Contents

General Course Description 2

Thoughts on Report Writing 4
Example of Technical Memo 5
Notes on Laorator! Noteoo"s #
$che%ule &
General Laorator! $afet! 'ractices (
)nit *+ ,nal!sis of -ailing $teel .olts /
)nit 2+ Engineering Characteri0ation of Metals *1
'art ,+ Determination of Case Depth *4
'art .+ Tensile 'roperties of Metals *#
'art C+ 2omin! Test for Comparing the 3eat Treatailit! of $teel *(
'art D+ 4%entif!ing the 4mpact Transition Temperature 25
)nit 1+ Engineering Characteri0ation of 'ol!mers 2*
'art ,+ Rate Depen%ence of Thermoplastic Mechanical 'roperties 21
'art .+ -arication an% Testing of a Composite 25
'art C+ Cure 6ptimi0ation of Thermosetting ,%hesi7es 2&
'art D+ 'h!sical an% Thermal 'roperties of a 'ol!mer 2(
Materials ,pplication 'lanning 12
Materials $election Example 11
$,-E 6'ER,T4NG 'R6CED)RE$
.uehler Mounting 'resses 15
'olishing of Metallographic $pecimens 1#
.uehler ,.R,$4MET Cut8off sa9 1&
LEC6 .elt Grin%er 1(
Roc"9ell 3ar%ness Tester 1/
$,TEC3 'en%ulum 4mpact Tester 45
D!natup Drop To9er 4mpact Tester 4*
Diamon% .an% $a9 42
-T$ $!stems Multi8Cool Temperature .ath 41
$4NTEC3 )T$ 44
Notes on Extensometers 45
*
General Course Description
EQUIPMENT: 'ermanentl! oun% la noteoo" 9ith caron cop! pages: safet! glasses
COURSE GRADE: Written Reports 55;
Wee"l! 'articipation *5;
6ral 'resentations *5;
La Noteoo" 25;
4n in%ustr! !our ailit! to asor an% communicate technical information in oth 9ritten an% oral
forms 9ill e a significant factor in !our success or failure< To help !ou impro7e !our s"ills in
these areas: this class 9ill re=uire !ou to recor% an% present the results of experiments in se7eral
%ifferent contexts<
*< Dataoo" of %ail! experimental results< Data oo" recor%s of experiments an% the
%e7elopment of ne9 i%eas are important in liailit! an% patent cases< Recor%s shoul% inclu%e not
onl! results ut the %etails of reasoning 9hich le% to the performance of experiments< , rea%er
shoul% e ale to reconstruct the entire thought process 9hich resulte% in a particular pro%uct or
%e7elopment< Caron copies of noteoo" pages shoul% e turne% in at the en% of each class
perio%
2< Written reports >letters?< , suggeste% format for a letter or memo >informal? report is
attache%< Rememer that much of !our communication in the outsi%e 9orl% 9ill e @informalA
ut it 9ill still nee% to e concise: complete: an% clear<
1< 6ral presentation Bou 9ill e performing a materials selectionCtesting proDect an% ma"ing an
informal oral presentation of !our anal!sis to the class %uring the final la perio%< Copies of !our
o7erhea%s 9ill e turne% in at the completion of the presentation<
4< 4n%ustrial $tan%ar%s The ailit! to rea% stan%ar%s an% translate them into a course of action
for a testing program is a critical s"ill for a practicing engineer< Bou 9ill e gi7en se7eral
opportunities to stu%! ,$TM testing stan%ar%s an% experimental proce%ures an% then %e7elop
!our o9n laorator! proce%ure from them<
Attendance Policy
-or this class to pro7i%e the necessar! exposure an% experience it is imperati7e that !ou atten% all
la sessions< 4f !ou must miss a session: see the instructor aout oser7ing %uring other class
perio%s< 6tain an! %ata !ou nee% from !our la partners< When !ou miss class !our
participation gra%e 9ill suffer< De%uctions 9ill e sli%ing scale *5 points for the first asence: *5
for the secon% an% so on< $houl% !ou miss more than three las: !ou ma! e %roppe% from the
course at the %iscretion of the instructor<
Individual Wor Policy
Bou 9ill e 9or"ing together in the la en7ironment to otain !our %ata an% results< Bou are
encourage% to 9or" together in anal!0ing those results< 3o9e7er: the 9ritten 9or" !ou turn in
must e B6)R 6WN< E7i%ence of %irect cop!ing from another stu%ent or a text 9ill result in
2
loss of cre%it for the assignment< Repeate% cases of cop!ing ma! result in %ismissal from the class
an% loss of cre%it<
Cla!! Structure
Bou 9ill e assigne% to laorator! teams of 1 to 5 stu%ents in 9hich !ou 9ill perform all la
experiments this semester< The course 9ill consist of a series of rotations< Each group 9ill 9or"
on a %ifferent component of the rotation each 9ee" until all ha7e complete% the rotation< Reports
an% letters for each rotation 9ill e %ue one 9ee" after the completion of the rotation<
1
Thoughts on Memo Writing
There is a spell chec"er in e7er! 9or% processing program on campus 8 use itE 6ne of the fastest
9a!s to raise =uestions aout !our competence is to create %ocuments 9ith misspelle% 9or%s<
$tatistics F ,nal!sis
1. Beware of confusing precision and accuracy.
2. Specimens and samples have different statistical meanings, they are
not interchangeable.
$ources of Error
*< DonGt list error sources that arenGt actuall! li"el!<
2< List specific sources of error: not generalities<
1< 3uman error is al9a!s an assume% source: %onGt remin% !our customer<
Technical $t!le
*< Large listings of %ata are not appropriate< Means F stan%ar% %e7iations onl!<
2< .re7it! is a 7irtue<
1< ,7oi% use of first person pronouns< >4: 9e: us: me?
4< ,7oi% HfeelH an% other suDecti7e: emotional terms< The %ata ma! in%icate: ut it %oes not
ma"e us feel something<
5< DonGt use HtrueH: >except in reference to a long straight oDect? this is not a metaph!sical
science an% 9e ma! ha7e accurate measures ut the! are not Htrue<H 4n fact: the actual 7alue
>truth? of a measurement is un"no9n an% un"no9ale to our science<
#< 3o9 %oes it soun% if !ou rea% it alou%I 4t shoul% ma"e goo% sense an% shoul% not soun% too
otuse
Graphing
*< Watch out for the %efault graph settings in Excel< The! are the 9rong t!pe for most
engineering prolemsE
2< When !ou are as"e% to plot @, 7s< .A this means that . is the in%epen%ent 7ariale > x axis or
hori0ontal? an% , is the %epen%ent 7ariale >! axis or 7ertical?
4
De%uctions for Memos
Misspelle% 9or%s+ 5 points
Wrong 7er tense+ 1 points
6ther grammar 1 points
,9"9ar% sentence 2 points
.ogus filler material 5 to *5 points
Wrong or missing proce%ure *5 points
Missing name *5 points
-ailure to use graphics1 to *5 points
MEMO >Example of Technical Memo?
Date+ ,ugust 25: *//2
To+ 2ohn Doe: Manager 8 4ron 'ro%ucts Di7ision
"ro#+ Dr< .iff .urns: Jualit! ,ssurance Manager 8 Wi%gets Di7ision
Su$%ect:+ Jualit! ,ssurance Testing of 3eat 258/5
The results of testing on the =ualit! assurance samples from heat 258/5 are summari0e% elo9<
The fi7e samples 9ere ta"en from roun%s rolle% from %ifferent illets poure% from the heat< Each
sample 9as cut into fi7e tensile specimens 9hich 9ere har%ness teste% >Roc"9ell . scale? an%
then loa%e% to failure in a tension test< $amples 9ere allo9e% to air cool to laorator!
temperature an% 9ere age% t9ent!8four hours in the laorator! prior to testing< Mill scale 9as
remo7e% from the har%ness test regions using a 9ater8coole% elt grin%er< Tensile tests utili0e% a
constant strain rate of 5<55Cmin an% testing conforme% to ,$TM stan%ar% E8(<
Re!ult! Su##ary
Mean Biel% $tan%ar% Mean
$trength De7iation 3ar%ness $tan%ar%
$ample 4D >"si? >3R.? De7iation
258/58* #5<5 2<55 &5<5 1<52
258/58& #5<2 2<12 #/<5 1<55
258/58** #5<* 2<*1 &*<2 1<#5
258/58*( #4</ 2<5( #(</ 4<52
258/5822 55<& 2<1* #*<4 2<5&
Hardness & Strength of Heats
0
10
20
30
40
50
60
70
80
2
5
-
9
5
-
1
2
5
-
9
5
-
7
2
5
-
9
5
-
1
1
2
5
-
9
5
-
1
8
2
5
-
9
5
-
2
2
Heat ID
H
R
C

o
r


S
t
r
e
n
g
t
h

(
k
s
i
)
Yield Strength (ksi)
Hardness (HRC)
$tu%entsG t8test >using a /5; confi%ence le7el? in%icates that sample 258/5822 is %ifferent from the
prior samples ! a statisticall! significant margin< Thus the last material rolle% is sustantiall!
softer than earlier pro%uct< The most li"el! explanation for this is the loss of caron in the
molten metal on the top of the la%le as it sits expose% to atmosphere 9hile the la%le is %raine%<
$pectroscop! has een re=ueste% to 7erif! the composition of these specimens an% results shoul%
e a7ailale 9ithin the 9ee"< $houl% !ou re=uire further information please contact me<
Note! on &a$oratory Note$oo! version 1.2
5
The eeping of accurate and complete laboratory noteboos is a critical
basic component of most design and development !obs. The noteboo is a
legal record of the problems encountered and ideas developed in the course
of engineering. "ood records are critical to support patent claims and for
defense against in liability claims. #t is important that the noteboo be an
accurate record of the thought processes and activities leading to a final
product or conclusion.
Content! o' a Well Written &a$ Entry
I( Pro$le# !tate#ent: Wh! are !ou %oing thisI What %o !ou hope to learnI
II. Procedur e $ %ow were specimens prepared, tests done& This should be
complete but you may use reference to commonly accepted procedures
rather than detailing the steps in a process which is fre'uently performed.
