M&AE 3272; Lecture #1B

27 January 2014

M&AE 3272: Mechanical Property and Performance Laboratory

The Fundamental Second Week Mechanical Materials Triangle Property Measurements

Structure
Processing Operations change a materials internal structure (the materials state evolves)

Internal Structure and Composition of materials dictates their Properties

Properties

Processing
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Material Properties determine the Processing Operations that can be used

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Relationships Two key questions :

Whats the relationship between material microstructure and mechanical properties? Whats the relationship between material processing (solidification, forming and heat-treating) and the obtained material microstructures - and hence mechanical (and electrical and other) properties? For a quick review check-out:
https://blackboard.cornell.edu/bbcswebdav/pid-1819946-dt-content-rid3419254_1/courses/10922_2013SP/Suppl%20Materials%20Lect2%20Material%20Prop erties.pdf

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27 January 2014

Mechanical Properties of Isotropic Materials:

Deformation Descriptors: Elastic Properties (Moduli):
Load, P; Stress, Elongation, ; Strain, Reduction of Area, %RA Youngs Modulus, Y Bulk Modulus, B Shear Modulus, G (or ) Poissons Ratio,

Inelastic Properties:
Yield Strength, ys Tensile Strength, TS or ult Shear Strength, F Fracture Strength, crit
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Other Properties:
Ductility Toughness Hardness Flexural Modulus; Strength Buckling Strength
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Mechanical Properties are Critical Consequences can be catastrophic!

Failure of: Bridges, Buildings, Structures Failure of F-15: Aircraft The Air Force determined that the cause of the accident was a defective metal Medical Devices support beam . . .
A failure of the upper right longeron, a critical support structure in the F-15C Eagle, caused the crash of a Missouri Air National Guard F-15C . . . The longeron didn't meet blueprint specifications. This defect led to a series of fatigue cracks in the right upper longeron which expanded under life cycle stress, causing the longeron to fail, thus initiating a catastrophic failure of the entire aircraft.
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M&AE 3272; Lecture #1B

27 January 2014

Properties of Metals:
Atomic Scale: Bonding Metallic Microstructure
Defects and Imperfections Crystal grains; Lamella

Useful Characteristics Mechanical Properties

Electrical Conductivity Huge Information and Experience Base Machinability; Formability

Concerns:
Fracture Fatigue Corrosion Oxidation
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Measurement Challenge:
Youre given a new super-material, just announced by HRL Laboratories which is claimed to be the lightest material in the world! Ultralight Metallic Micro-lattices.
18-Nov-2011

Density: <10 mg/cm3 Periodic array of connected, hollow Nickel microtubes Octahedral unit cell Large strain (50%) deformations Completely reversible

How would you propose to determine the Youngs Modulus for the Micro-lattice?
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M&AE 3272; Lecture #1B

27 January 2014

Measurement Challenge:
To determine the Youngs Modulus for a specimen of the new Ultralight Metallic Micro-lattice material, your best suggestion would be:
1. Make a beam specimen, bend it and measure the deflection. 2. Shake it and measure the modal frequencies. 3. Pull on a chunk of it and measure its stretch. 4. Push on a chunk of it and measure its contraction. 5. Send a sound wave through it and measure the travel time.
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Measurement Results: Youngs Modulus

Test the Microlattice specimen in compression and record the applied load P and measure the resulting compression of the sample. Stress: = P/A A Area; L0 initial thickness. Strain: = /L0 ; E=/

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27 January 2014

Your Specimen Materials:

1050 Steel SAE-AISI (American Iron and Steel Institute) Numbering System XXXX The first two digits indicate the grades of the steel. The last two digits give the nominal carbon content in 0.01%. 1050 Plain carbon steel; Non-sulfurized, Mn less than 1%; 0.50% Carbon Heated to the Austenizing temperature (723-deg C) and slowly cooled; Oil quenched at 845-deg C and tempered at 540-deg C.
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Your Specimen Materials:

6061 Aluminum IADS International Alloy Designation System The first digit indicate the major alloy; 6=Mg and Si Second digit gives the impurities and mill data The next two digits are alloy registration numbers. This is followed by an index denoting the heat treatment: 0 Annealed; Hx Strain Hardened; Txx Thermal treatment (higher number, stronger treatment.) O - Heated to recrystallization temperature; cooled to soaking temperature (413-deg C; 3 hrs) then slowly cool (28-deg/hr) to 260-deg C T6 Solution heat-treated, quenched and furnace aged (Heated to 529-deg C; quenched; aged at 160-deg C for 18 hrs)
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M&AE 3272; Lecture #1B

