Metal Identification Tests Guide

When you are selecting a metal to use in fabrication, to perform a mechanical repair, or even to
determine if the metal is weldable, you must be able to identify its underlying type. 
Some field
metal identification tests can be used to identify a piece of metal.

It is necessary to know metal composition to produce a satisfactory weld. Metal workers and
Welders must be able to determine various metal products so that proper work methods may
be applied. For equipment, drawings (MWOs) should be available. They must be examined to
determine the metal to be used, and any heat treatment if required.

After some practice, the welder or metal worker will learn that certain parts of equipment or
machines are forgings, others are cast iron, other and so on.

Common Metal Testing Methods

There are seven tests commonly used to identify metals. Each is summarized below. Use tests
along with information on the mechanical and physical properties of each metal.

These tests are as follows:

 surface appearance
 spark test
 chip test
 magnet test
 torch test
 chemical test
 hardness test
Metal Identification Testing Order

When conducting a metal identification test, we suggest performing tests in the order outlined
in these metal identification charts, starting with the easiest to execute:

If the metal is not magnetic follow the following test sequence

Metal Identification Test Sequence for Non-Magnetic Metals

For slightly magnetic metals go down this test sequence

Metal identification test series for slightly magnetic metals

For magnetic metals follow this test sequence

Metal identification test sequence for magnetic metals

Summary Metal Identification Chart

Use this metal identification chart to quickly identify methods that can be used for scrap metal
identification or other metal ID requirements.

Magnetic
Base Metal or Fracture Torch or Spark
Color Test Properties Chisel Test
Alloy Test Flame Test Test
Test
Alloys & Blueish- Non-
non-magnetic Easily Cut White Melts wo/col
Aluminum white spark
Reddish or Non-
Brass non-magnetic Easily Cut Not Used Not Used
Yellow spark
Bronze, alum Reddish Non-
non-magnetic Easily Cut Not Used Not Used
(90Cu, 9A1) Yellow spark
Bronze,
Reddish Non-
phosphor non-magnetic Easily Cut Not Used Not Used
Yellow spark
(90Cu, 10Sn)
Bronze, Silicon Reddish Non-
non-magnetic Easily Cut Not Used Not Used
(96Cu, 3Si) Yellow spark
Copper Red; 1 cent Non-
non-magnetic Easily Cut Red Not Used
(deoxidized) piece spark
Copper (nickel White; 5 Non-
non-magnetic Easily Cut Not Used Not Used
70Cu - 30 Ni) cent piece spark
Everdur (96Cu - Non-
Gold non-magnetic Easily Cut Not Used Not Used
3Si - 1 Mn) spark
Non-
Gold Yellow non-magnetic Easily Cut Not Used Not Used
spark
Inconel (76Mi - Non-
White non-magnetic Easily Cut Not Used Not Used
16cr - 8Fe) spark
Not Easily See
Cast Iron Dull Gray magnetic Brittle Melts Slowly
Chipped text
Bright
See
Wrought Iron Light Gray magnetic Easily Cut Gray Melts Fast
Text
Fibers
Non- White Non-
Lead Dark Gray Very Soft Melts Quick
magnetic Crystal spark
Silvery Non-
Magnesium non-magnetic Soft Not Used Burns in Air
White spark
Monel (67Mi - slightly Non-
Light Gray Tough Light Gray Not Used
30Cu) magnetic spark
Almost See
Nickel White magnetic Easily Cut Not Used
White Text
 Magnetic
Base Metal or Fracture Torch or Spark
Color Test Properties Chisel Test
Alloy Test Flame Test Test
Test
Non-
Nickel Silver White non-magnetic Very Soft Not Used Not Used
spark
White; pre-
Non-
Silver 1965; 10 non-magnetic Easily Chipped Not Used Not Used
spark
cent piece
Depends on Medium See
Low Alloy Steel Blue-gray Magnetic Shows Color
composition Gray test
High Carbon Very Light See
Dark Gray Magnetic Hard to Chip Shows Color
Steel Gray test
Low Carbon Continuous Bright See
Dark Gray Magnetic Shows Color
Steel Chip Gray test
Manganese Non- Course See
Dull Work hardens Shows Color
Steel (14Mn) magnetic Grained test
Medium Carbon Very Light See
Dark Gray Magnetic Easily Cut Shows Color
Steel Gray test
Stainless Steel Bright Continuous Depends See
See text Melts Fast
(austentic) Silvery Chip on Type test
Stainless Steel Slightly Continuous Depends See
Gray Melts Fast
(matensitic) magnetic Chip on Type test
Stainless Steel Bright Slightly Depends See
- -
(ferritic) Silvery magnetic on Type test
Non-
Tantalum Gray Hart to chip - High Temp -
magnetic
Silvery Non- Usually as Usually as Non-
Tin Melts Quick
White magnetic plating Plating spark
Non- See
Titanium Steel Gray Hard Hard Not Used
magnetic test
Non- Hardest Highest Non-
Tungsten Steel Gray Hardest metal
magnetic Metal Temperature spark
Non- Usually as Usually as Non-
Zinc Dark Gray Melts Quick
magnetic plating Plated spark
Surface Appearance Metal Test

