MM 212

Materials Evaluation Techniques

Fall Semester 2020, FMCE, GIK Institute

Lecture 1-4
Instructor:
Muzammil Irshad
(Lecturer)

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Brief Introduction of the Instructor:

Muzammil Irshad
Lecturer, FMCE, GIK Institute

➢MS in Materials Science & Eng. (2016), ME Department, KFUPM, Saudi Arabia

Research Interests: Materials Characterization, Composite materials, Ceramics,

Nanocomposites, Tribology, Electrochemistry , Welding

Research Experience: Centre of Research Excellence in Nanotechnology (Research Institute)

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Selective Publications
• Investigation of the Structural and Mechanical Properties of Nano/Micro Al2O3and cBN Composites prepared by Spark
Plasma Sintering. (Ceramics International), May 2017, 10645-10653
• Effect of Ni content and particle size of Al2O3 on the Thermal and Mechanical properties of Al2O3/Ni composites Prepared
by Spark Plasma Sintering. (International Journal of Refractory Metals and Hard Materials), 24 May 2018, 76, 25-32
• Carbon/carbon Nano Composites as Counter Electrodes for Platinum free dye-sensitized solar cells (Organic Electronics) 35
(2016): 128-135.
• The Effect of Impingement velocity and angle variation on the Erosion-Corrosion performance of API 5L-X65 Carbon Steel
in a Flow Loop. Metals, Special Issue: Failure Mechanisms in Alloys (MDPI), 31 May 2018
• Effect of accumulation of environmental dust and subsequent mud formation on textural, chemical and optical properties of
silicon wafers for photovoltaic cell applications. Published 19 May 2018, IEEE Journal of Photovoltaic.
• Structural and Mechanical Properties of Nano and Micro Al2O3-cBN Composites Prepared by SPS. (Patent, 503462US)
• Tribological behaviour and performance of alumina-based nanocomposites reinforced with uncoated and Ni-coated cubic
Boron Nitride (August 2019) Research Aggregators: (Below links for your information and interest)

https://scholar.google.com/citations?user=yPbALhYAAAAJ&hl=en 3
 Contact Details

Office: M06 – FMCE

Email: [email protected]

Office Visiting hours:

Monday-Friday : 3:30pm – 4:30pm

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Course Learning Outcomes
Mapping of CLOs and PLOs PLOs
1. Engineering Knowledge
Blooms 2. Problem Analysis
Sr. No Course Learning Outcomes PLOs 3. Design analysis
Taxonomy
4. Design/Development of solutions
Be able to understand various 5. Investigation
properties of materials by C2: 6. Modern Tool Usage
CLO_1 PLO1 7. The Engineer and Society
comprehending the interaction of Comprehension
material with different energy types. 8. Environment and Sustainability
9. Ethics
Be able to distinguish different 10. Individual and Team Work
destructive and non-destructive C2: 11. Communication
CLO_2 PLO1
techniques for the evaluation of Comprehension 12. Project Management
materials. 13. Lifelong Learning
Be able to apply different destructive Bloom Taxonomy Level (BTL)
CLO_3 and non-destructive techniques for the PLO2 C3: Applying 1. Knowledge
materials evaluation. 2. Comprehension
3. Application
4. Analysis
5. Evaluation
6. Creating

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Course Grading and Assessment
Overall Grading Policy
Assessment Items Percentage CLO Assessment Mechanism
Project/Case Studies/Presentations 10%
Assessment tools CLO_1 CLO_2 CLO_3
Quizzes (scheduled) 15%
Assignments 5% Quizzes/Mid Final 100% 100%
Midterm Exam 30% Exam
Final Exam 40% Course Project 100%

Administrative Instructions
1. According to institute policy, 80% attendance is mandatory to appear in the final
examination.
2. Assignments must be submitted as per instructions mentioned in the assignments.
3. In any case, there will be no retake of (scheduled/surprise) quizzes.
4. For queries, kindly follow the office hours in order to avoid any inconvenience.

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Text Book

Title: Introduction to the Principles of Materials Evaluation

Author: David C. Jiles

Reference Book

ASM Handbooks: Vol. 8 and 17

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 Text and Reference Books:

1. “Introduction to Principles of Materials Evaluation” by David C. Jiles, 2008

2. “Testing of Materials” by Vernon John, Macmillan Education Ltd, 1992

3. “Nondestructive Evaluation-Theory, Techniques, and Applications” by Peter J. Shull, 2002”

4. “Mechanical Metallurgy” by G.E Dieter, McGraw-Hill, 1988

5. “Non-Destructive Testing” by R. Halmshaw, 2nd Edition, 1991

6. “ASM Handbooks: Vol. 8, 10, 11, 17 ”

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 Materials Evaluation Techniques & Instrumentation (MM212)
Credit hours: 3, Prerequisites: MM102
Brief Outlines of the Course

❑ Introduction to Materials evaluation techniques

❑ Classification of materials evaluation techniques

❑ Destructive testing (DT)

❑ Non-Destructive Testing (NDT)

❑ Introduction to spectroscopy

❑ Microscopy (SEM, TEM, AFM)….