27 January 2014

ASTM Standard E8-04

1. Scope

5. Apparatus 3. Terminology

6. Specimens

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ASTM Standard E8-04

Section 5, 5.2 we will be using wedge grips Section 6, 6.2 we will be using sheet type wide standard specimens Section 7, 7.6 we will be using a rate of separation of the two heads testing speed method. We will be using a rate determined by previous experience. Section 7, 7.7 you will use the appropriate method to determine yield strength, when choice of a method is not clear, use the offset method.

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M&AE 3272; Lecture #1B

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Measurements: Tensile Test using Instron

Activate (1) Hydraulics and (2) Actuators (OFF-LOW-HIGH 5 sec each) Warm-up Machine (Sine Wave 2-in Amplitude; 2 Hz; ~5 min) Mark on your Specimen where you will attach your Extensometer Mount your Specimen with Extensometer in the Testing Machine Grips Machine Control is via Instron Console and LabVIEW software
Set Maximum Extension: 1-inch; Maximum Rate: 0.01 in/sec

Machine Data Collection is via LabVIEW

software

Load (lbs) and Extensometer Reading (in)

Remove specimen from grips; Return ram to initial position Download mechanical test data to thumb drive; Upload to LabArchives Convert data: = P/A (P Load; A Cross-section Area of Specimen) Determine Youngs Modulus, Yield Stress; Ultimate Tensile Strength;
Elongation at Fracture; Reduction of Area; Watch Units!
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e = L/L0 (L Extensometer Reading; L0 Initial Gage Length)

Ductility Measures: Elongation (%EL); Reduction of Area (%RA):

Plastic tensile strain at failure: % EL =
Engineering tensile stress,
Adapted from Fig. 6.13,

smaller %EL (brittle if %EL<5%) larger %EL (ductile if %EL>5%)

L f Lo x 100 Lo

Lo

Ao

Af

Lf

Callister 6e.

Engineering tensile strain, A Af x100 Another ductility measure: %RA = o Ao

Note: %RA and %EL are often comparable.

--Reason: crystal slip does not change material volume. --%RA > %EL possible if internal voids form in neck.
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Comment on Reduction of Area (%RA):

Reduction of Area:
%RA = Ao A f x100 Ao

Lo

Ao

Af

Lf

Area = [(t1 + 4t 2 + t 3) / 6] [( w1 + 4w2 + w3) / 6]

t = Thickness w = Width
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Hardness Measurements:
Hardness Testing Methods: Provide a quick and easy determination of a number related to the flow stress of a material. Rockwell Hardness Test Rockwell Superficial Hardness Test Brinnel Hardness Test Vickers Hardness Test Microhardness Test Mohs Hardness Test Scleroscope; other hardness testing methods
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Hardness: Common Measurement Procedures

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Vickers Hardness Measurements:

Vickers Hardness Test:
Indentation with a diamond indenter (right pyramid, angle 136-degs between faces) Load: 1 to 100 kgf for 10-15 seconds; then unload Measurement: Two diagonals of indentation measured and averaged Determination: Divide Load by area of sloping surfaces of indentation

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Hardness: Common Measurement Procedures

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Rockwell Hardness Measurements:

Principle: The hardness test method consists of indenting a test material with a diamond cone or hardened steel ball indenter and after unloading measuring the permanent depth of penetration. Procedure: The indenter is forced into the test material under a preliminary minor load F0 (Fig. 1A) usually 10 kgf. Then the major load is applied resulting in an increased penetration. The permanent increase in penetration is then used to compute the Rockwell Hardness number, HR: HR = E - e
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Rockwell Hardness Scales used in Lab:

Scale C B E Indenter Diamond Cone 1/16 Steel Ball 1/8 Steel Ball Minor Load kgf 10 10 10 Major Load kgf 140 90 90 Total Load kgf 150 100 100 Value of E 100 130 130

[e: Units of 0.002mm]

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Rockwell Hardness Measurements TIPS!