Sometimes you can identify a metal simply by its surface appearance. The table below indicates
the surface colors of some of the more common metals.

The appearance test includes such factors as appearance and color of un-machined and
machined surfaces.

Role of Shape and Form

Shape and form give certain clues as to metal identity. The form can be descriptive; for
example, shape includes such things as cast engine blocks, automobile bumpers, reinforcing
rods, angle irons or I-beams, pipe fittings pipes.

Consider the form and how the part is made. Castings will have signs of parting mold lines, cold
rolled or extruded surfaces or hot rolled wrought material. As an example is a piece of pipe is
cast, it could be cast iron or wrought iron, which would typically be composed of steel.

Color As A Clue in Metal Identification Methods

A strong clue in metal identification is color. It can differentiate precious metals, magnesium,
aluminum, brass, and copper. If there are signs of oxidation, remove it via scraping to reveal the
color of the unoxidized surface. Scraping aids in the identification of copper, magnesium, and
lead. Rust or oxidation on steel is a sign that can be used to differentiate corrosion resisting
steels from plain carbon steels.

Fractured surfaces or filed metal surfaces can also provide clues. Working with a metal
sometimes leaves distinctive marks that can help with identification.

 Malleable iron and cast iron can have sand mold evidence.
 High carbon steel reveals rolling or forging marks
 Low-carbon steel shows forging marks

Role of Surface Feel and Examination

The surface feel can provide additional indications of metal type. For example, stainless steel is
rough when not finished, and metals such as Monel, nickel, bronze, brass, copper and wrought
iron are smooth. Lead has a velvety appearance and is smooth.

Limitations of a surface examination are that you often do not have the information needed to
classify the metal.

Metals such as malleable iron and cast iron often show evidence of sand mold.
Surface Color vs. Other Tests

When the metal surface does not provide enough information for identification other tests can
be used. Tests that are simple to perform in any shop include:

 magnetic tests
 spark tests
 chip test
 magnetic tests

Color of Unfinished Color and Structure of Color of Freshly

Metal
Unbroken Surface Newly Fractured Surface Filed Surface
Aluminum Light Gray White, Finely Crystalline Whiite
Brown, reddish yellow Yellowish white to
Bronze & Brass Yellow to Red
or yellow-green Reddish yellow
Cast Steel & Low
Dark Gray Bright Gray Bright Silvery Gray
Carbon Steel
Green to Reddish
Copper Bright Red Bright Copper Color
Brown
Gray Cast Iron Dull Gray Crystalline, Dark Gray Light Silvery Gray
High-carbon Steel Dark Gray Light Gray Bright Silvery Gray
Lead Gray to White Crystalline, Light Gray White
Malleable Iron Dull Gray Finely Crystalline, Dark Gray Light Silvery Gray
Monel Dark Gray Light Gray Light Gray
Nickel Dark Gray Off-white Bright silvery white
Stainless Steel Dark Gray Medium Gray Bright Silvery Gray
White Cast Iron Dull Gray Crystalline, Silvery White Silvery White
Wrought Iron Light Gray Bright Gray Light Silvery Gray