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Terminologies used in Evaluation of Materials

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 What is Materials Evaluation ?

❑ Materials Evaluation is the analysis and testing of materials.

❑ Applications ranging from consumer products and heavy industry

to electronic and medical devices

❑ Underlying principle behind all materials evaluation techniques

is the interaction of energy of some type with a material.

❑ Types of energy i.e. heat, light, sound, electricity, magnetism, and

radiation.

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Engineering Materials

Metals Semiconductors Ceramics

Nano-materials Smart materials Polymers

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FUNDAMENTALS OF MATERIALS EVALUATION

❑ Most important concept in materials evaluation

and non-destructive testing is that materials
change with time.

❑ In practice, after service exposure, the material

is not the same as when it began life.

❑ Degradation of the materials properties

eventually leads to a failure

❑ It is therefore desirable to monitor the

degradation of the material, if for no other reason
than to identify when failure is likely to occur.

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Degradation of Materials
Internal wall of a carbon steel oil
sands tailings pipe

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Monitoring of Welding Work

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EFFECTS OF DIFFERENT FORMS OF ENERGY ON MATERIALS

❑ Structural changes occur in a material as a result of prolonged exposure to high levels of different forms of energy.

❑ These changes can include:

✓ Residual Stress
✓ Embrittlement
✓ Fatigue
✓ Creep
✓ Radiation damage
FACTORS THAT CAN CAUSE FAILURE OF A MATERIAL

❑ Mechanical Component

❑ Mechanical component together with other factors, such as

temperature, chemical action, or radiation.

❑Some of the main failure mechanisms are:

✓Fatigue

✓Creep

✓Corrosion

✓Oxidation

✓ Thermal embrittlement
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✓ Radiation embrittlement. Embrittlement Oxidation/Corrosion
Testing of Materials
Materials testing can be either destructive testing (DT)or Non-
destructive testing (NDT).
1. Destructive:

MACROEXAMINATION
✓ Either with the naked eye or under a very low magnification (5x-
10x) (e.g. Poor Weld Profile)
✓ Traditional destructive examination, which involves cutting and
polishing a material to look for macroscopic flaws and
inhomogeneities.
✓ After polishing the material is often etched to emphasize
metallurgical differences.

MICROEXAMINATION (MICROGRAPHS)

✓ This consists of cutting and polishing a material, followed by

examination under a microscope (20x-2000x).
✓ The surface is usually photographed, which allows documentation 18
and examination of the metallurgical microstructure.
Macro and Micro-examination of Materials

Polished and etched grains of a Optical micrographs showing inter- Optical micrograph showing the
sample of iron granular stress corrosion cracking in brass pearlitic structure of the grains

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Micro Examination of Materials (SEM)
Mechanical Component of Failure
15° 30°
Deep
impression

ploughing

Extruded lip
Elongated formation Plastic
ploughing deformation
5µ 5µ 2µ

60° 90° 90°

Wide craters

Indentation/ Indentation/
extrusion craters

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2µ 100µ 2µ
Various methods in Materials Evaluation

▪ In most cases, the evaluation of materials is through measurement of the physical properties
of materials.

▪ Physical properties can be observed or measured without changing the composition of

matter. Physical properties are used to observe and describe matter. Physical
properties include: appearance, texture, colour, odour, melting point, boiling point, density,
solubility, polarity, tensile strength, yield strength , Phase Transformation Temperatures,
Specific Gravity, Thermal Conductivity, Thermal Expansion, Electrical Conductivity,
Resistivity and many others.

▪ This involves utilizing the interaction of different forms of energy with materials i.e.
Mechanical, Acoustic, Thermal, Optical, Electrical, Magnetic, Radiative etc.

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Concept for Non-destructive Evaluation

▪ When a test material needs to be interrogated to assess its condition, it should be affected or impacted
appropriately (energy input) and its response (energy output) studied.

▪ General concept for NDE of materials is that relationship between the output energy and input energy gives
information about the state of the material.

▪ Different types of Non-destructive evaluation techniques are available i.e. VI, DPT, MPI, RT, UT etc.

▪ Methods or techniques are classified by the type of energy used (i.e. electrical, optical, thermal, radiation
etc.)

▪ Different types of energies used, depending on information required.