#f an (ST) procedure is followed, you may merely reference it and cite any
deviations from the procedure or identify subtypes with in the standard.
*e.g.. Type ### specimens were prepared and tested according to (ST) +,-
procedures..
III( Data ) Re!ult! , /hat did you measure, see, hear during the testing or
evaluation.
I* Di!cu!!ion , discuss the significance of the data, offer interpretation, point
out any surprising results.
*( Conclu!ion ) Reco##endation!$ /hat does it mean& 0id you fulfill your
ob!ective, answer the 'uestion&
#
PROCEDURA& RU&ES "OR &A+ +OO,S
*< Lael the first page as a tale of contents an% fill it in as !ou use the noteoo"<
2< La noteoo"s shoul% e 9ritten in -en.
1. 0o not erase or blac out errors. 2ine through them and continue.
3. 4ages should be signed and dated when finished.
5. 4ages which are not filled should have blan areas mared out with an 6.
7. 2eave no blan pages.
8. 9i6ed pages should remain in the noteboo , carbon copies are to be
turned in.
:. 2egibility is mandatory, beauty is not.
-. /rite the records as you go during lab. 0o not write on scratch paper and
recopy later.
1;. 9igures should be firmly taped in place *all four sides. not stapled.
$che%ule
Wee &a$ Out-ut
* 6rientation: Group assignments
Rotation I . Analy!i! o' "ailin/ Steel +olt
2 3ar%ness an% $EM >*F2: 1F4?
>*?
1 Metallograph! >1F4: *F2? Memo
Rotation II . C0aracteri1ation o' a Metal2Alloy
4 Determination of Case Depth >*:2:1:4? Memo
5 Tensile 'roperties of metals >2:1:4:*? N.
>2?
# 2omin! Test for Comparing 3eat Treatailit! of $teels >1:4:*:2? Memo
& 4%entif!ing the 4mpact Transition Temperature of steel >4:*:2:1? Memo
Note+ Group three >fourth 9ee"? 9ill egin the farication an% testing
6f composites la ! constructing their laminate this 9ee"<
Rotation III . C0aracteri1ation o' Poly#er!
( Rate Depen%ence of Thermoplastic 'roperties >*:2:1:4? N.
/ Cure 6ptimi0ation of Thermosetting ,%hesi7es >2:1:4:*? Memo
*5 -arication an% Testing of Composite Materials >1:4:*:2? Memo
** Thermal ,nal!sis of a pol!mer >4:*:2:1? Memo
During thermal anal!sis la: groups 9ill also faricate the composite laminate to e
use% in la the next 9ee"
Rotation I* . "inal Pro%ect
*2 Material testing assignment
*1 Materials Testing assignment
*4 Material selection proDect presentations F la cleanup $li%es
>*? Numers in parenthesis are the group numer or%er for that la< -irst numer is group to %o
la first 9ee": secon% the secon% 9ee": etc<<< -or example >2:1:4:*? means group 2 9ill %o la
first 9ee": group 1 secon% 9ee": group 4 thri% 9ee" an% group * fourth 9ee"<
>2? N. 8 Noteoo" entries onl!
General &a$oratory Sa'ety Practice! ver!ion 3(4
&
*< $afet! glasses are to e 9orn at all times in the laorator!< Exceptions are onl! permitte%
9hen using optical microscopes an% the $EM<
2< ,ll chemicals shoul% e treate% as ha0ar%ous unless !ou "no9 other9ise< Wear chemical
goggles >glasses are ina%e=uate? an% glo7es 9hen han%ling them< ,prons are a7ailale to protect
!our clothing<
1< 4f !ou shoul% get chemicals in !our e!e>s? go imme%iatel! to the e!e9ash station an% egin
irrigation< Do not stop irrigation until %irecte% to %o so ! me%ical personnel<
4< 4f there is a significant splash ha0ar% or sharp proDectile ris": 9ear a full face shiel%: a7ailale in
the la<
5< 6e! poste% safet! notices<
#< No san%als or open toe% shoes are permitte% in the la< Ruer sole% shoes are preferre% for
increase% protection against electrical shoc"s<
&< ,l9a!s note the location of the emergenc! stop uttons on e=uipment< 4f an!thing strange
happens: %o not hesitate to hit the utton< 6n larger e=uipment >MT$: $intech? one in%i7i%ual
shoul% e %esignate% to stan% near the emergenc! stop: rea%! to shut e7er!thing %o9n<
(< Rea% $6'Ks for each piece of e=uipment: efore !ou use it< Bou must sign the $6' log sheet
in the e=uipment in%er efore using an instrument< $ignature in%icates that !ou ha7e rea% an%
un%erstoo% the $6' an% therefore the ha0ar%s an% precautions associate% 9ith the instrument<
The $6' is not an exhausti7e explanation of e=uipment operations: operating principles: or
theor!< Do not use e=uipment for 9hich the $6' re=uires personal protecti7e e=uipment !ou %o
not possess<
(
Unit 3: Analy!i! o' "ailin/ Steel +olt!
INTRODUCTION: The materials scientist has se7eral tools 9hich are use% to characteri0e the
microstructure of materials< These are 7ital since the macroscopic eha7ior of materials is
%epen%ent on the microstructure
APPARATUS: Roc"9ell har%ness tester: Metallographic preparation e=uipment: 6ptical
Microscope: Metallograph: $canning electron microscope
ASTM: Roc"9ell 3ar%ness Testing E*(
O+5ECTI*E: To master asic metallographic an% microstructural measurement s"ills
9hile exploring the relationship et9een microstructure an% har%ness<
TERMINO&OG6+ Metallo/ra-0+ optical microscope %esigne% for metallurgical examination:
usuall!: the specimen is place% ao7e the oDecti7e lens on a platform >in7erte% microscope?<
P0oto#icro/ra-0 >or micrograph?+ photograph ta"en through a microscope< Bou must al9a!s
in%icate the magnification if a micro graph is to e useful<
Etc0in/+ microstructure is often %ifficult to oser7e on a highl! polishe% specimen< The %iffering
resistance of the phases an% the phaseCgrain oun%aries to aci% attac" ma"e it possile to highlight
the phases ! coating or %ipping the material in an aci% solution for a time< $amples must e
thoroughl! 9ashe% an% %rie% efore they are placed in a microscope to protect
fragile optical instruments from corrosion.
PRO+&EM +AC,GROUND: <our company is having problems with a batch
of bolts stripping as they are tightened to the specified tor'ue levels. <ou
are given e6amples of the bolts as well as e6amples from prior batches
which performed ade'uately. 0etermine the metallurgical factors which
may be contributing to this change in performance.
TEC7NICA& +AC,GROUND Metallographic techni=ues permit the examination of the
microstructure of engineering materials< The microstructure ma! consist of 7arious phases:
grains: grain oun%aries: %islocations: fiers: particles: 7oi%s: crac"s etc< $ince mechanical
properties are %etermine% ! the microstructure: metallograph! is a 7aluale tool in anal!0ing
no7el materials an% in %etermining the cause of failure of structures<
Grain $i0e Determination
There are a numer of metho%s for %etermining the a7erage grain si0e in a polishe% an% etche%
metallographic specimen<
*< ,$TM Grain $i0e+ -errous allo!s are rate% on a Logarithmic scale ase% upon the expression
a L 2
n8*
/
where, n is the (merican Society for Testing and )aterials *(ST).
grain si=e and a is the number of grains per s'uare inch when viewed at a
magnification of 1;;6. >onferrous grain si=es have generally been based
upon a linear diameter scale and have been e6pressed as average grain
diameter in inches or in millimeters. #f your micrograph is not taen at
1;;6, you can convert to get the (ST) grain number using the following
e'uation$
*
2
*55

=

n m
m
M
N
2< Direct comparison 9ith stan%ar%s+ The grain si0es 7ie9e% at *55x can e %irectl! compare% to
stan%ar% micro graphs prepare% ! ,$TM< This option is a7ailale to !ou in this la through use
of a special e!epiece<
1< Measurement of ,7erage Grain Diameter+ Direct measurement of the a7erage %iameters of a
large numer of grains is a fre=uentl! use% metho%< Bou can %o this %igitall! in the la<
4< The 2effries Metho%+ 4n this metho%: the numer of grains falling 9ithin: an% on: a circle &/<(
mm in %iameter >5:555 mm
2
area? %ra9n on a groun% glass screen: is %etermine%< This metho% is
extremel! te%ious if use% properl!<
5< ,lternati7e Metho%+ Diagonals are %ra9n across the microstructure< The numer of
intersections et9een a %iagonal an% grain oun%aries are counte%< The grain si0e ma! e
%etermine% using the e=uation+
grain %ia< L *<#( x LC>N x M?
9here: L is the %iagonal length: N is the numer of intersects: an% M is the magnification at 9hich
the grain si0e is measure%<
3ar%ness >Roc"9ell?
3ar%ness usuall! implies a resistance to %eformation< 4n metals: it refers to the materialKs
resistance to permanent or plastic %eformation< 4n materials science it 9ill generall! refer to the
resistance to the %epth of permanent %eformation %ue to a surface in%entation<
3ar%ness tests >Roc"9ell: .rinell: Mnoop: an% others? are fre=uentl! use% to monitor the
=ualit! of material coming into an% or out of a manufacturing facilit!< Though har%ness numers
are not %irectl! useful to the engineer: the! can e use% to estimate engineering parameters such
as !iel% strength an% %uctilit!< Thus: the! pro7i%e a =ualit! control parameter for the %esign
engineer to specif! 9hich can e easil! measure%<
The Roc"9ell t!pe har%ness uses the %epth of in%entation un%er loa% as a measure of
har%ness< , minor loa% of *5 "g is first applie% to the sample< This step minimi0es re=uirements
for surface preparation< The maDor loa% >selecte% ase% upon the scale eing use%? is then applie%
an% the %epth of in%entation is recor%e% ! the machine< The result is an aritrar! har%ness
numer< , high har%ness material 9ill allo9 little penetration< The %ial >or %igital rea%out? is
*5
configure% so that a small penetration correspon%s to a high har%ness numer< Thus a high
har%ness numer means a har% material<
.rinell an% Nic"ers har%ness numers ha7e units of "gCm
2
: ho9e7er Roc"9ell numers
ha7e no units< Though it is aritrar!: the Roc"9ell scale is the most 9i%el! use% ecause of the
huge existing ase of %ata lin"ing har%ness 7alues to heat treatments: !iel%: an% ultimate strength<
There are a numer of Roc"9ell scales a7ailale< The! inclu%e the ,: .: an% C scales as
9ell as superficial scales R8*58N an% R8158N< Each scale is otaine% ! an appropriate use of
%ifferent in%entors >steel all or %iamon% rale? an% maDor loa%s >*5: 15: 45: *55: *55 "g?<
$uperficial scales are use% 9hen the specimen eing teste% is 7er! thin or 9hen a thin coating on a
sustrate nee%s to e characteri0e%< $ee the attache% chart for %etails of the %ifferent scales<
4t is sometimes useful to compare the relati7e har%nesses of materials for 9hich 7alues are
"no9n on %ifferent Roc"9ell scales< 4n these situations: an e=ui7alence tale >such as the one
poste% on the 9all of the laorator!? 9ill permit the approximate con7ersion from one scale to
another<
Note: Always identi fy the Rockwell scal e you are using when
presenti ng data. The numers alone are meani ngl ess.
