Spark Test

1. Objective
The activity aims to:

1.1 Identify the different types of ferrous metals and their properties through spark test
2. Intended Learning Outcomes (ILOs)
The student shall be able to:

2.1 Identify the Ferrous metals and their properties based on the data gathered
through spark test.
2.2 Describe the procedures and observation in determining the ferrous metals.
2.3 Properly use the equipment in conducting the activity.
2.4 Develop professional work ethics, including precision, neatness, safety and ability
to follow instruction.
3. Discussion

This is a simple identification test used to observe the color, spacing, and quantity of
sparks produced by grinding. It is a fast and convenient method of sorting mixed steels with
known spark characteristics. This test is best conducted by holding the steel stationary and
touching a high-speed portable grinder to the steel with sufficient pressure to throw a spark
stream about 12 inches long. The characteristics of sparks generated by a spark grinding test
are shown in Figure. These spark patterns provide general information about the type of steel,
cast iron, or alloy steel. In all cases, it is best to use standard samples of metal when
comparing their sparks with that of the test sample.
 A sprig is a spark stream that divides into more lines at the end of the stream. They
occur in different locations on the carrier line. These sprigs are called either fan bursts or stars.
At times, a carrier line slightly enlarges for a short length, continues, and then enlarges for a
short period. When you see heavier portions at the end of the carrier line, they are called buds
or spear points.

 If there is a presence of high sulfur levels, it results in thicker areas in the carrier lines.
These thick areas are called spearheads.
 Cast iron metal has extremely short streams
 Most alloy steels and low-carbon steels have relatively long streams.
 Steels usually have white to yellow color sparks
 Cast irons are reddish to straw yellow
 Sparks in long streaks that have a tendency to burst into a sparkler effect are seen with
.0.15 percent carbon steel.
 Carbon tool steel exhibits pronounced bursting
 1.00% Carbon Steel shows minute and brilliant sparklers or explosions. As the carbon
content increases, the intensity of bursting increases.

4. Materials and Equipment

4.1 Equipment

To perform a standard spark test, you’ll need a bench or handheld grinder equipped
with a 24-grit carborundum wheel. The grinder produces a steady stream of sparks from a
metal piece in a safe, reliable manner. If the metal sample is small enough to handle easily,
use the bench grinder. If you’re testing a piece that’s too big to safely use with a bench unit,
bring a handheld grinder to it.

4.2 Materials

 High Carbon Steel

 Medium Carbon Steel
 Cast Iron
 High Speed Steel
5. Procedure
5.1 Turn the grinder on.
5.2 Bring the metal into light contact with the grinding wheel, such that the sparks fly
clear of the grinder and wheel.
5.3 Carefully observe the color, pattern and length of the sparks produced. The spark
patterns may have combinations of bright lines, bursts and zigzags.
5.4 Compare the sparks you see against a printed reference. You may need to go
back and forth between the reference and the sparks, performing several tests until
you’ve identified the metal.
6. Observations

6.1 Medium-Carbon Steel

Based on the test we conducted, the spark formation

of low carbon steel has relatively long spark trajectory,
and the width is fairly big. Also there is some splitting
to the end of the spark.

Other observations:

 Spark stream is orange.

 Spark stream is long.
 Volume is moderately large.
 A few sparkles occur at some ends of the spark
stream and are forked.
 6.2 High-Carbon Steel

It shows in the pictures that when we

conducted the testing there is a lot of splitting to the
spark itself at the end and in the middle. It indicates
that it is a high carbon steel as per it’s property that
the number burst in the spark steam are directly
proportional to the amount of carbon in the metal.

Other observations:

 Spark stream is orange.

 Spark stream is shorter than the mild-carbon
steel.
 Volume is larger than the mild-carbon steel.
 Sparklers are small and repeating.

6.3 Cast Iron

In testing gray cast iron we found out that the spark

stream that is created is smaller in both volume and
size compare to carbon steel. However the sparklers
are repetitious. Also, the spark stream which begins
closer to the grinding wheel is reddish and light
yellow on the outside part.

Other observations:

 Spark stream is long.

 Spark stream near the wheel is red.
 Spark stream in the outer portion is straw
colored.
 Volume is rather small.
 Sparkles are small and repeating.
 6.4 High Speed Steel

In testing High Speed Steel

Other observations:

7. Conclusion
Through performing this experiment we are able to identify the processes on spark testing and on how to operate
the equipment need for the said experiment. We have identified the parts and the functions of the equipment we
use for this kind of testing, regarding to the test proper, using visual observation of the spark produced by our
workpiece, we are able to categorize and identify the certain type of metal through the spark that it emits regarding
to the standard table provided. We also prove that different type of metals produce different spark that can be
differentiate, how long and the volume that was produce.

8. References

 Smithy: Identification of Metals

 “Metal Tests: How to Identify Metals for Welding” . N.p., n.d. Web. 18 Feb. 2017
 “SPARK TEST – tpub.com.” I N.p., n.d. Web. 18 Feb. 2017
 Metal characteristics, Plasma Welding, welding positions …” N.p., n.d. Web. 18 Feb.
2017
 “Fundamentals of Professional Welding – Free-Ed.Net.” . N.p., n.d. Web. 18 Feb. 2017
 “MECHANICAL PROPERTIES OF METALS AND ALLOYS ” . N.p., n.d. Web. 18 Feb.
2017
 Carnegie Mellon University: Properties, Identification, and Heat Treatment of Metals
 Engineering Toolbox: Identification Tests for Stainless Steels
 http://constructionmanuals.tpub.com/14250/css/Chip-Test-25.htm
 Althouse, Andrew D., Carl H. Turnquist, and William A. Bowditch, Modern Welding,
Goodheart-Wilcox Co. Inc., 1970.
 Giachino and Weeks, Welding Skills, American Technical Publishers Inc., 1985.
 Welding Theory and Application, TM 9-237, Department of the Army Technical Manual,
Headquarters, Department of the Army, Washington D.C., 1976.