Metal Filing Test

Brinell
Resistance to File Type of Steel
Hardness
Unalloyed and Low
No resistance; the file bites into the metal 100
alloyed steel
Little resistance; the file bites into Medium-carbon 2 00 the Medium-carbon
200
metal, but the pressure has steel to be increased. steel
Medium resistance. The file does not bite into the metal
High-alloy steel 300
and the pressure has to be increased.
High resistance. The metal can be filed, but with difficulty. Tool steel 500
Metal Spark Test

A metal spark test is useful for identifying the type of metal and in the case of steel,
determining its relative carbon content. Spark tests use sparks given off when holding
metal against a grinding wheel as a way of classifying iron and steel.

What is a spark test?

The test involves holding a sample lightly against a grindstone or abrasive wheel. Take note and
visually inspecting the spark color, shape and length, a metalworker can with accuracy identify
the metals.

While the test is fast and extremely convenient, it does not replace chemical metal analysis. It is
a quick method for sorting metals where the spark characteristics are known such as when
sorting mixed steels.

When metal is held lightly against a grinding wheel, the different kinds of steel and iron
produce sparks that vary in color, shape, and length.

Carrier Line Definition

This test is particularly useful when identifying cast steel or cast iron scrap metal. These metals
create give off small particles of the metal which are torn off quickly, becoming red-hot. As they
shoot off the abrasive wheel, they follow what is called a carrier line or trajectory.

When examining a “carrier line” look at the spark length, stream, and color.

Advantages

One advantage of the spark test is that it can be used with all types and stages of metals,
including finished parts, machined forgings and bar stock in racks.

Limitations

When using the spark test on steel, some steels have the same carbon content but differing
alloying elements, such as the difference between unalloyed and low alloyed steel. Steel has
different types of alloys that can affect the characteristics of the bursts in the spark picture, the
bursts themselves and the carrier lines. Alloys can accelerate or slow the carbon spark or make
carrier lines darker or lighter.

For example, the metal Molybdenum looks like an orange-colored, detached spearhead at the
end of the carrier line. When working with nickel, it can suppress the carbon burst effect. That
said, the nickel spark can be identified by brilliant white light in tiny blocks. The carbon burst is
contained by silicon even more than the nickel. Silicon causes the carrier line to end in a white
flash of light abruptly.
Do Not Use Spark Testing on Nonferrous Metals

Conducting a spark test is not helpful for identifying nonferrous metals such as nickel-base
alloys, aluminum, and copper. These metals do not show significant spark stream. That said,
this method can be used to differentiate between nonferrous and ferrous metals.

How To Conduct a Spark Test

You can use either a portable or stationary grinder for spark testing. In either case, the speed
on the outer rim of the wheel should not be less than 5,00 feet per minute (1,525 m) to get a
good spark stream. The abrasive wheel should be very hard and kept clean to produce a true
spark rather than a coarse spark.

Use a grinding wheel that has a hardness to last for some time, but soft enough to maintain a
free cutting edge. Conduct spark tests in little light to make it easier to see the spark color. As a
recommendation, use standard metal samples when comparing sparks with test patterns.

1. When holding the metal piece, position it so that the stream of sparks moves across
your line of vision. Steadily hold the metal park still and then touch the high-speed
grinder wheel to the metal with enough pressure to create a spark stream that is
horizontal and about 12 inches (30.48cm) long. The spark stream should be at a right
angle to your line of vision. Be careful not to have too much wheel pressure pressing
against the metal since increased pressure raises the spark stream temperature.
Increased pressure also makes it appear as if the metal has a higher percentage of
carbon content.All aspects of the spark stream (near the wheel, mid-stream,
incandescent particles at the end of the stream, are noted as part of the identification
process. Through trial and error, you will get a feel for the right amount of pressure to
apply to the project, without changing grinder wheel speed, to get an accurate spark
stream.
2. When looking at the spark stream, observe 1/3 of the way from the tail end. Watch how
the sparks cross your line of vision. Attempt to form an image of an individual spark.
Once your do this, then look at the entire spark stream.