PR!"#$%R#:
Metallograph!
*< Cut specimens suitale for mounting from the pro7i%e% olts using the arasi7e cutoff sa9<
2< Mount specimens in a"elite using the h!%raulic mounting press< >'ut oth specimens in one
mount?
1< 'olish samples< Refer to the polishing $6' for %etails aout polishing proce%ures<
4< Etch the specimens using Nitol solution< Juench the etche% sample 9ith methanol<
5< Examine the specimen surface using the metallographic microscope< $ur7e! the specimen an%
choose a representati7e area<
#< Ta"e a micro8graph or ma"e a s"etch of representati7e areas of the specimens< <ou will
need to include the micrograph in your memo.
3ar%ness
<ou will be evaluating the hardness of the specimens. +ach test
specimen re'uires five readings. #t is common practice with the ?ocwell
test to tae si6 measurements and throw out the first reading to permit
fi6tures and the specimen to seat firmly. @se the smooth shan portion of
the bolt for ?ocwell testing.
**
$EM F O8ra! Microanal!sis
<ou will need an unmounted piece of the threaded region from each of
the bolts for S+) evaluation. The pieces should be cleaned with acetone to
remove oily residue.
Po!!i$le Que!tion!:
Does the grain structure 7ar! 9ithin the oltI
Does har%ness 7ar! 9ith location an%Cor orientation in the oltI
Can !ou explain the grain structure of the olt in terms of the manufacturing processI
,re there compositional %ifferences et9een the t9o oltsI
3o9 %oes the grain structure %iffer in the t9o oltsI
Note$oo: Recor% all experimental results an% oser7ations >inclu%ing a %escription of the
olts e7aluate%?< 4n%icate ho9 man! micrographs 9ere ta"en< .e sure to inclu%e important
%etails of proce%ures ut %onGt 9rite exhausti7e accounts of the process<
Re-ort: Write a letter report< Bour compan! is ha7ing prolems 9ith a ne9 atch of olts
9hich are failing in ser7ice< Bou are to %etermine the metallurgical %ifferences et9een the failing
an% a%e=uate olts an% report on the li"el! source of the prolem an% recommen% appropriate
action< Bou shoul% inclu%e har%ness results: micrographs: grain si0e results >! at least t9o
metho%s? an% an! other rele7ant oser7ations<
*2
Unit 8: En/ineerin/ C0aracteri1ation o' a Metal
INTRODUCTION: The eha7ior of engineering materials is usuall! characteri0e% ! se7eral
%ifferent test metho%s< , complete un%erstan%ing of the engineering properties cannot e
otaine% from a single test or proce%ure< This unit 9ill intro%uce a stan%ar% group of proce%ures
9hich might e use% to characteri0e a metal or allo!<
APPARATUS: Metallographic e=uipment: Roc"9ell har%ness tester: Micro8har%ness
tester: Charp! pen%ulum impact tester: $intech Electromechanical )ni7ersal Testing Machine:
optical metallograph an% microscopes:
O+5ECTI*ES: Measure a stan%ar% set of material parameters commonl! use% to
characteri0e a material for engineering %esign< Then relate these parameters to the microstructure
an% processing histor! of the material an% compare them 9ith other materials 9ith %ifferent
compositions or processing histories<
ASTM STANDARDS:
E8( Tension Testing of Metallic Materials
,8255 En%8Juench Test for 3ar%enailit! of $teel
E*( Roc"9ell 3ar%ness Testing
E/2 Nic"ers 3ar%ness Testing
E*45 $tan%ar% 3ar%ness Con7ersion Tales for Metals
+AC,GROUND: This unit 9ill consist of four rotations< The group 9ill perform four
characteri0ation proce%ures: one each 9ee"<
,< Case Depth ,nal!sis
.< Tensile 'roperties of metals
C< 2omin! 3eat Treatailit! of $teel
D< 4mpact transition temperature of Metals
Refer to the follo9ing sections for instructions an% ac"groun% on the in%i7i%ual units<
-errous materials are i%entifie% ! one of three numer schemes< We 9ill e utili0ing the
,$TM stan%ar% nomenclature for all specimens< 4n this scheme the first t9o %igits of the four
%igit i%entifier in%icate the allo! famil!< The thir% an% fourth numers in%icate the caron
content< To otain the 9eight percent caron: %i7i%e the last t9o %igits ! one hun%re%<
Examples+
*5*( steel *5 L plain caron steel >no allo!ing?
*( L *(C*55 L 5<*( 9t; caron
4*45 steel 4* L allo! steel
45 L 45C*55 L 5<45 9t; caron
Unit 8: En/ineerin/ C0aracteri1ation o' a Metal
'art ,+ Determination of Case Depth
*1
INTRODUCTION: This rotation in7ol7es the asic characteri0ation of the har%ness of a heat
treate% component< Man! manufacture% ferrous components un%ergo processing to pro%uce a
har%ene% surface< This process 9ill har%en the material to some %epth elo9 the surface< This
har%ene% region is calle% the case<
O+5ECTI*E: Determine the %epth of case har%ening in a heat treate% %ri7e train
component<
+AC,GROUND: Man! engineering components are speciall! treate% to pro%uce a har%er
outer casing< Components such as gears: splines: %ri7e shafts an% earings are often surface
har%ene% ! caruri0ing: nitri%ing or other process< 4n =uenche% components the natural thermal
gra%ient in the part generall! insures that the surface 9ill e har%er than the ul"< The %epth of
this har%er region can e critical to the performance of a component an% is often specifie%<
Microhar%ness Testing is a har%ness measurement ma%e using a special optical instrument< The
area sample% ! a microhar%ness tester is much smaller than that of Roc"9ell t!pe testers an% the
position control is extremel! fine< 4n fact: in%i7i%ual features such as grains an% inclusions can
often e anal!0e% using the microhar%ness tester< The instrument can e use% to map the har%ness
profile across a component< This permits the i%entification of the 9or" har%ene% 0one or the
%epth of har%ening in a case har%ene% component<
The Nic"ers techni=ue also %iffers from the Roc"9ell t!pe machines in that it uses a %ea% loa% to
push a %iamon% in%enter into the surface of the specimen< The %epth of penetration is %etermine%
! measuring the %iagonals of the p!rami%al in%entation after loa% remo7al rather than the %epth
of tra7el %uring the loa% application< Thus the techni=ue can e applie% to specimens 9hich are
mounte% in softer materials such as acr!lic or phenolic 9ith no appreciale error in measurement<
The Tu"on tester uses a %iamon% p!rami% in%entor to perform the Nic"ers test an% ma! e use%
to %etermine a 9i%e range of har%ness 7alues through a%Dustment of the applie% loa%< Nic"ers
%iamon% p!rami% har%ness >D'3? is ase% on the relation+
D'3 L *(5#<4 x 'C ,
2

9here: ' L loa% in grams: , L a7erage of t9o %iagonal lengths >in units of <55* mm? 4f
appropriate tales are a7ailale: the Nic"ers numer can e con7erte% to other common har%ness
7alues<
The modern digital microhardnes s tester in the UTPA laborator y
performs the DPH calculation automaticall y when the optical
micromet er is utilized. It will also perform an automati c conver si on
to one other hardnes s scal e .
PROCEDURE: Cut the specimen 9ith the 9et sa9 to allo9 9or" on a face perpen%icular
to the original surface contour< 'olish the cut surface using stan%ar% metallographic preparation
techni=ues< -ine polishing is not necessar!< )se microhar%ness tests to pro%uce a map of the
har%ness profile near the surface of the tooth< Ma"e measurements to at least a %epth of 4 mm
>approximatel! 5<25 inches?<
*4
Rea%ings are est ma%e in a lightl! etche% con%ition to ai% in locating structures of interest< 4f
structures are not eing teste% then the surface nee% merel! e polishe%< 3ea7! etching shoul% e
a7oi%e% since it coul% a%7ersel! affect test results<
DATA+OO,: *< Microhar%ness map >plot of har%ness 7s< Distance from surface?
2< Estimate of %epth of case 9ith Roc"9ell C 45 har%ness<
MEMO: Bour compan! has experience% fiel% failures 9ith this component< The %esign
engineers specifie% a case %epth of 4 mm 9ith a minimum har%ness of 3RC 45< Determine if the
part meets this specification an% pro7i%e e7i%ence< Bou shoul% inclu%e the actual %epth of this
case an% the har%ness map in support of !our conclusion<
*5
Unit 8: En/ineerin/ C0aracteri1ation o' a Metal
'art .+ Tensile 'roperties of Metals
INTRODUCTION: The tensile test is the most commonl! use% metho% of estimating
engineering parameters for a material< 4t is a simple: uniform stress state test 9hich is easil!
anal!0e%<
O+5ECTI*E: To %etermine stan%ar% engineering material parameters for se7eral allo!s
an% examine the %ifference et9een elastic an% plastic %eformation<<
ASTM STANDARD: E( Tensile Testing of Metals
+AC,GROUND: The most commonl! use% material characteri0ation test is a uniaxial tension
test< 4n the tension test: a specimen is suDecte% to a continuousl! increasing tensile %isplacement
>or loa%? 9hile simultaneous measurements are ma%e of the elongation of the specimen an% the
applie% loa%< The measurements are use% to construct an engineering stress8strain cur7e for the
test<
The engineering stress is the a7erage longitu%inal stress in the specimen 9hich is gi7en !+
s L 'C,
o
>*?
