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    Karthi

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    s.manjunarayana
    The document describes various tests conducted to determine the nature of braze joints, including dye penetration and radiography testing to check for defects, microstructural characterization using optical microscopy, Vickers microhardness testing to analyze hardness variation, scanning electron microscopy with EDS for composition detection, tensile, three-point bend, and impact testing, as well as immersion corrosion and electrochemical corrosion testing.

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    Karthi

    Uploaded by

    s.manjunarayana
    5 views23 pages
    The document describes various tests conducted to determine the nature of braze joints, including dye penetration and radiography testing to check for defects, microstructural characterization using optical microscopy, Vickers microhardness testing to analyze hardness variation, scanning electron microscopy with EDS for composition detection, tensile, three-point bend, and impact testing, as well as immersion corrosion and electrochemical corrosion testing.

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    The document describes various tests conducted to determine the nature of braze joints, including dye penetration and radiography testing to check for defects, microstructural characterization using optical microscopy, Vickers microhardness testing to analyze hardness variation, scanning electron microscopy with EDS for composition detection, tensile, three-point bend, and impact testing, as well as immersion corrosion and electrochemical corrosion testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    5 views23 pages

    Karthi

    Uploaded by

    s.manjunarayana
    The document describes various tests conducted to determine the nature of braze joints, including dye penetration and radiography testing to check for defects, microstructural characterization using optical microscopy, Vickers microhardness testing to analyze hardness variation, scanning electron microscopy with EDS for composition detection, tensile, three-point bend, and impact testing, as well as immersion corrosion and electrochemical corrosion testing.

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    of 23

    Determining the nature of braze joint by

    following tests
    A)DYE PENETRATION AND RADIOGRAPHY TEST TO CHECK THE
    SOUNDNESS OF THE BRAZING JOINT.
    B)MICROSTRUCTURAL CHARACTERIZATION BY OPTICAL
    MICROSCOPY.
    C)VICKER’S MICROHARDNESS TEST TO DETERMINE THE VARIATION
    IN HARDNESS IN THE TRANSVERSE
    DIRECTION TO THE WELD BEAD.
    D)SCANNING ELECTRON MICROSCOPY WITH EDS TO DETECT
    COMPOSITION.
    E)TENSILE TEST.
    F)THREE POINT BEND TEST.
    G)IMPACT TEST
    H)IMMERSION CORROSION TEST.
    I)CORROSION TEST USING ELECTROCHEMICAL WORKSTATION.
    A)Dye penetration and radiography test
    to check the soundness of the brazing joint.

    Dye penetration test


    Purpose: To assess the integrity of brazing joints by detecting surface-breaking
    defects.
    Procedure:
    •Clean the surface of the joint.
    •Apply a penetrant dye to the joint.
    •Allow the dye to seep into any surface defects.
    •Wipe off excess dye from the surface.
    •Apply a developer that draws out the dye from the defects, making them visible.
    •Inspect the joint for indications of defects.
    Advantages and Limitations
     Advantages:
     Detects surface cracks, laps, or leaks.
     Simple and cost-effective.
     Can be used on a variety of materials.

     Limitations:
     Limited to surface defects.
     Requires proper cleaning and preparation.
     Not suitable for detecting internal defects.
    Radiography test

     Purpose: To examine the internal structure of brazing joints for


    defects.
     Procedure:
     Place the brazed assembly between an X-ray source and a detector.
     X-rays penetrate the material and create an image on the detector.
     Defects such as voids, inclusions, or insufficient fusion are revealed in
    the X-ray image.
     Interpret the radiographic image for any indications of defects.
    Advantages and Limitations

     Advantages:
     Provides detailed images of internal defects.
     Non-destructive testing method.
     Suitable for complex geometries.
     Limitations:
     Requires specialized equipment and trained personnel.
     Exposure to radiation necessitates safety precautions.
     Costlier compared to some other testing methods.
    B)Microstructural characterization
    by Optical microscopy.
     Introduction to Optical Microscopy: Optical
    microscopy is a powerful technique used to study the microstructure of materials at a
    scale ranging from micrometers to nanometers.

     Principle: Optical microscopes utilize visible light and lenses to magnify and
    resolve details of a specimen's microstructure.

     Components: Optical microscope components include an objective lens,


    eyepiece, light source, and stage for holding the specimen.

     Types of Optical Microscopy: Bright-field microscopy, dark-field


    microscopy, phase-contrast microscopy, and differential interference contrast (DIC)
    microscopy are common techniques used for microstructural characterization.