Metal Identification Spark Test

Studying The Spark

The spark resulting from the test should be directed downward and studied. Spark length,
color, activity, and shape relate to characteristics of the material being tested. The spark stream
has specific items which can be identified.

What are spark test carrier lines?

Carrier lines are straight lines of sparks. They are usually continuous and sold. They may divide
into three short forks or lines at the end of the carrier line.

What are the types of spark streams?

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.

Proficiency in Spark Testing Ferrous Metals

If you are interested in becoming proficient as a spark tester of ferrous metals, collect several
types of metals for practice. Prepare the metals so that they are the same shape and size so
that this alone doesn’t indicate the identity. Put a unique number on an each sample. Then
create a list of names with the corresponding numbers.

Then, test each sample, recording the name after you do the test. Repeat until you get good
enough to identify each sample.
Metal Type Description Spark Pattern
Weak red sparks, ending in many
pronged yellow stars. Stream of
sparks is about 25 inches in length.
Gray Cast
Sparklers are small and repeating
Iron
with a small volume. The spark
stream closest to the wheel is red,
the outer stream is straw-colored.

White Cast
Relatively short spark stream.
Iron

High Speed
Weak red sparks, with forked ends.
Steel

Manganese The sparks split up, and end in stars.

Weak red sparks, quickly

extinguished. Monel and nickel form
almost identical spark streams. The
sparks are small in volume and
Monel and orange in color. The sparks form
Nickel wavy streaks with no sparklers.
Because of the similarity of the
spark picture these metals must be
distinguished from each other by
another method.
Bright yellow sparks with pointed
ends. Stainless steel produces a
spark stream about 50 inches in
Stainless length, moderate volume, and with
Steel few sparklers. The sparklers are
forked. The stream next to the
wheel is straw-colored, and at the
end, it is white.
The spark stream is about 70 inches
long and the volume is moderately
Low Carbon
large. The few sparklers that may
and Cast
occur at any place in low-carbon
Steel
steel are forked. Spark Stream is
white in color.
Metal Type Description Spark Pattern
The spark stream is about 65 inches
Machine
in length. The stream has a large
Steel
volume and few sparklers.
The spark stream is shorter (about
55 inches) and the volume larger.
High Carbon
Sparklers that occur in high-carbon
Steel
steel are small and repeating. Spark
stream is white in color.
Produces a spark stream about 65
inches in length. The stream has a
large volume with few sparklers.
Wrought The sparks appear near the end of
Iron the stream and are forked. The
stream next to the wheel is straw-
colored, and the outer end of the
stream is a brighter red.
The sparks separate at the end into
Unalloyed
several small sparks (leaf shaped).
Steel
Some sparks are short.
Abrasive Wheel Safety

Using a Grinding Wheel Dresser for Metal Spark Testing

 Never use an abrasive wheel that is out of balance or cracked because the vibration can
cause the wheel to break or shatter. A shattering wheel can be dangerous to anyone
standing in the area.
 Before using, always check the wheel for cracks and secure mounting.
 Be sure that any new grinding wheel is sized correctly. As the size of the wheel radius
increases, the rim speed increases, despite the face that the motor rpm is the same. If
using an oversized wheel, there is a risk that the speed at the rim (peripheral speed) and
any centrifugal force becomes so great, that the wheel comes apart. Only use a grinding
wheel that is designed for use at a specific RPM.
 To protect against a wheel that shatters, place guards on grinders as protection. DO
NOT use a grinder when the guards are missing.
 Stand to one side when activating the grinder. Stay out of line with the wheel to protect
against a wheel that bursts.
 Never put sideways pressure on the abrasive wheel or overload a grinder unless it is
expressly built to withstand such use.
 Always wear a face shield or safety goggles when using the grinder. Ensure that the tool
rest (the device that helps the operator hold the work) is adjusted to the minimum
clearance for the wheel. Move the work across the wheel face to prolong wheel life.
Moving the work minimizes grooving and any wheel dressing.
 When working with a grinding wheel, keep fingers clear of the wheel. Also, watch for
any loose clothing or rags that can become entangled in the wheel.
 When using an abrasive wheel, do not wear gloves.
 Never hold metal with tongs while grinding.
 Never grind nonferrous metals on a wheel intended for ferrous metals because such
misuse clogs the pores of the abrasive material. This buildup of metal may cause it fly
apart after becoming unbalanced.

