgraw Hill Higher Education,
pp.287-290.
Internet
1. The

Engineering

Toolbox,

Available

from: <http://www.engineeringtoolbox.com/young-modulus-d_417.html>

[07

UEMT 2223 MATERIALS TESTING AND FAILURE ANALYSIS

March 2015].