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 Overview of Nondestructive Testing

▪ Introduction to NDT

▪ Overview of Six Most

Common NDT Methods

▪ Selected Applications
Definition of NDT

▪ The use of different (noninvasive) techniques to

determine the integrity of a material, component or
structure

▪ Quantitatively measure some characteristic of

an object.

i.e. Inspect or measure without doing harm or damage.

Methods of NDT

Visual
What information you can get with use of NDE Methods ?

▪ Flaw Detection and Evaluation

▪ Leak Detection
▪ Location Determination
▪ Dimensional Measurements
▪ Structure and Microstructure Characterization
▪ Estimation of Mechanical and Physical Properties
▪ Stress (Strain) and Dynamic Response Measurements
▪ Material Sorting and Chemical Composition Determination
▪ To assist in product development
▪ To monitor, improve or control manufacturing processes
When are NDE Methods Used ?

▪ There are NDE applications at almost any stage of the production and life cycle of component
 To verify proper processing such
as heat treating
 To verify proper assembly
 To inspect for in-service damage
Six Most Common NDT Methods

• Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• Eddy Current
• X-ray
Visual Inspection (Unassisted & Assisted)

Most basic and common inspection

method.

Tools include fiberscope's, borescopes,

magnifying glasses and mirrors.

Portable video inspection unit with zoom

allows inspection of large tanks and vessels,
railroad tank cars, sewer lines.

Robotic crawlers permit observation in

hazardous or tight areas, such as air ducts,
reactors, pipelines.
 Liquid Penetrant Inspection

• A liquid with high surface wetting characteristics is applied to the surface of the part
and allowed time to seep into surface breaking defects.

• The excess liquid is removed from the surface of the part.

• A developer (powder) is applied to pull the trapped penetrant out the defect and
spread it on the surface where it can be seen.

• Visual inspection is the final step in the process. The penetrant used is often
loaded with a fluorescent dye and the inspection is done under UV light to
increase test sensitivity.
Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen.
These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over
the discontinuity. This indication can be visually detected under proper lighting conditions.
Magnetic Particle Crack Indications
 Radiography

The radiation used in radiography testing is a higher energy (shorter

wavelength) version of the electromagnetic waves that we High Electrical Potential
see as visible light. The radiation can come from an X-ray generator
or a radioactive source. Electrons
+ -

X-ray Generator or
Radioactive Source
Creates Radiation

Radiation
Penetrate
the Sample

Exposure Recording Device

Film Radiography

The part is placed between the radiation source and a piece of film.
The part will stop some of the radiation. Thicker and more dense area
will stop more of the radiation.

The film darkness (density) will vary with the

amount of radiation reaching the film through the
test object.
X-ray film

= less exposure

= more exposure
Top view of developed film
Radiographic Images
 Eddy Current Testing

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
 Eddy Current Testing

Eddy current testing is particularly well suited for detecting surface cracks but can also be
used to make electrical conductivity and coating thickness measurements. Here a small
surface probe is scanned over the part surface in an attempt to detect a crack.
 Ultrasonic Inspection (Pulse-Echo)

High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing
the depth of features that reflect sound.

initial f
pulse

back surface
echo
crack
echo

0 2 4 6 8 10

Oscilloscope, or flaw plate crack

detector screen
 Ultrasonic Imaging

High resolution images can be produced by plotting signal strength or time-of-flight using a computer-controlled
scanning system.

Gray scale image produced using the sound reflected

Gray scale image produced using the sound
from the back surface of the coin (inspected from
reflected from the front surface of the coin
“heads” side)
Common Application of NDT

➢ Inspection of Raw Products

➢ Inspection Following Secondary Processing
➢ In-Services Damage Inspection

▪ Forgings,
▪ Castings,
▪ Extrusions,
▪ etc.
Inspection Following Secondary Processing

▪ Machining
▪ Welding
▪ Grinding
▪ Heat treating
▪ Plating
▪ etc.
Inspection For In-Service Damage

▪ Cracking
▪ Corrosion
▪ Erosion/Wear
▪ Heat Damage
▪ etc.
Power Plant Inspection

Periodically, power plants are shutdown for inspection.

Inspectors feed eddy current probes into heat
exchanger tubes to check for corrosion damage.

Pipe with damage Probe

Signals produced by
various amounts of
corrosion thinning.
 Wire Rope Inspection

Electromagnetic devices and visual inspections are used to

find broken wires and other damage to the wire rope that is
used in chairlifts, cranes and other lifting devices.
Storage Tank Inspection

Robotic crawlers use ultrasound to inspect

the walls of large above ground tanks for
signs of thinning due to corrosion.