     Applications: Optical microscopy is widely used in materials science,


    metallurgy, biology, and other fields to analyze grain structure, defects, phases, and
    surface features of materials.
    Microstructural Analysis Process

     Sample Preparation: Samples are prepared by cutting, mounting, polishing,


    and etching to reveal the microstructure.

     Imaging: The prepared sample is placed on the microscope stage, and light is
    directed through the specimen. The objective lens magnifies and focuses the image onto
    the eyepiece or camera.

     Image Analysis: Microstructural features such as grain size, grain boundaries,


    phase distribution, and defects are analyzed using image processing software.

     Interpretation: The observed microstructural characteristics are interpreted to


    understand material properties, performance, and behavior.

     Reporting: Findings are documented in reports or publications, often including


    micrographs and quantitative data to support conclusions.
     Further Analysis: Additional techniques such as electron microscopy or spectroscopy
    may be employed for complementary analysis if needed.
    C)Vicker’s microhardness test to determine
    the variation in hardness in the transverse

    Brief overview of Vicker’s microhardness


    test.
     Definition: Vicker’s microhardness test is a method used to determine the
    hardness of materials by measuring the size of impressions made by a pyramidal
    diamond indenter under a certain load.
     Purpose of the test: To assess the variation in hardness across a
    material's transverse section.
     Importance: Understanding hardness distribution helps in material
    characterization, quality control, and predicting material behavior under
    different conditions.
     Key components: Microhardness tester, Vickers indenter, optical
    microscope for measuring indentation sizes.
    D)Scanning Electron Microscopy
    with EDS to detect composition

    Working principle:
     SEM uses electron beam scanning to produce high-
    resolution images.
     When the electron beam interacts with the sample, it
    generates characteristic X-rays.
     EDS detects and measures these X-rays to determine the
    elemental composition of the sample.
     Mapping and quantitative analysis are possible with SEM-
    EDS, providing valuable insights
    Versatility and Importance of
    SEM-EDS
     Versatility: SEM-EDS is applicable across diverse scientific
    disciplines and industries.
     Material Analysis: Enables detailed examination of elemental
    composition, morphology, and microstructure.
     Research: Facilitates groundbreaking discoveries in fields like
    materials science, biology, and environmental science.
     Industry: Essential for quality control, failure analysis, and product
    development in manufacturing sectors.
     Innovation: Supports innovation by providing insights into material
    properties and behavior at the microscale.
     Problem-solving: Helps troubleshoot issues, identify
    contaminants, and optimize processes
    Applications:

     Material characterization in metallurgy, geology, biology,


    and nanotechnology.
     Identification of unknown substances, contaminants, and
    defects.
     Analysis of particle morphology, chemical composition, and
    distribution.
     Quality control in industries such as semiconductor
    manufacturing, automotive, and aerospace.
    E) Tensile test
    Introduction:
     Tensile test, also known as tension test, is a fundamental mechanical test used to determine the
    behavior of materials under tensile loading.

    Objective:
     To assess the mechanical properties of materials, including yield strength, ultimate tensile
    strength, elongation, and modulus of elasticity.

    Testing Procedure:
     A standardized specimen is subjected to a gradually increasing tensile load until failure occurs.
     Load and extension measurements are recorded throughout the test.

    Equipment:
     Tensile testing machine equipped with grips to hold the specimen.
     Extensometer for accurate measurement of elongation.

    Standards:
     ASTM E8/E8M and ISO 6892 are commonly referenced standards for tensile testing.
    Tensile Test Results and
    Interpretation
    Parameters Measured:
     Yield Strength: Stress at which material begins to deform plastically.
     Ultimate Tensile Strength: Maximum stress material can withstand before failure.
     Elongation: Percentage increase in gauge length at failure.
     Modulus of Elasticity: Measure of material's stiffness.
    Typical Stress-Strain Curve:
     Initial linear region represents elastic deformation.
     Yield point indicates transition to plastic deformation.
     Ultimate tensile strength is the peak stress before fracture.

    Significance:
     Helps in material selection for engineering applications.
     Provides insights into material behavior under load.

    Applications:
     Aerospace, automotive, construction, and manufacturing industries utilize tensile testing for quality control and material
    characterization.
    F)Three point bend test.