Grinding Wheel Care

Recondition frequently to keep the grinding wheel in good condition. The process for cleaning
the periphery of the wheel is called dressing. The dressing process involves breaking away any
dull abrasive grains to create a smooth wheel surface.
Magnetic Tests

Magnets are frequently used for metal identification. Ferrous iron-based alloys are magnetic,
while nonferrous metal is non-magnetic.

Using a small pocket magnet a test can be performed where with experience, it is possible to
distinguish between a material that is slightly magnetic with one that has a strong magnetic
pull. The nonmagnetic materials are easily recognized.

Magnetic metal identification tests are not 100-percent accurate because some stainless steels
are nonmagnetic. In this instance, there is no substitute for experience.

There are three major groups of stainless steel:

 Martensitic: contain 11.5% to 18% chromium and up to 1.2% carbon, sometimes some
nickel
 Ferritic: contain 10.5% to 27% chromium and are nickel-free
 Austenitic: contain 16% to 26% chromium and up to 35% nickel – highest corrosion
resistance. These steels have good weldability (do not heat before welding.) The most
common type of Austenitic steel is 304 grade or 18/8 (18% chromium and 8% nickel.)
Used in food processing, dairy, and aircraft industries.

Magnetic Metals

If a metal clings to a magnet, it means that it is ferritic. It is stainless steel, low-alloyed or

unalloyed steel or normal steel. Note that stainless steel has poor weldability while low alloy or
unalloyed steel has high weldability. Ferritic steels are in architectural and auto trim
applications. It has less anticorrosion applications and is not hardenable by heat treatment.

Strongly magnetic materials include:

 Types of Steel
o Carbon steel
o Low-alloy steel
o Martensitic stainless steels
 Pure nickel
 Iron alloy

Slightly magnetic reactions are from metals that include:

 Monel
 High-nickel alloys
 Stainless steel of the 18 chrome 8 nickel type when cold worked, such as in a seamless
tube.
A Magnet Clinging to Metal Indicates a Ferretic Metal

Non-magnetic Metals

Nonmagnetic materials include:

 Copper-base alloys
 Aluminum-based alloys
 Zinc-base alloys
 Annealed 18 chrome and 8 nickel stainless
 Magnesium
 Precious metals
 Austenitic stainless steel

Non-magnetic Steel is austenitic

Metal Chisel, Fracture or Chip Tests

Several metals can be identified by examining chips produced with a hammer or chisel or the
surface of a broken part. The only tools required are a cold chisel and a banner. Use the cold
chisel to hammer on the edge or corner of the material.

Once chiseled, the surface will reveal the base metal color without oxidation. This is true for
magnesium, lead, and copper. In some cases, an indication of the structure is the roughness or
coarseness of the broken surface.

The ease or difficulty of chipping the metal part also indicates the level of ductility. If a metal
piece bends easily without breaking it is one of the more ductile metals. It is one of the brittle
metals if it breaks quickly with little or no bending.

A simple test used to identify an unknown piece of metal is the chip test. The chip test is made
by removing a small amount of material from the test piece with a sharp, cold chisel.

Unalloyed or Cast Steel Chisel Test

The material removed varies from a continuous strip to small, broken fragments. The chip may
have smooth, sharp edges; it may be coarse-grained or fine-grained, or it may have saw-like
edges.