9here+ ' L loa%: ,
o
L original specimen cross8sectional area
The engineering strain use% to construct the cur7e is the a7erage linear strain foun% from+
e L >L 8 L
o
?CL
o
>2?
9here+ L 8 L
o
L elongation of the gage length
L
o
L the original gage length
$e7eral parameters are commonl! use% to %escrie the shape of the stress8strain cur7e< These
inclu%e BoungKs mo%ulus >E?: !iel% strength >$
!
?: tensile strength >)T$: or $
u
? percent
elongation: an% re%uction in area >R6,?<
BoungKs Mo%ulus >elastic or tensile mo%ulus? is the slope of the linear portion of the stress strain
cur7e<
Tensile $trength: or ultimate tensile strength is the maximum applie% loa% %i7i%e% ! the original
cross8sectional area of the specimen+
Biel% $trength is the loa% correspon%ing to a small aritraril! specifie% plastic strain >generall!
5<552? %i7i%e% ! the original cross8sectional area of the specimen< The actual elastic limit is
extremel! %ifficult to %etermine: thus the strength at 5<2; plastic elongation is the preferre%
engineering parameter for %escriing the onset of plastic %eformation< Biel% strength is generall!
more sensiti7e than the tensile strength to the effects of heat treatment: processing: an% the
metho% of testing<
*#
'ercentage Elongation >or strain to failure? is the ratio of the increase in the length of gage section
of the specimen to its original length: expresse% in percent+
; elongation L >L
f
8 L
o
? C L
o
x *55 >5?
9here: L
f
L gage length at fracture: an% L
o
L original gage length
The elongation of the specimen is uniform along the gage length up to the maximum loa%< When
nec" formation egins: the strain is no longer uniform<
Re%uction in ,rea+ The percentage re%uction in area is the ratio of the %ecrease in the cross8
sectional area after fracture to original area<
; R6, L >,
o
8 ,
f
?C,
o
x *55 >#?
, high percentage elongation or re%uction of area in%icates the material has a significant ailit! to
%eform 9ithout fracture< This ailit! is commonl! calle% %uctilit!<
PROCEDURE:
Measure specimens an% chec" them for surface fla9s< Carefull! test the tensile specimens
follo9ing the ,$TM stan%ar%< 4t is al9a!s goo% practice to chec" the calculate% mo%ulus an%
strength of the first specimen as soon as it has een teste% 8 to e sure !our results are reasonale8
efore testing the secon%< $teel has a mo%ulus near 15 msi an% it changes 7er! little 9ith allo! or
caron content<
DATA+OO,:
*< Mo%ulus: Biel% $trength: strain to failure: )T$<>printe% out from computer?
2< Calculate an% recor% the ;R6, for each allo!<
1< 'lot of engineering stress8strain cur7e for each material< >a single comine% plot is acceptale?
4< Compare the results for the materials to expecte% 7alues foun% in the literature<
E9P&ORATION:
*< The strain le7el at failure 7aries along the length of the nec"e% region< 3o9 is this reflecte% in
the Roc"9ell 3ar%nessI
2< 3o9 %o the fracture surfaces of the 7arious materials compare in the $EMI
*&
Unit 8: En/ineerin/ C0aracteri1ation o' a Metal
'art C+ 2omin! Test for Comparing 3eat Treatailit! of $teel
INTRODUCTION: $teel allo!s are an extremel! 7ersatile group of materials< Chief among the
sources of this 7ersatilit! is the ailit! to control the microstructure of components through
Du%icious heat treatment< Not all allo!s are easil! har%ene% ! heat treatment so har%enailit! is a
asic propert! of a ferrous allo! 9hich shoul% e characteri0e%<
O+5ECTI*E: 'ro%uce har%enailit! cur7es for 7arious allo!s< Descrie the effects of
caron an% allo! content on har%enailit!<
ASTM STANDARD+ , 2558(5
+AC,GROUND: The 2omin! en% =uench test is commonl! use% to characteri0e the
fun%amental har%enailit! of allo!s< The test uses en% =uenching >9ater onl! applie% to the 7er!
en% of a c!lin%er? to pro%uce a continuousl! %ecreasing =uench rate along the length of the
c!lin%er< Ner! near the en%: the material 9ill experience nearl! instantaneous =uenching an% 9ill
thus ha7e the maximum achie7ale har%ness< Material along the c!lin%er 9ill cool more slo9l!
9ith increasing %istance from the en% an% 9ill thus e progressi7el! softer< -or this la:
normali0ing of specimens efore heat treating 9ill e neglecte% >this is an option if supplier an%
customer agree?< -or a%%itional ac"groun% see Callister pages 1258115<
PROCEDURE:
*< Refer to the ,$TM stan%ar% for the %etails of the proce%ure >9ater flo9 rates:
heating times: grin%ing proce%ure: har%ness testing: %ata recor%ing: 9ater temperature
etc<<? an% the metho% for estimating har%enailit!<<
2< ,usteniti0e the specimen ! placing in preheate% o7en set at the appropriate
temperature<
Caron Content ,usteniti0ing Temp<
o
->
o
C?
P5<25 *&55 >/25?
5<2#85<1# *#55 >(&5?
Q5<1& *555 >(45?
1< Remo7e from furnace an% =uic"l! place in =uench fixture in the sin"<
4< ,llo9 to cool to room temperature<
5< Grin% a length9ise flat strip >remo7e approximatel! 5<5*5H of material? to prepare a
clean surface for har%ness testing<
#< 'lace specimen in special 2omin! test fixture on Roc"9ell tester an% measure har%ness
eginning at the =uenche% en% for t9o inches along the specimen length<
-irst 5<5H of ar perform a test e7er! *C*#H >one turn?
-rom 5<5 to 2 inches test e7er! *C(H >t9o turns?
*(
DATA+OO,:
*< Water temperature
2< 3ar%ness %ata an% plot of har%ness 7ersus position
1< 3ar%enailit! >see ,$TM stan%ar%?
MEMO+
'lot the har%ness cur7es for all the allo!s stu%ie% ! !our class< 4n%icate 9hich allo!
9oul% pro7i%e for the %eepest case >3RC 25 or ao7e? an% 9hich 9oul% pro7i%e the
highest surface har%ness<
*/
Unit 8: En/ineerin/ C0aracteri1ation o' a Metal
'art D+ 4%entif!ing the 4mpact Transition Temperature
INTRODUCTION: $teel allo!s are among the materials 9hich exhiit an important eha7ior+
as the temperature is re%uce% elo9 some critical le7el: the! un%ergo a rapi% %ecrease in impact
toughness as measure% ! Charp! or 40o% impact tests< The actual temperature of the transition
7aries from allo! to allo! an% 9ith processing histor!<
O+5ECTI*E: Determine the %uctile to rittle transition temperature for a specifie% metal
an% pro%uce a cur7e of impact energ! as a function of temperature using Charp! t!pe specimens<
ASTM STANDARD : ,$TM E21
DE"INITIONS: Ductile to .rittle Transition Temperature >D.TT?< Metals ha7ing a .CC
or 3C' cr!stal structure experience a transition in their %ominant fracture mo%e from %uctile to
rittle >clea7age? fracture at a characteristic temperature< This temperature %epen%s on the
particular composition: thermal histor!: an% %eformation histor! of the metal< .elo9 this
temperature the metal 9ill asor 7er! little energ! in fracture< ,o7e this temperature it is
unli"el! to fail ! clea7age an% 9ill asor much more energ! %uring failure< The i%entification
of the D.TT can e ase% on three %ifferent criteria 9hich are %iscusse% in the ,$TM stan%ar%<
+AC,GROUND+
Earl! efforts to un%erstan% the rittle failure of metallic materials utili0e% the Charp! or
40o% t!pe impact fracture test specimen< The most common approach to pre7enting rittle
fracture in ser7ice 9as to utili0e "no9le%ge of the %uctile to rittle transition temperature< This
temperature is %etermine% ! testing a series of specimens at progressi7el! lo9er temperatures<
4n theor!: rittle fracture 9oul% e pre7ente% ! limiting ser7ice to temperatures ao7e the
D.TT< 4n practice: there are se7eral prolems 9ith the approach< The primar! %anger in using
this approach is the li"elihoo% of un%erestimating the D.TT ecause of limitations in the %esign
of the specimens themsel7es< The Charp! an% 40o% specimens are small: lunt notche% %esigns
9hich 9ill gi7e unrealisticall! lo9 7alues for the D.TT in some materials< 3o9e7er: the test is
still 9i%el! use% an% can e 7aluale if applie% 9ith care<
PROCEDURE:
Bou 9ill e testing a fe9 specimens of an allo! 9hich 9ill also e teste% ! the other
groups in !our la< ,ll of the results 9ill e comine% to gi7e e7er!one a large enough %ata set
for useful anal!sis< Each group 9ill e gi7en 1 specimens< Bou 9ill test all of them at the same
25
Metho%s of D.TT Determination
:3; Temperature at the energ! mi%9a! et9een the rittle an% %uctile plateaus
:8; Temperature at the mi%point of the transition in the lateral expansion 7s< Temp< 'lot
:<; Temperature at 9hich 55; of the fracture surface is rittle an% 55; %uctile< The last is calle%
the fracture appearance transition temperature or -,TT<
temperature an% recor% !our a7erage 7alues on the results chart< Test temperatures >in Celsius?