Determine the Appropriate Hardness Scale to use. Procedure: Use the diamond indenter first; then 1/16; then 1/8. (If the test material is too hard, the ball-indenters might get damaged!) Measurement Procedure:

After inserting the indenter, set the minor load to R. Set the load selector to the total test load (e.g. 100 or 150 kgf.) Press D/B to select test scale Press AUTO Place sample on anvil Press Reset to read 0.0 Turn elevating handle until SET lights up If you overshoot the SET position, you will have to unload and repeat the test! Press START Record Hardness value prior to releasing load. Release load Repeat 10 times on each material NOTE: Stay away from edges, and indents not too close to each other!

ASTM E18-03:

Section 5, 5.3 we will be using a

diamond indenter and 1/16 and 1/8-inch dia steel ball indenters

Linear Range: Rockwell B

Section 6, 6.3 and 6.4 we will be using

1-inch diameter specimens

Rockwell Hardness Conversion Chart for Soft Materials

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Ultrasonic Measurements:
Implementation. and Signal: Set-up in B30 Upson:

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M&AE 3272; Lecture #1B

27 January 2014

Ultrasonic Measurements per ASTM E494:

Critical Comments:
6. Procedure

Actual Observed:

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Ultrasonic Measurements for Elastic Modulus Determination:

Underlying Equations:
Modulus = Density * Wavespeed E = * vS
2 2

Waves and Signals: G = * vS

2

3vL 4vS vL
2 2 vS

{1 2(vS/vL) }
2

2 {1 (vS/vL) }

vS vL

Set-up in B30 Upson:

v = 2h/t

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Ultrasonic Moduli Measurement Procedure:

Procedure:
Determine the density of your specimen(s). Repeat several times. Weigh your sample to determine its mass and then measure its diameter and thickness (H) . Then compute the volume of your specimen and the error in your volume determination: V/V = 2r/r + h/h . Couple the P-wave (with couplant; or S-wave transducer with pine tar removed with alcohol!) to the ultrasonic source/receiver unit. Look for echoes on the oscilloscope display. Vary the pressure on the transducer and observe the cleanest possible echo pattern. Measure the wave arrival time for 2H, 4H, 6H, etc. How much do they vary? If you know how, use the delayed sweep of the oscilloscope. Can you estimate the error in your arrival time determination? Compute the longitudinal wavespeed. Repeat for using shear waves. Compute the Moduli of your material. Can you estimate the error in your modulus determination?
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NEW: Ultrasonic Moduli Determination on LabArchives:

Suggested Procedure:
Logon to LabArchives and in your Module 1 Folder add a `New Item where you will do the data input and data analysis. Create a spreadsheet for inputting echo arrival times, compute the echo time intervals. Input propagation length and estimated error. Compute the wavespeed(s) and the estimated error:

LabArchives Window

Enter the mass and estimated error; enter diameter and error. Compute the Volume and Density and Shear Modulus: Watch Units!
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27 January 2014

Your Material Test Data Sheets:

(Available on Blackboard or in your LabArchives Folder)

Expected Reduction of Area:

% RA = 1 A f /A 0

= (L f L 0 ) /L 0

Incompressibility:

A 0L 0 = A f L f

% RA = f f +1
Now available as a LabArchives Widget !
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Your Report Summary:

Abstract: Mechanical Property Measurements

1. What was (were) the measurement problem(s) you solved? 2. What procedures did you follow to solve the problem? 3. What were your principal results? 4. What is the significance or impact of your results?

Create in MS-WORD; Place into your Electronic Lab Notebook

. . . Written in complete sentence form; 200-500 words (1 page) maximum. No figures.

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Tasks to do this Week:

Learn all about your specimen materials:

Al: 6061-O; 6061-T6; C1050: Annealed; Oil Quenched

Famililarize yourself with LabArchives. This will save you

lots of time later when you process your data.

Determine Expected Values of Density; Rockwell C; Yield

Strength; Ultimate Tensile Strength; Elongation to Fracture; Reduction of Area; Modulus of Elasticity; Bulk Modulus and Poissons Ratio. Upload to LabArchives.

Read the Handout for Module 1 Measurements. Peruse the ASTM Standards and read the relevant
paragraphs.

Lab Sections #401, #402, #403, #404, #409, #411 and #413
meet this week. Go to B30 Upson. Please be on-time!
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