Cast Iron Chisel Test

Chip size is a critical input in metal identification. The ease with which the chipping happens is
considered since it indicates metal hardness. A chip will break apart if it is a brittle material and
for a continuous chip, it means the metal is ductile.

Metals With Continuous Chips (easily chipped and the chips do not tend to break apart)

 Aluminum
 Mild steel
 Malleable iron

Brittle Chips: small broken fragments

 Gray cast iron

Chips Hard to Obtain: because of metal hardness, but can be continuous

 High-carbon steel

The information in the table below can aid in metal identification using this test.

Metals Chip Characteristics

Aluminum, Rolled Chips are smooth, with sawtooth edges. A chip can be cut as a continuous
Aluminum and strip. Aluminum castings show a bright crystalline structure. A fracture in
Aluminum Alloys rolled aluminum sections shows a smooth and bright surface.
Aluminum Bronze The fractured surface of aluminum bronze is smooth.
Generally, the alloy steels are very fine grained. Sometimes the fracture
Alloy Steels
has a velvety appearance.
Chips are smooth with sawtooth edges. These metals are easily cut, but
chips are more brittle than chips of copper. Continuous strip is not easily
Bronze & Brass cut. The fractured surface ranges from smooth to crystalline, depending
on the composition of the metal and on whether it has been cast, forged,
or rolled.
Chips are smooth, with sawtooth edges where cut. Metal is easily cut as a
Copper
continuous strip.
Chips are about 1/8 inch in length. Metal not easily chipped; therefore,
Gray Cast Iron
chips break off and prevent a smooth cut.
Chips show a fine-grain structure. Edges of chips are lighter in color than
High-carbon Steel chips of low-carbon steel. Metal is hard but can be chipped in a
continuous strip.
Chips of any shape may be obtained because the metal is so soft that it
Lead can be cut with a knife. Lead has a smooth gray-white surface when
polished, oxidizing to a dull gray.
Low-carbon and Chips have smooth edges. Metal is easily cut or chipped, and a chip can be
Cast Steel taken off as a continuous strip.
 Metals Chip Characteristics
Magnesium The fractured surface is rough and finely granular.
Chips vary from 1/4 to 3/8 inch in length (larger than chips from cast iron.)
Malleable Iron
Metal is tough and hard to chip.
Chips have smooth edges. A continuous strip can be cut. Metal chips
Monel easily. The fractured surface is crystalline. Its color is similar to that of
nickel.
Chips have smooth edges. A continuous strip can be cut. Metal chips
Nickel
easily.
The surface of the fractured area is bright crystalline gray. Steel castings
Steel Castings are tough and do not break short. Chips made with a chisel curl up, except
manganese steel which can not be cut with a chisel.
Forgings may be of low carbon, high carbon, or tool steel and the color
Steel Forgings will vary from bright crystalline to silky gray. When the specimen is nicked,
it is harder to break than cast steel and has a finer grain.
White Cast Iron Chips are small, brittle fragments. Chipped surfaces are not smooth.
White Metal Die-
The fracture is white and somewhat granular.
Castings
Chips have smooth edges. Metal is easily cut or chipped and a chip can be
Wrought Iron
made as a continuous strip.

Aluminum and Magnesium Test

To test for the presence of aluminum and magnesium perform the following steps:

1. Wash with clean water and wait 5 minutes. If you see the following colors, it indicates
the presence of the indicated metals:
2. Drip on the clean area one to two drops of 20% caustic soda (NaOH) solution.
3. Clean an area of the metal.Black: Al + Cu (copper), Ni (Nickel) or Zn (Zinc)
Grey/Brown: AL + Si (silicon, over 2%)
White: Pure Aluminum
No color change: Magnesium (Mg)

Metal Flame or Torch Test

Using an oxyacetylene torch, a welder can identify various metals by studying how the puddle
of slag and molten metal looks and how fast the metal melts during heating.