9ill e as follo9s+
Grou
p
* 2 1 4
Tue RT 5 8
25
845
We% 8
*5
8
55
*5 855
Thur 8
15
55 (5 **5
DATA+OO,:
*< Energ! asore%: lateral expansion: surface appearance: plot of toughness 7s< Temp<
2 4%entif! the D.TT using all three metho%s
ADDITIONA&: Enter !our %ata >temperature: energ!: lateral expansion: fracture
appearance >as percent %uctile? on the mar"er oar% next to the impact tester<
E9P&ORATION:
4t can e 7er! interesting to compare the fracture surfaces of the lo9 energ! an% high
energ! specimens in the $EM< 3o9 %oes this comparison she% light on the origins of the
fracture appearance transition temperature<
MEMO+
Bour compan! is planning to uil% e=uipment for arctic applications an% is consi%ering
this allo!<
a< Determine the %uctile to rittle transition temperatures ! all three metho%s >each
metho% ma! !iel% slightl! %ifferent results? for !our allo! onl!< 'ro7i%e supporting
%ocumentation<
< 4s this material suitale for operating con%itions near 845CI<
2*
Unit <: En/ineerin/ C0aracteri1ation o' a Poly#er
INTRODUCTION:
'ol!meric materials ha7e egun to see significant use in engineering applications >as
oppose% to pac"aging: or light %ut! uses? an% thus a "no9le%ge of their engineering properties
an% general eha7ior is critical for the engineer<
The laorator! unit 9ill consist of four rotations o7er a four 9ee" perio%+
*< Rate Depen%ence of Tensile 'roperties
2< -arication an% Testing of Composite Materials
1< Thermosetting ,%hesi7es
4< Thermal ,nal!sis
EQUIPMENT:
Microscopes: MT$ #*5 $er7o8h!%raulic tester: thermal ath: anal!tical alance: ,%hesi7e
test panels: laorator! o7en: instrumente% impacter
O+5ECTI*E:
Measure a 7ariet! of engineering parameters an% characteri0e the state of a pol!meric
soli%< Then relate these results to real concerns in %esigning 9ith pol!meric materials<
&A"'(R!%N$:
'ol!mers are seeing increasing use as engineering materials< Their ease of processing:
light 9eight: lo9 cost: an% flexiilit! ha7e resulte% in more 9i%esprea% application in areas 9hich
9ere pre7iousl! consi%ere% the pro7ince of HstructuralH materials alone< 3igh performance
thermoplastics: fille% engineering thermoplastics: an% reinforce% thermosets an% thermoplastics
are no9 eing extensi7el! applie% in automoti7e: electrical: chemical: an% home appliance
pro%ucts< Thus: the engineering characteristics of these materials ha7e ecome a much greater
concern<

The term pol!mer refers to a general class of materials 9hich consist of long chains of
molecules of co7alentl! on%e% atoms< The most common materials are ase% on a ac"one of
caron 9ith h!%rogen: chlorine: fluorine: alcohol an% other atoms or groups attache% to the
primar! chain< $oli% pol!mers use% in ul" are calle% plastics an% can e ro"en into t9o general
su8categories+ thermoplastics an% thermosets< 4n a thermoplastic >T'? the molecules are not
chemicall! oun% to each other ut instea% rel! on entanglements: h!%rogen on%ing an% other
intermolecular interactions for their cohesion< Thermoplastics are easil! forme% an% can e
melte% %o9n an% mol%e% into ne9 pro%ucts 9ith a 7er! small expen%iture of energ!< Thermosets
>T$? are forme% 9hen molecules are co7alentl! on%e%: usuall! ! reaction 9ith a Hcross8lin"ing
agentH< 6nce a thermoset has een forme% it cannot e reshape% 9ithout rea"ing it %o9n into
constituent atoms >%epol!meri0ing? an% completel! starting o7er<
The materials stu%ie% in this la are a mixture of thermoplastics an% thermosets< The!
ma! inclu%e+
Polypropyl ene *44. - commodity T4 used in containers
Polyethyleneterpthalate *4+T. , commodity T4 used in soda bottle
22
Acrylic/Polymethylmethacrylate , *4))(. , amorphous T4, ple6iglass
Polycarbonate , *4A. engineering T4 , optical applications
Blends , synergistic combinations polymers *4AB(BS etc..
Polystyrene *4S., Aommodity T4 with good stiffness, very low cost
High Impact Polystyrene *%#4S. , 4S toughened with rubber particles
Styrene-Butadiene Copolymer *SB. , C resin
Acrylonitrile-butadiene-styrene*(BS., +ngineering copolymer T4
Acrylonitrile-styrene-acrylate *(S(. , +ngineering copolymer T4
Nylon =>= :PA==; or Nylon = *4(7.
Acetal or Polyo?y#et0ylene *4D).
Bisphenol A or DGEBA Epoy , standard thermosetting material, epo6y refers to
the chemistry of the crosslinable functional group.
!illed Polymers 8 ,n! of the ao7e thermoplastics ma! e len%e% 9ith particles or short fiers
to re%uce the material cost an% stiffen the material<
.ecause of their chemical ma"eup an% molecular structure: the performance of plastic
components is greatl! influence% ! processing histor!: temperature: an% notch an% rate
sensiti7it! of the pol!mer< These characteristics 9ill e the asis for the in7estigations in this
laorator!<
Rate De-endence: The spaghetti8li"e structure of pol!mers lea%s to a strong rate
%epen%ence in their mo%ulus: !iel% strength an% other mechanical properties< The! are suDect to
7iscoelastic >time %epen%ent elastic? %eformation 9hich is oser7e% in the rate %epen%ence in
stan%ar% tests as 9ell as time8%epen%ent creep eha7ior<
21
Unit <: En/ineerin/ C0aracteri1ation o' a Poly#er
'art ,+ Rate Depen%ence of Thermoplastic Mechanical 'roperties
INTRODUCTION: 'ol!mer mechanical properties are strongl! %epen%ent on strain rate< Bou
9ill examine this %epen%ence using tensile testing<
EQUIPMENT: MT$ #*5 test frame: micrometer: test specimens
O+5ECTI*E: Aharacteri=e the tensile behavior of the material provided
including the effect of test rate on yield strength, modulus, and strain to
failure. (lso, gain e6perience with the tensile behavior of several classes of
polymers..
ASTM STANDARDS: D #1(8/*: D #1(M8/1: D*&5(8/1: D((28/*
+AC,GROUND: The most commonl! use% material characteri0ation test is a uniaxial tension
test< 4n the tension test: a specimen is suDecte% to a continuousl! increasing tensile %isplacement
>or loa%? 9hile simultaneous measurements are ma%e of the elongation of the specimen an% the
applie% loa%< The measurements are use% to construct an engineering stress8strain cur7e for the
test<
$e7eral parameters are commonl! use% to %escrie the shape of the stress8 strain cur7e< These
inclu%e !iel% strength >$
!
?: tensile strength >)T$?: percent elongation: an% re%uction in area
>R6,?<
Tensile $trength: or ultimate tensile strength is the ma6imum applied load
divided by the original cross,sectional area of the specimen$
Biel% $trength is usuall! %efine% for pol!mers as the loa% at 9hich nec"ing egins: usuall! a local
maximum earl! in the test< $emi cr!stalline materials 9ill ten% to ha7e a more clearl! %efine%
pea" since !iel%ing is %ue to the rea" up of cr!stallites< Biel% strength is generall! more sensiti7e
than the tensile strength to the effects of rate: processing: an% the metho% of testing<
'ercentage Elongation is the ratio of the increase in the length of gage section of
the specimen to its original length, e6pressed in percent$
E elongation F *2
f
, 2
o
. B 2
o
6 1;;
Where: L
f
L gage length at fracture
L
o
L original gage length
The elongation of the specimen is uniform along the gage length up to the formation of a nec"<
When nec" formation egins: the strain is no longer uniform<
PROCEDURE:
24
)se one of the ars to estalish a aseline eha7ior for the material ! testing at a
constant crosshea% rate of * inCmin< )se the remaining specimens to in7estigate the rate
%epen%ence of the material ! testing them at other rates 9hich are or%er of magnitu%e
increments >factor of *5? higher an%Cor lo9er than the aseline rate >ie<: 5<*ACmin: *5ACmin: etc<?<
.ecause the loa%s applie% in testing are relati7el! small an% the test frame is extremel!
stiff: the machine errors from not using an extensometer 9ill e relati7el! small< The remaining
error is %ue to the inaccurac! in the gage measurement<
$pecimens of other materials shoul% e run at one of the interme%iate rates >5<5
inchesCminute?< 6ser7e %ifferences in %eformation processes an% failure mo%es<
DATA+OO,: -rom the tensile tests: report for the pol!prop!lene onl!+
*< Mo%ulus
2< Biel% strength
1< )ltimate strength >engineering?
4< True ultimate strength ase% on actual cross section in the nec"
Characteri0e the effects of strain rate an% comment on an! implications for tensile testing
of pol!mers< Comment on ho9 9ell the proce%ure use% in La correlates 9ith ,$TM practice
%efine% in D #1(<
E9P&ORATION$ +6amine the fracture surfaces of the samples under the
optical microscope and setch the morphology of the fracture. Aompare the
morphologies of the failures under different test rates. Aan you mae any
conclusions about the source and se'uence of failure& 0oes the
morphology vary with test rate&
Sputter coat some of the fracture surfaces and observe them in the
S+). /hat can you say about the mode of fracture and the effect of test
rate&
MEMO$ >one
25
Unit <: En/ineerin/ C0aracteri1ation o' a Poly#er
4art B$ -arication an% Testing of Composite Materials
INTRODUCTION: Bour compan! is intereste% in utili0ing a pol!mer composite in an
application 9hich in7ol7es re=uires compressi7e strength an% impact Construct
EQUIPMENT+ 4nstrumente% 4mpact testing machine: Composite farication e=uipment:
Compression testing fixtures<
O+5ECTI*E: Determine the temperature %epen%ence of the impact toughness<
ASTM STANDARDS: 0257,-1a, 018;-,-1, 01;2-,-1, 0532;
DE"INITIONS:
Tup is the hardened metal blade or point which contacts the specimen
during an impact test.
4nitiation Energ! is the energ! asore% ! a specimen 9hile the crac" 9hich lea%s to
ultimate failure is eing forme%< The initiation process is usuall! associate% 9ith the
portion of the loa%8time cur7e up to the maximum loa%<
'ropagation Energ! is the energ! asore% ! a specimen as the ultimate failure crac"
propagates< This is usuall! the portion of the loa% time cur7e after the maximum loa%<<
+AC,GROUND:
The test utili=es a free falling weight. (ttached to the weight is an
instrumented tup. This tup measures the load during the impact event and
the measurement is recorded by the attached computer. @sing the
resulting data, it is a relatively simple tas to estimate the initiation and
propagation energies associated with the failure event.