Cameras on long articulating

arms are used to inspect
underground storage tanks for
damage.
Aircraft Inspection

▪ Nondestructive testing is used extensively during the

manufacturing of aircraft.
▪ NDT is also used to find cracks and corrosion damage
during operation of the aircraft.
▪ A fatigue crack that started at the site of a lightning
strike is shown below.
 Jet Engine Inspection

▪ Aircraft engines are overhauled after being in service for a

period of time.
▪ They are completely disassembled, cleaned, inspected and
then reassembled.
▪ Fluorescent penetrant inspection is used to check many of the
parts for cracking.
Crash of United Flight 232 Sioux City, Iowa, July 19, 1989

A defect that went undetected in

an engine disk was responsible
for the crash of United Flight
232.
Pressure Vessel Inspection

The failure of a pressure vessel can result in the rapid

release of a large amount of energy. To protect against
this dangerous event, the tanks are inspected using
radiography and ultrasonic testing.
Rail Inspection

Special cars are used to inspect thousands of miles of

rail to find cracks that could lead to a derailment.
 Bridge Inspection

▪ The US has 578,000 highway bridges.

▪ Corrosion, cracking and other damage can all
affect a bridge’s performance.
▪ The collapse of the Silver Bridge in 1967
resulted in loss of 47 lives.
▪ Bridges get a visual inspection about every 2
years.
▪ Some bridges are fitted with acoustic emission
sensors that “listen” for sounds of cracks
growing.
 Pipeline Inspection

NDT is used to inspect pipelines to prevent leaks that could

damage the environment. Visual inspection, radiography
and electromagnetic testing are some of the NDT methods
used.

Remote visual inspection using a

robotic crawler.

Magnetic flux leakage inspection. This

device, known as a pig, is placed in the
pipeline and collects data on the condition of
the pipe as it is pushed along by whatever is
being transported.
Radiography of weld joints.
Special Measurements

Boeing employees in Philadelphia were given the privilege of evaluating the Liberty Bell for damage using
NDT techniques. Eddy current methods were used to measure the electrical conductivity of the Bell's
bronze casing at various points to evaluate its uniformity.

Remedial actions after evaluation of materials

1. Replace
2. Repair
3. Continue service
Mechanical Testing of Materials

❑ Primary concern in non-destructive evaluation is mechanical condition of materials.

❑ Therefore, investigations begin with the study of mechanical properties.

❑ This includes elastic and inelastic properties of materials.

❑ Stress/strain curves give us very basic information on the mechanical condition of a

material.

❑ Hardness measurements are means of determining the resistance of a material to plastic

deformation.

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Mechanical Testing of Materials

Effects of Stress on a Material

❑ Stress can cause strain, which can be elastic deformation for low stress levels, and plastic deformation at
higher stress levels.

❑ Failure can be caused by a single application of stress, when it exceeds the tensile strength, whereby the
material is effectively stretched until it fails.

❑ Objective of material evaluation is to determine the condition of material, how much permanent
damage has been done to a material and how close it is to failure.

❑ One way to achieve this material evaluation objective, is through mechanical testing.

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Mechanical Testing of Materials

Different forms of Mechanical Testing include the following:

✓ Tensile testing
✓ Hardness testing (i.e. Brinell, Rockwell, Vickers, Knoops )
✓Fatigue testing
✓Creep testing
✓Impact testing (i.e. Charpy, Izod)

❑ Elastic Moduli can be obtained from tensile tests and tell us about the deformation of material.

❑ Other mechanical properties may be of interest for materials evaluation e.g. ultimate tensile strength,
brittleness and the fracture toughness.

❑ Such properties are obtained from destructive tests performed on a selected representative group of
samples, and it is then assumed that the properties of the untested materials are the same as those obtained
with the representative group.
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Mechanical Testing of Materials (Representative group of samples)

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Mechanical Testing of Materials

Destructive testing of Materials

❑ Part or product tested no longer maintains its original shape or surface texture.

❑ Mechanical test methods are all destructive.

Other destructive tests include:

✓ Speed testing of grinding wheels to determine their bursting speed.

✓ High pressure testing of pressure vessels to determine their bursting pressure.

Destructive vs Non-destructive

✓ Hardness tests with large indentations may be regarded as destructive testing.

✓ Micro hardness tests may be regarded as non-destructive because of the very small
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permanent indentations.
Mechanical Testing of Materials (Material Selection)
A particular material is selected on the basis of following considerations:

1. Properties of material
Mechanical properties - strength, ductility, toughness, hardness, strength to weight ratio etc.
Physical properties - density, specific heat, thermal expansion, conductivity , melting point etc.
Chemical properties - oxidation , corrosion, flammability, toxicity etc.
Manufacturing properties - formed, casting, machined, welding etc.

2. Cost of material

3. Availability of material (desired shape and size and quantity) & reliability of supply.

4. Service in life of material

5. Appearance of material: Colour, Surface texture etc.

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