When a sharp corner of a white metal part is heated, the rate of melting can be an indication of
its identity.
 Metal Characteristics
In the case of copper, if the sharp comer melts, it is normally deoxidized
copper. If it does not melt until much heat has been applied, it is
electrolytic copper. Copper alloys will boil if composed of lead. A larger
Copper and Copper
flame is required to produce fusion than for other metals Because of the
Alloys
heat conducting properties of copper. Copper melts suddenly and
solidifies instantly. Copper alloys, containing small amounts of other
metals, melt quicker and solidify slower.
Steels containing a considerable quantity of chromium display a greenish
colored slag on the weld or puddle when cold. In general, the effects of
Alloy Steels
the torch test depend on the composition of the alloy steel and must be
determined by trial and experience.
If the material is aluminum, it will not melt until sufficient heat has been
used because of its high conductivity. Aluminum does not show red
before melting. It holds its shape until almost molten and then collapses
suddenly. A heavy coating of white oxide forms instantly on the molten
Aluminum, surface. Place the component on a piece of paper and file some shavings
Magnesium-alloyed onto the paper. Hold the paper over a flame and let the filings fall into
aluminum or the flame. If the filings glow the metal is aluminum. If some of the filings
Magnesium spark in the flame the aluminum is alloyed with magnesium (seawater
resistant aluminum). Distinguishing Magnesium vs. Aluminum Apply a
torch to metal filings to distinguish aluminum from magnesium. If all the
filings spark in the flame, the metal is magnesium and must not be
welded. Magnesium will burn with a sparkling white flame.
The surface is quickly covered with a heavy scum that tends to mix with
Aluminum Bronzes the molten metal and is difficult to remove. Welding of these bronzes is
extremely difficult.
True brass contains zinc which gives off white fumes when melted, while
Brasses and Bronzes bronzes contain tin that increases fluidity. Some bronzes contain zinc and
will fume, but not as much as brass.
Cast Steels The steel sparks when melted and solidifies quickly.
A heavy tough film forms on the surface as it melts. The puddle is quiet
and very fluid. When the torch flame is raised, the depression in the
Gray Cast Iron
surface of the puddle disappears instantly. The molten puddle solidifies
slowly and gives off no sparks.
The molten metal is brighter than molten low carbon steel and the
High-carbon Steels
melted surface has a cellular appearance.
Lead melts at a very low temperature and the molten metal becomes
Lead
covered with a thin, dull slag.
The steel gives off sparks when melted and, when the flame is removed,
Low-carbon Steel
solidifies almost instantly.
Magnesium oxidizes rapidly when heated in the air to its melting point;
Magnesium
because of this and as a safety precaution, this metal is melted in an
 Metal Characteristics
atmosphere free from oxygen. When heated in the open air, it produces
an oxide film which is highly refractory and insoluble in the liquid metal.
The molten metal boils under the torch flame and, when the flame is
withdrawn, the surface will be full of blowholes. The melted part will cool
Malleable Iron very hard and brittle; it is, in fact, white cast iron or chilled iron produced
by the melting and comparatively rapid cooling. The outer steellike shell
will give off sparks under the torch, while the center portion will not.
Monel flows clearly without any sparkle. A heavy black scale forms on
Monel
cooling.
Steel Steel will show characteristic colors before melting.
Steel forgings spark when melted. The greater the carbon content, the
Steel Forgings
greater the number and brilliance of the sparks.
White Metal Die-
The melting points are low and the metal will boil under the torch.
Castings
If the part is zinc, the sharp corner will melt quickly, since zinc is not a
Zinc
good conductor.

Hardness Tests

Hardness quality is complex and requires a review of the metal’s physical qualities.

It is most often defined regarding the method used for its measurement and usually, means
indentation resistance. Hardness may be related to wear resistance since one measure is
scratch resistance. The word “hardness” is sometimes used to refer to the temper or stiffness
of wrought products because tensile strength is related to the indentation hardness of the
metal. The cutting characteristic of metal, when used as a tool, is sometimes called its
hardness, but with experience, you will see how the various indications of hardness are not the
same.