PROCEDURE:
1. 9abricate a composite laminate using the provided glass fabric and
epo6y thermoset polymer matri6.
2. Aut the laminate into specimens for testing. <ou should produce
fle6ural test specimens as well as plates for impact testing.
1< Test the specimens an% recor% the results<
$ATA&!!': a. )aterial description *type of fabric, G of layers, resin
type.
b #mpact energies *both initiation and propagation.
c. 0escription of the mode of failure *setches or phots.
including an assessment of relative damage *area of
delamination, penetration area.
%< -lexural properties< Note the mo%e of failure >%i% crac"ing prece%e
failure or 9as it instantaneous<
2#
MEMO$ Summari=e damage resistance and fle6ural properties of the
candidate material.
2&
Unit <: En/ineerin/ C0aracteri1ation o' a Poly#er
'art C+ Cure 6ptimi0ation of Thermosetting ,%hesi7es
INTRODUCTION:
Bou are %e7eloping an a%hesi7el! on%e% s!stem for asseml! of some metal components
,n epox! ase% a%hesi7e film has een selecte% ecause of its superior toughness an%
en7ironmental resistance< Bou nee% to %etermine the optimum cure time an% temperature<
O+5ECTI*E: 0etermine the appropriate cure time at several
temperatures for ma6imum adhesive strength.
ASTM STANDARDS: ,$TM D152(
+AC,GROUND: ,%hesi7e Doints ma! fail in one of three mo%es+ a%hesi7e: cohesi7e: or
a%heren%< 4n a%hesi7e failure: the oun%ar! et9een the a%hesi7e an%
the on%e% oDect >s? fails< 4n cohesi7e failure: the a%hesi7e itself fails:
remaining on%e% to the a%heren% >s?< 4n a%heren% failure: the a%hesi7e is
strong enough that the on%e% components themsel7es fail<
PROCEDURE: +ach group will perform a component of a larger study,
data will be pooled to create a complete picture of the curing properties of
this system.
The curing temperatures and times to be used will be varied systematically.
Group R Temp< >
o
C? Cure Time *min.
1 11; 2;,15,5;,75
2 **5 25:15:55:#5
1 *55 25:45:55:&5
4 *55 25:45:55:&5
Cut * inch ! S inch pieces of the a%hesi7e film an% faricate single lap shear specimens using the
steel a%hesi7e test coupons pro7i%e%< Clamp the specimens using in%er clips: eing careful to
center the clips o7er the lap Doint< 'reheat the o7en to the specifie% cure temperature< 'lace the
coupons on a steel sheet in the preheate% o7en< Remo7e a coupon thereafter at the appropriate
time an% test it in the $intech )T$< Write !our results >temperature: cure time: shear stress:
failure mo%e? on the 9hiteoar% in the laorator!<
DATA+OO,: * 0ata *including ma6imum stress, failure mode.
2. H,< plot of your data *strength vs. Aure time.
MEMO: Report the cure time an% temperature for maximum strength 9ith minimum time<
2(
Unit <: En/ineerin/ C0aracteri1ation o' a Poly#er
'art D+ Thermal ,nal!sis of a 'ol!mer
INTRODUCTION: ( basic analytical tool which is widely used in the polymer
industry is Thermal (nalysis. T( consists of a family of instruments which
all measure some engineering property as a function of temperature. The
instrumentation suite in the materials laboratory includes four instruments$
0ifferential Scanning Aalorimeter *0SA., Thermo,gravimetric
(nalysisB0ifferential Thermal (nalysis *T"(B0T(., Thermo,mechanical
(nalysis *T)(., and 0ynamic )echanical (nalysis *0)(..
T0er#al Analy!i! Tec0ni@ue! and Mea!ured Pro-ertie!
Tec0ni@ue Pro-erty Mea!ured a! 'unction o'
Te#-erature
D$C 3eat capacit! to &55C
TG,CDT, Weight an%Cor heat capacit! &55C 8 *555C
TM, Thermal Expansion
DM, Mechanical properties >stiffness: %amping?
O+5ECTI*E: Determine critical transition temperatures an% structural characteristics for
the pro7i%e% pol!mer using %ifferent thermal anal!sis techni=ues< 4%entif! the as8mol%e% sample
of material as cr!stalline or amorphous< Where rele7ant: %etermine the cr!stalli0ation
temperature: heat of cr!stalli0ation: glass transition temperature: melting temperature: an% the
presence or asence of 9ater in the recei7e% sample<
EQUIPMENT: TC, 4nstruments 4nc< D$C an% DM,: nippers for cutting specimens:
anal!tical alance: micrometer or caliper<
+AC,GROUND The D$C pro%uces a trace of the heat flo9 intoCout of the specimen as a
function of temperature< Certain features on the trace re7eal structural characteristics of the
material< The three asic feature t!pes are+ >,? step transitions> :.? exotherms or up9ar% pea"s:
>C? en%otherms or %o9n9ar% pea"s< $tep transitions represent a change at a particular
temperature from one state to another: for example from the glass! to ruer! state: as in the Tg
i%entifie% on the follo9ing page< Exotherms represent energ! flo9 out of the specimen an% are
generall! pro%uce% ! chemical reactions >resi%ual curing: comustion? or ! phase changes
>cr!stalli0ation of amorphous material?< En%otherms represent extra energ! flo9ing into the
specimen an% are usuall! associate% 9ith phase changes such as cr!stalline melting: or
7apori0ation of a 7olatile such as 9ater<
The DM, pro7i%es a plot of material mo%ulus as a function of temperature< 4mportant transitions
such as the Tg can e estimate% from the cur7e<
PROCEDURE: 4repare samples for each instrument$
0SA$ ( thin piece should be weighed and placed in a sample cup.
0)($ rectangular bar 1B2 wide, 1B: thic, and at least 2.5 long
2/
Refer to the operatorKs manual for each instrument for setup< Test temperatures shoul% range
from amient to aout 255
o
C for most materials< Bou 9ill nee% to run the D$C sample through a
looping >heat up 8 cool %o9n? temperature profile<
DATA+OO,: *< Cop! of plotte% cur7es
2< $ummar! of critical temperatures >Tg: melting: cr!stalli0ation: etc< .!
all methods I discussion
MEMO: *< 4%entif! the critical temperatures an% the presenceCasence of 9ater or
plastici0ers< Compare an% explain the results of the t9o metho%s<
15
Material! A--lication Plannin/
Introduction
When approaching a ne9 prolem of material selection: it is fre=uentl! necessar! to %e7elop a
program of tests to %etermine the est can%i%ate material for an application< The %esign of the
test program must e %ri7en ! the performance re=uirements of the application< The usual
metho% is to %etermine one or t9o relati7el! eas!Ccheap tests or properties a7ailale in the
literature 9hich can e use% to screen a large numer of materials or formulations for suitailit!<
The lea%ing conten%ers are then suDecte% to a more %etaile% stu%! an% the selection ma%e< ,fter
the selection: e7en more %etaile% characteri0ation of the chosen material ma! e re=uire% to meet
certification or =ualification re=uirements of go7ernment agencies >-,,: -D,: D6D: etc<<<?<
Thus the selection process ma! consist of as man! as three stages+
4< $creening
44< $election
444< -ull Characteri0ation
The testing 9ill reflect the re=uirements of the application< These can fall into a numer of
categories inclu%ing+
4< Mechanical performance
a< $tructural >mo%ulus: strength: har%ness?
<Toughness >fracture toughness:impact toughness:<<<?
c< Durailit! >9ear resistance: fatigue resistance:<<<?
44 6ther 'erformance
a< En7ironmental >corrosion: aci%Case: )N:<<<?
< -inishC,ppearance
c< Thermal properties >con%ucti7it!: expansion: capacit!?
%< Electromagnetic properties >con%ucti7it!: %ielectric constant?
444< Economics
a< Manufacturailit! >energ!: scrap rate: c!cle times<<<?
< Ra9 material cost
c< Rec!clailit!
$pecial applications ma! also nee% to consi%er 9eight: iocompatiilit!: response to ra%iation:
resi%ual stresses: an% other properties<
Note that this can ecome fairl! complicate% since the choice of material often constrains the
%esign approach< Thus the selection process shoul% e performe% in parallel 9ith the total %esign
process<
Materials $election Example
1*
'erformance matrix for pol!meric material for "nife han%le is %ri7en ! primar! re=uirement that
material remain firml! attache% to the "nife hilt un%er all concei7ale ser7ice con%itions< ,fter
estalishing that con%ition: other re=uirement come into pla!<
4nitial anal!sis >list performance re=uirements from the consumers perspecti7e an% in no particular
or%er 8 rainstorm?+
*< 3an%le %oes not rea" in extreme ser7ice
2< 3an%le sta!s fixe% to hilt of "nife
1< Nice appearanceCsurface finish
4< Durale surface finish
5< Electrical an% thermal insulator
#< Lo9 cost
&< Will 9ithstan% exten%e% exposure to oiling 9ater 9ithout %iscoloration or %egra%ation
Next: translate these performance re=uirements into specific performance characteristics<
This is engineering terminolog! as oppose% to a coo"Gs 7ie9<
*< $trength an% surface har%ness to 9ithstan% stress of maximum loa% 9ithout permanent
%eformation 9hich 9oul% loosen hol% on la%e hilt< Estimate maximum loa% from "nife geometr!
an% "no9le%ge of human anatom!<
2< Toughness re=uirements %ri7en ! most li"el! misuse >as a hammer?: acci%ents >remo7e% from
free0er: %roppe%?
1< -atigue a concern: %o not 9ant gro9th of fatigue crac"s un%er ser7ice >estimate loa%ing an%
numer of c!cles?
4< -inishC,ppearance 8 class , surface finish 9ith har%ness to maintain finish
5< En7ironmental 8 must perform after repeate% 9ashes in a sterili0ing %ish9asher: *#5C 9ater
an% %etergent<
#< Manufacturailit! 8 -a7or lo9est cost material possile: largest processing range possile
&< Thermal con%ucti7it! can e specifie% from nee% to limit heat con%uction 9hen la%e is left in
oiling 9ater< >i<e<+ *55C metal at core of han%le for 25 minutes shoul% not pro%uce a surface
temperature in excess of 55 C 8 from that a heat transfer prolem coul% e sol7e% to %etermine
the re=uire% maximum thermal con%ucti7it!?