     Introduction to Three-Point Bend Test


     Definition: The three-point bend test is a mechanical test
    method used to determine the flexural strength and modulus of
    elasticity of materials.
     Setup: The test involves applying a load to a specimen placed on
    two supports while a third point applies force to the center of the
    specimen, causing it to bend.
     Purpose: It is commonly used in material science and
    engineering to evaluate the behavior of materials under bending
    stress, aiding in material selection and structural design.
     Applications: Widely employed in industries such as
    aerospace, automotive, construction, and manufacturing for
    quality control and research purposes.
    Procedure and Results

     Procedure:
     Prepare the specimen according to ASTM or ISO standards.
     Place the specimen on two supports.
     Apply a load at the center of the specimen using a loading nose or roller.
     Record the applied load and the resulting displacement until failure occurs.
     Calculate flexural strength and modulus of elasticity based on the recorded
    data.
     Results:
     Flexural Strength: Measure of the maximum stress a material can
    withstand before it breaks under bending.
     Modulus of Elasticity: Measure of a material's stiffness and ability to
    deform under stress.
    Analysis and conclusion

     Analysis: Interpret the results to understand the material's


    mechanical properties and behavior under bending stress.
    Compare results with industry standards or specifications.
     Conclusion: Summarize the findings and discuss
    implications for material selection, design optimization, and
    potential improvements in manufacturing processes.
    G)Impact test

     Overview and importance


     Overview: The impact test is a crucial method for evaluating the toughness
    and resistance of materials against sudden or dynamic loading conditions.
     Purpose: It assesses how a material responds when subjected to high-velocity or
    impact loading, simulating real-world scenarios such as collisions, drops, or other
    abrupt forces.
     Importance:
     Ensures product safety: Impact testing helps ensure that products meet
    safety standards and can withstand potential impacts during use.
     Material selection: It aids engineers and designers in selecting appropriate
    materials for applications where impact resistance is critical.
     Quality control: By assessing the material's ability to absorb energy under
    impact, manufacturers can maintain consistent quality and durability of their products.
    Methods and Applications

     Common Test Methods:


     Charpy Impact Test: Measures the amount of
    energy absorbed by a material during fracture.
     Izod Impact Test: Similar to the Charpy test but
    involves a different sample geometry.
     Applications: Widely used in industries such as
    automotive, aerospace, construction, and manufacturing to
    ensure the reliability and safety of materials and products.
    H)Immersion Corrosion Test
    Introduction:
     Immersion corrosion testing is a widely used method to evaluate the corrosion resistance of
    materials.
     It involves exposing materials to a corrosive environment by immersing them in a solution for a
    specific duration.

     Purpose:
     Assess the susceptibility of materials to corrosion in various environments.
     Determine the effectiveness of corrosion protection methods or coatings.

    Procedure:
     Prepare the test samples by cleaning and pre-treating them as per standard procedures.

     Immersion: Submerge the samples completely in the corrosive solution.


     Duration: Maintain the immersion for a predetermined period, typically ranging from hours to
    months.
     Monitoring: Regularly inspect the samples for signs of corrosion such as rust, discoloration, or
    surface degradation.
     Evaluation: Analyze the extent and type of corrosion to assess the material's resistance.
    Parameters and Applications
    Parameters:
     Corrosive solution composition (e.g., saltwater, acid, alkali).
     Temperature and pressure conditions.
     Immersion duration.

    Applications:
     Quality control in manufacturing industries (e.g., automotive,
    aerospace).
     Material selection for infrastructure projects.
     Research and development of corrosion-resistant materials and
    coatings.
    I)Corrosion test using electrochemica
    workstation.

    Corrosion Test Using Electrochemical


    Workstation
     Objective: Evaluate the corrosion resistance of materials using
    electrochemical techniques.

     Importance: Corrosion can lead to structural degradation,


    safety hazards, and economic losses, making accurate testing crucial for
    various industries.
     Overview: This presentation discusses the principles, methods, and
    benefits of corrosion testing using electrochemical workstations.
    Electrochemical Workstation and
    Testing Process
    Electrochemical Workstation:
    A sophisticated instrument for measuring and controlling electrochemical
    processes such as corrosion, electroplating, and battery testing.
     Testing Process:
     Setup: Prepare the sample, electrolyte solution, and electrodes
    according to the testing standards.
     Measurement: Apply a controlled potential or current to the
    sample and measure the resulting electrochemical parameters (e.g.,
    corrosion rate, polarization resistance).
     Data Analysis: Analyze the obtained data to assess the
    corrosion behavior and performance of the material.
    Advantages and Application

    Advantages:
     Precise control over experimental conditions.
     Real-time monitoring of corrosion processes.
     High sensitivity and accuracy.
     Applications: Widely used in industries such as
    automotive, aerospace, marine, and oil & gas for material
    selection, quality control, and research purposes.

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