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
Metal Properties
Physicalproperties (density)
Mechanical properties *
Alloy chemistry
Alloy heat treatment
* Mechanical properties depend on alloy

chemistry, heat treatment and cold work.
Module 6 - 3
Strength
The ability of a material to bear an applied

load
Module 6 - 4
Strength
Two common methods of expression:
Ultimate tensile strength (UTS)

Yield strength (or yield point)
Module 6 - 5
Metal Behavior Under Load

Elastic - No permanent deformation
Plastic - Permanent deformation
Module 6 - 6
Elastic
Behavior of
Steel
Module 6 - 7
Temperature Effects
As metal temperatures increase:
Strength decreases
Hardness decreases
Ductility increases
Module 6 - 8
Ductility
The ability of a metal to deform without breaking
Module 6 - 9
Brittle vs Ductile Failure
Brittle Ductile
Module 6 - 10
Ductility Terms
Percent elongation
Percent reduction of area
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.
Module 6 - 12
Rolling Directions
X Direction Best Strength & Ductility

Y Direction 10 - 30% Less Strength
20 - 50% Less Ductility
Z Direction Still Lower Strength & Ductility
Module 6 - 13
Hardness
Ability to resist indentation
Module 6 - 14
Indenter Types
Module 6 - 15
Hardness Tester
Module 6 - 16
Indentation
Shapes
Module 6 - 17
Toughness
The ability to absorb energy
Module 6 - 18
Toughness Comparison
Module 6 - 19
Notch Toughness
Toughness in the presence of surface notches

and rapid loading
(also referred to as Impact Strength)
Module 6 - 20
Stress Riser
A surface condition, or geometric feature,

that increases the applied stress at the
condition or geometry
Module 6 - 21
Stress Risers (Notch Effects)
Module 6 - 22
Notch Effects on Fatigue
Module 6 - 23
Surface Finish Effects on Fatigue
Module 6 - 24
Ductile - to - Brittle
Transition Temperature
The temperature at which a metal fracture

mode changes from ductile to brittle
Module 6 - 25
Fatigue Strength
The strength of a metal when exposed to

repeated reversals of cyclic stresses
Module 6 - 26
Endurance Limit
The maximum stress at which no failure will

occur, regardless of cycles
Module 6 - 27
Typical S-N Curves
Module 6 - 28
Soundness
Freedom from discontinuities
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
Module 6 - 30
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 - 31
Low Alloy Steels

Highstrength, low alloy additions
Used for Automotive sheet & machinery
Good low temperature properties
Good elevated temperature properties
Module 6 - 32
High Alloy Steels

Corrosion resistant
Good high temperature properties
High strength
Module 6 - 33
Stainless Steels
Contain at least 12% Cr

Austenitic
Martensitic
Ferritic
Precipitation hardening
Duplex
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
Module 6 - 35
Elements in Steels - 2 of 2
Mo - Hardenability
Ni - Toughness, Ductility
Al - Deoxidizer
V - Hardenability
Nb - Stabilizer
Module 6 - 36
Dissolved Gases
(Embrittle steels, cause porosity)
Hydrogen
Oxygen
Nitrogen
Module 6 - 37
Aluminum Alloys
Heat treatable
Major Alloying Aluminum Association

Element Number
Cu 2XXX
Mg & Si 6XXX
Zn 7XXX
Module 6 - 38
Aluminum Alloys
Non-heat treatable
Major Alloying Aluminum Association

Element Number
Pure Al 1XXX
Mn 3XXX
Si 4XXX
Mg 5XXX
Module 6 - 39
Nickel Alloys
Corrosionresistant
Good low temperature properties
Good high temperature properties
Module 6 - 40
Copper Alloys
Electrical
conductivity
Resistance to corrosion
Resistance to erosion
Resistance to water and salt water
Module 6 - 41
Destructive Testing
Failing, or destroying, a part, or a portion

thereof, to determine its properties
Module 6 - 42
Nondestructive Testing
Does not affect the serviceability of the part

after testing is completed
Module 6 - 43
Tensile Testing
Module 6 - 44
Typical Stress/Strain Curve - Steel
Module 6 - 45
Sample Preparation
Module 6 - 46
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 - 47
Alternate Calculation
Example 2 (using diameter directly)
Area = D2
4
Area = 3.1416 x (0.505) 2

4
Area = 0.20 in2
Module 6 - 48
Calculation Shortcut
Area of Circle shortcut:
Area = 0.7854 x D2
because:
4 = 3.1416 4 = 0.7854
Module 6 - 49
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 - 1

* Mechanical properties depend on alloy

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

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

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