(< Electrical insulating capailit! can e specifie% from re=uirement that shoc"s not occur if the
"nife is inserte% into a 9all soc"et >**5N: #530?
-rom this anal!sis a prioriti0e% list of material properties >!iel% strength: har%ness: i0o% impact
strength: fatigue toughness: 3eat %istortion temperature: thermal c!clic stailit!<<<? is %e7elope%
an% then a screening matrix is %esigne%<
The screening matrix shoul% egin 9ith a large numer of materials chec"e% against the
nonnegotiale re=uirements or teste% 9ith a relati7el! inexpensi7e test to rapi%l! narro9 the fiel%<
The remaining materials shoul% then e compare% for the alance of propertiesC=ualities the! ring
to the application< Bou can use a %ecision matrix 9hich 9eighs the relati7e 7alue of the
properties<
Example+
12
Pro-erty Wei/0t Material 3 Material 8
Mo%ulus 25 *5 *2
Densit! 25 *# *(
Color stailit! *5 *5 (
Toughness *5 *5 (
Mol%ailit! 25 *2 *(
Cost *5 *5 *5
Wear Resistance *5 # (
Total *55 &4 (2
A!!i/n#ent+ Bour ,nal!sis shoul% consist of fi7e parts+
*< 'erform a preliminar! anal!sis an% list the consumerGs performance re=uirements<
2< De7elop a list of more specific performance characteristics in engineering terms 9hich
fulfill the consumerGs re=uirements in R*
1< 'rioriti0e in a list the engineering properties re=uire% to meet the performance
characteristics< >i%entif! the non8negotiales an% ran" ! importance the negotiale
properties?
4< De7elop a matrix to screen materials for suitailit!<
5< Create a list of can%i%ate materials from pro%uct literature an% !our textoo" an%
suDect these to the screening program< 4%entif! t9o or three goo% can%i%ates for the
application
#< 4%entif! an! special testing 9hich !ou thin" 9oul% e appropriate to assist in ma"ing
the final selection< Cite rele7ant ,$TM stan%ar%s for these tests<
'repare an oral presentation >informal? of !our plan< This shoul% inclu%e o7erhea%s %escriing
the prolem: summari0ing consumer nee%s: outlining engineering %escriptions of performance:
an% a tree of the propose% screening program< The reports 9ill e presente% %uring la perio%<
Bou 9ill nee% to turn in a cop! of the sli%es use% as a 9ritten report of the process<
11
Sa'e O-eratin/ Procedure: +ue0ler Mountin/ Pre!!e! v 8(4
7AAARDS
*< $erious urns from heating elements: mol% parts: an% hot sample mounts<
2< 'inching ! h!%raulic Dac" han%le or mol% components<
1< E!e inDur! in case of component failure or improper mol% alignment %uring loa% application<
REQUIRED SA"ET6 EQUIPMENT
*< Goggles or $afet! Glasses >for all in7ol7e% personnel?
*< 3eat protecti7e glo7es >for operator?
*< Tongs
OPERATING PROCEDURE
*< $9itch on the heating element 8 using s9itch mounte% on cor%< Re% light on
heating element shoul% light< When light goes out: element is at mol%ing temperature<
2< Loa% $pecimen in mol%+
a< 'lace small c!lin%er insi%e the hollo9 tue 8 e7ele% en% to outsi%e
< 'lace the sample an% enough .a"elite to full! co7er the specimens in the tue<
c< 'lace the larger c!lin%er in the c!lin%rical 8 e7ele% en% to the outsi%e<
1< 'ic" up the ao7e structure an% place it on the platform< .e careful to pic" up the
structure from the ottom so that the c!lin%rical insert %oes not fall through<
4< Lo9er the heating element o7er the c!lin%rical tue: once it is up to temperature<
The heating element is up to temperature 9hen the light on the han%le goes out<
:CAUTION: 7eatin/ ele#ent i! e?tre#ely 0ot #ae !ure t0at you are Bearin/
/love!(;
5< ,lign the ram ro% an% the large c!lin%rical piece< Raise the platform ! pumping
the han%le until the pressure nee%le mo7es to the preloa% line< Maintain this pressure for
fi7e minutes< :CAUTION: +e care'ul not to -inc0 your 0and!(;
#< 'ump the han%le to increase the pressure until the nee%le rea%s et9een the t9o
re% semi8%iscs< 3ol% at this pressure for 25 minutes< The pressure ma! %rop as the
pol!mer melts: so close oser7ation is nee%e% in or%er to maintain constant pressure< 4f
pressure %oes %rop: resume pumping han%le until pressure is once again in the %esire%
range<
&< Lo9er platform ! turning release "no at ase of Dac" han%le countercloc"9ise<
(< Raise heating element an% place cooling fins aroun% c!lin%rical tue< :CAUTION:
E?tre#ely 0ot> Bear /love!;
/< ,llo9 to cool for 58*5 minutes<
*5< Remo7e the sample from c!lin%rical tue< :CAUTION: +e care'ul !a#-le #ay
!till $e 0ot> Bear /love! or u!e ton/!(;
**< Clean e=uipment an% turn off heating element<
14
Sa'e O-eratin/ Procedure: Poli!0in/ o' Metallo/ra-0ic S-eci#en! v 3(8
7AAARDS
*< ,rasion of fingers %uring polishing
2< E!e inDur! %ue to foreign o%!
1< Chemical urn or irritation from etchant solutions
4< 4nhalation inDur! from reacting or e7aporating chemicals
REQUIRED PROTECTI*E EQUIPMENT
*< $afet! glasses >all personnel? %uring polishing
2< Chemical goggles an% glo7es %uring etching
1< -ume hoo% for etching
PROCEDURE
C6,R$E '6L4$3
*< $pecimens shoul% generall! e mounte% in a pol!mer mounting material to allo9 eas! han%ling
an% to insure that a flat surface is pro%uce% ! the polishing process<
2< 'olishing egins 9ith the manual strip polishers< Chec" the =ualit! of the expose% polishing
paper< 4f the paper is saturate% 9ith arasion pro%uct or the arasi7e has een 9orn a9a!: loosen
the clamps at the ottom of the unit: pull the paper through the ase to expose fresh paper: an%
tear off ol% paper< 6nl! change the paper if necessar!<
1 Turn on 9ater suppl! to strip polisher< The flo9 rate shoul% e a%e=uate to flush arasion
pro%uct from the polishing surface<
4< .egin polishing 9ith the coarsest paper< 'olishing stro"es shoul% e in one %irection an% the
specimen shoul% not e rotate%< 6nl! mo%erate pressure is necessar!<
5< 'erio%icall! inspect the specimen surface< Continue polishing until the surface consists entirel!
of polishing mar"s running in the same %irection< >3int+ !our Do 9ill e easier if !ou gra%uall!
%ecrease the applie% pressure as the polishing progresses on each paper?
#< Wash specimen thoroughl! to remo7e an! polishing %eris<
&< Turn specimen /5
o
an% polish on the next finer strip of paper< 'olish until all scratches from
pre7ious steps ha7e een oliterate% ! current step< Repeat steps 58& for each successi7el! finer
paper<
(< When !ou ha7e finishe% the manual coarse polishing< Thoroughl! clean the specimen 9ith
9ater<
-4NE '6L4$3
15
-ine polishing is accomplishe% using the faric 9heel polishers< CAUTION: T0e B0eel! t0roB
o'' dro-let! o' Bater containin/ a$ra!ive and a$ra!ion -roduct!( Wear !a'ety /la!!e! at all
ti#e! <
*< $et the 9heel spee%< The higher the spee% the more rapi% the polish< 3o9e7er: specimen
control ecomes more %ifficult at high spee%s<
2< $ha"e the appropriate s=uee0e ottle of polishing compoun% mixe% 9ith 9ater< $tart 9ith the
larger >*5825 micron? arasi7e particles on the left 9heel< $pra! a =uantit! of compoun% onto the
9heel<
1< 'lace the specimens on the 9heel an% egin to polish
,< 6nl! gentle pressure is re=uire%< 4f lint egins to pull out of the 9heel: !ou are using
too much pressure<
.< Rotate the specimen as !ou hol% it on the 9heel<
C< The 9heel nee%s a stea%! ut slo9 suppl! of %istille% 9ater to ensure goo% suspension
of arasi7e an% arasion pro%ucts< , %rop e7er! 281 secon%s is a%e=uate<
4< When all the scratches ha7e een remo7e%: rinse the specimen thoroughl! an% finish polishing
using the fine arasi7e on the right 9heel<
ETC7ING
*< $pecimens shoul% alrea%! e mounte% in a pol!mer material an% polishing complete% through
the final stage an% the surface to e etche% %r! an% free of %irt or oil<
2< Etching is %one ! either immersing the specimen in the etchant or ! painting the etchant on
the surface using a cotton s9a< CAUTION: Etc0ant! are corro!ive( Wear /o//le! and
/love! B0en 0andlin/ t0e# <
1< ,fter allo9ing the appropriate etching time: the etchant shoul% e H"ille%H ! rinsing the
surface< )se 9ater 9ith 9ater or alcohol to match the primar! li=ui% in the etchant< Do not
touch the etche% surface since oils from the han% can ruin the surface<
$ome $uggeste% Etchants
Tinc 55; conc< h!%rochloric aci% in 9ater: s9ae%
copper allo!s ,lcoholic ferric chlori%e >-eCl
1
?: immerse%
copper allo!s ,=ueous ferric chlori%e: immerse%
,luminum allo!s Mixe% aci%s: immerse%
$teels F irons 2; Nital >2; nitric aci% ! 7olume in alcohol?: immerse%
1#
Sa'e O-eratin/ Procedure: +ue0ler A+RASIMET Cut.o'' !aB v 3(4
7AAARDS
'inch ha0ar% from protecti7e co7er
,rasionCCut ha0ar% from arasi7e 9heel %uring speciment loa%ing
REQUIRED PPE
$afet! glasses
PROCEDURE
*< $pecimen to e sectione% shoul% e firml! loc"e% %o9n in the 7ise<
2< Chec" 9heel for chips or maDor misalignment< 4f the la%e is chippe% %o not attempt to ma"e
a cut<
1< Close co7er: pull out on emergenc! stop utton until it clic"s an% press start utton to start
motor an% 9ater pump< Cooling 9ater shoul% egin to floo% the cutting area< 4f the 9ater %oes
not flo9 DO NOT ATTEMPT A CUT<
4< Gentl! lo9er the sa9 la%e to contact< , gentle continuous pressure is all that is nee%e% for
the sa9 to cut< Too high a pressure can rea" the la%e< The pro%uction of smo"e is a sign that
the fee% spee% is too high or there is ina%e=uate cooling 88 lessen the pressure an% see if the
smo"e aates<
5< When the cut is complete: raise the sa9 an% press the emergenc! stop< Wait until the la%e
stops turning efore opening the co7er<
1&
Sa'e O-eratin/ Procedure: &ECO +elt Grinder v 3(4
7AAARDS
'inch ha0ar%s et9een ac"8stop an% elt
,rasion of fingers against elt
'roDectile ha0ar% from specimens torn loose on the 9heel
REQUIRED PPE
$afet! glasses
,ll safet! guar%s must e in place on machine<
PROCEDURE
*< The area ehin% the machine shoul% e clear of personnel at all times 9hile grin%er is
in operation<
2< $pecimens must e mounte% or large enough to permit them to e groun% 9ithout
ringing fingers into %angerousl! close proximit! to the grin%ing elt<
1< $tart the grin%er ! pulling the emergenc! stop utton all the 9a! out<
4< ,%Dust the 9ater flo9 using the lac" "no to pro7i%e a stea%! sheet of 9ater o7er the
elt<
5< 4f the elt is %rifting to one si%e of the rollers: a%Dust the elt trac"ing "no to center
an% staili0e it<
#< 3ol% the specimen firml! an% press it against the supporte% section of the elt< Large
specimens ma! e race% against the ac" stop<
1(
Sa'e O-eratin/ Procedure: RocBell 7ardne!! Te!ter v 3(4
7AAARDS
'inch ha0ar% et9een an7ilCspecimenCin%enter hea%
REQUIRED PPE
$afet! glasses
PROCEDURE:
*< $pecimens to e teste% must e free of rust: oil: an% %irt<
2< The specimen shoul% e securel! supporte% on one of the a7ailale test an7ils<
$pecimens cannot e encase% in plastic or other softer material %uring testing ut must
rest %irectl! on the an7il<
,n7il selection
-lat specimens -lat an7il
C!lin%rical $pecimen N8an7il
67ersi0e specimens 'oint an7il
1< $elect the appropriate scale: maDor loa% setting: an% in%enter< Refer to the summar!
tale mounte% on the instrument for %etails<
4< Turn the han% 9heel at the ase of the an7il pillar to raise the specimen to contact 9ith
the in%enter< Watch the preloa% in%icator an% stop turning 9hen the LED preloa% scale is
full! illuminate%(
5< When the rea%ing is complete%: ac" the specimen a9a! from the in%enter an% mo7e it
to select another test area< 4n%entations shoul% separate% ! more than 5 in%enter
%iameters<
Ne/ative readin/! or value! $eloB 3C on any !cale indicate t0at t0e !elected !cale i!
too a//re!!ive( C0an/e to a !cale Bit0 a loBer #a%or load and2or le!! a/re!!ive
indenter and try a/ain(
1/
Sa'e O-eratin/ Procedure: SATEC7 Pendulu# I#-act Te!ter v 3(4
7AAARDS
'inchCsmash ha0ar% et9een pen%ulum an% an7il
'roDectile ha0ar% from ro"en specimen pieces as 9ell as the s9inging tup
REQUIRED PPE
$afet! glasses
$pecimen placement tongs
PROCEDURE
All -er!onnel !0ould $e $e0ind t0e !a'ety line durin/ te!tin/(
*< Remo7e stop pin on top of pen%ulum stan% an% rotate control le7er all the 9a! right to
the loc"e% position<
2< Replace stop pin<
1< Raise the pen%ulum to the right until the latching mechanism catches >!ou can feel it
clic"? .e sure the pen%ulum path is clear: step ac" from machine an% let go of the
pen%ulum<
4< Loa% the test specimen using tongs 9ith self8centering alignment loc"s<
Charp! specimens 8 Notch faces a9a! from the tup
40o% specimens 8 Notch faces the tup
5< $et in%icator arro9 to maximum energ! for the chosen scale<
#< When all personnel are clear: push the control le7er to the left to release the pen%ulum<
&< ,fter the pen%ulum has complete% one s9ing >rea"ing the specimen?: remo7e the
stop pin an% push the control le7er all the 9a! to the left to appl! the ra"e<
45
Sa'e O-eratin/ Procedure: Dynatu- Dro- ToBer I#-act Te!ter v 3(4
7AAARDS
'inchCsmash ha0ar% et9een falling tup an% specimen or stops
'roDectile ha0ar% from ro"en specimens
REQUIRED PPE
$afet! glasses
$afet! guar%s must e in place for testing
PROCEDURE:
*< Raise an% latch impact hea%< 'lace race asseml! on unit: elo9 raise% impact tup<
Never -ut your 0and under a rai!ed tu- Bit0out t0e $race a!!e#$ly in -laceD
2< Remo7e access %oor on instrument guar% if necessar!<
1< 'osition specimen on appropriate fixture<
4< Replace access %oor on instrument guar%<
5< Remo7e race asseml!
#< When soft9are in%icates rea%! to test 8 pull %o9n on latch on cross hea% to release
impact hea%<
4*
Sa'e O-eratin/ Procedure: Dia#ond +and SaB v 3(4
7AAARDS
Cut ha0ar% from sa9 la%e
'roDectiles from cut components or la%e failures
REQUIRED PPE
$afet! glasses
PROCEDURE
*< Chec" 9ater le7el in sponge reser7oir< -ill if necessar!<
2< .e sure la%e is clear of an! ostructions an% turn on sa9<
1< $pecimens to e cut shoul% e large enough to permit ample clearances et9een
fingers an% the la%e<
4< )se the miter unit or other pusher assemlies to stea%! parts an% pro7i%e a%%itional
clearance et9een fingers an% the sa9<
5< $lo9l! push the specimen into the la%e< Do Not A--ly 7eavy Pre!!ureE
#< Turn off sa9 efore retrie7ing small cuttings<
&< Never -ut your 0and $etBeen t0e $lade and t0e $ody o' t0e !aB B0ile t0e $lade
i! turnin/(
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Sa'e O-eratin/ Procedure: "TS Sy!te#! Multi.Cool Te#-erature +at0 ver!ion 3(3
7AAARDS
Col% or heat @urnsA from specimens or thermal ath me%ium
4ngestion of silicon oil in ath
REQUIRED PPE
$afet! glasses
Thermal protection glo7es
All !-eci#en! !0ould $e 0andled Bit0 ton/!<
'R6CED)RE
*< Chec" flui% le7el< 6il shoul% e S @ elo9 the gas"et at the flui%Ks highest operating
temperature< -or $!ltherm T
max
L 255
o
C<
2< 'lace sample in the reser7oir using specimen han%ling tongs< Do not %rop specimens as
!ou ma! %amage the cannister<
1< Turn on the stirrer using s9itch on front panel< Ne7er operate s!stem 9ithout the
stirrer acti7ate%<
4< 4ncrease the i%le spee% to some 7alue greater than *55 using the arro9 "e!s<
5< $et the %esire% temperature<
#< $pecimens generall! 9ill nee% to soa" 185 minutes after reaching the %esire%
temperature to assure uniform internal con%itions<
41
Sa'e O-eratin/ Procedure: SINTEC7 UTS ver!ion 3(4
7AAARDS+
Crush F 'inch ha0ar%s %uring fixturing an% machine operation
'roDectiles pro%uce% ! ro"en specimens
$harp e%ges of ro"en specimens
REQUIRED PPE
$afet! glasses must e 9orn at all times
PROCEDURE
Note t0e location o' t0e e#er/ency !to- $utton( T0e !-ace $ar on t0e
co#-uter ey$oard Bill al!o !0ut t0e #ac0ine doBn(
Sa'ety !0ield! #u!t $e in -lace durin/ te!tin/(
*< 4nstall appropriate fixtures
2< $et cross hea% limit stops >lac" an% !ello9 rings on roun% post? to pre7ent
contact et9een test fixtures<
1< Turn on computer an% start Test9or"s $oft9are<
4< $elect the t!pe of test to e performe% from the metho% 9in%o9
5< Calirate the loa% cell an% extensometer >if use%?< This must e %one efore
!ou egin to loa% specimens or the loa% rea% out 9ill not function<
#< Clic" on the @TestA utton< Bou 9ill e prompte% to enter specimen
%imensions ! the soft9are: e sure !ou ha7e ta"en the measurements efore !ou
loa% them into the test frame<
&< Loa% specimen to e teste%: attach extensometer >if use%? an% close the
protecti7e shiel%<
(< Run the test< When the specimen has ro"en an% the crosshea% stops: remo7e
the pieces from the fixtures< .e careful of the sharp e%ges in the fracture area of
the ro"en parts<
/< ,fter each test choose one of the follo9ing from the uttons on the screen+
Discar% 8 thro9s out %ata an% calculate% results
Next $pecimen 8 sa7es onl! calculate% results
-ile 8 $a7es ra9 %ata an% calculate% results
4f the test 9as a goo% one: use the -ile option so that !ou can pro%uce stress strain
cur7es of the test<
44
*5< Repeat the process 9ith the next specimen<
**< When testing is complete%: %ispose of ro"en specimens >scrap arrel or
trash?: close safet! guar%s an% cainets: an% turn off po9er to oth computer cart
an% the frame<
Note! on E?ten!o#eter!
Extensometers are extremel! expensi7e instruments an% shoul% e han%le% 9ith
care< To protect them: most tensile test proce%ures 9ill pause %uring testing for
gage remo7al< When the machine stops: open the %oor an% carefull! remo7e the
gage< When the space ar is %epresse% the test 9ill resume<
45