The following describes the processes for the performance of various hardness tests.

File Test

The file test is a less precise test of hardness. The file test is a method of determining the
hardness of a piece of material by trying to cut into it with the corner edge of a file. The
hardness is indicated by the file bite. This is the oldest and one of the simplest methods of
checking hardness; it will give results ranging from quite soft to glass hardness. The principal
objection to the use of the file test is that no accurate record of results can be maintained as
numerical data.

The table below summarizes the reaction to filing the relative Brinell hardness, and the possible
type of steel.
 Brinell
Steel Type File Reaction
Hardness
Mild Steel 100 BHN File bites easily into metal
Medium Carbon Steel 200 BHN File bites into metal with pressure
High Alloy Steel and High File does not bite into metal except with extreme
300 BHN
Carbon Steel pressure
Unhardened Tool Steel 400 BHN Metal can only be filed with difficulty
File will mark metal but metal is nearly as hard as
Hardened Tool Steel 500 BHN
the file and filing is impractical
Hardened Tool Steel 600+ BHN Metal is harder than file

Rockwell Hardness Test

The Rockwell Hardness Test uses as Rockwell hardness testing machine to measure the
impression depth when using a known load to make by a hard test point. Soft metals will result
in a deeper impression and low hardness numbers. It is more difficult to make an impression
using hard metals, resulting in higher hardness numbers.

A dial indicates the hardness number. In this test, a 1/16″ steel ball for softer metals or a 120°
diamond cone for hard metals is pressed into the surface by a deadweight acting through
several levels. The dial gage indicates hardness using the Rockwell “B” and “C” scales. The
Rockwell number will be higher, the harder the piece. As an example, you will not see a reading
of more than 30 to 35 on the Rockwell “C” scale for machinable steel. At the same time, you
will see a reading of 63 to 65 for a hardened speed cutter. A “C” scale and a diamond point are
needed when doing a hard steel test. If testing nonferrous metal, use a “B” scale and a steel
ball.

Brinell Hardness Test

The Brinell test is similar to the Rockwell test. The difference between Rockwell and Brinell is
that the Brinell test looks at the area of the impression. The test is conducted by forcing a
hardened ball 10mm in diameter into the surface of the metal being tested.

For soft materials such as brass and copper, the ball has an applied pressure of 500
kilograms. The pressure changes to 3,000 kilograms for materials like steel and iron. With an
applied load, a small microscope is used to measure the diameter of the impression.

The metal hardness number is determined by dividing the load that was applied by the
impression area. This is then compared to the division results in a hardness conversion table.
The table indicates the metal number.
Scleroscope Test

With this process, the hardness is measured by the height of rebound of a diamond pointed
hammer after it has been dropped through a guiding glass tube onto the test piece and the
rebound checked on a scale. The harder the material used, the greater the rebound of the
hammer because the rebound is directly proportional to the resilience or springiness of the test
piece. The height of the rebound is recorded on a gage.

Since the scleroscope is portable, it can be carried to the work enabling tests to be performed
on a large section of metal too heavy to be carried to the work bench. The indentations made
by this test are very slight.

Vickers Hardness Test

The Brinell hardness method is similar to the Vickers hardness testing method. The penetrator
used in the Brinell test is a round steel ball while a Vickers machine relies on a diamond
pyramid. The impression made by this penetrator is a dark square on a light background. This
type of impression is easier to measure than the circular impression. One key advantage if that
the diamond point doesn’t deform like when using a steel ball.

Chemical Analysis

Some metals can be identified using a chemical test. These test can be performed right in the
metal shop. Chemical analysis is used to identify metals using a system developed by the
Society of Automotive Engineers (SAE.)

Monel vs. Iconel Identification

Inconel can be distinguished from monel with one drop of nitric acid applied to the surface. It
will turn blue- green on Monel but will show no reaction on Inconel.

Stainless Steel Identification

A few drops of a 45% phosphoric acid will bubble on low-chromium stainless steels.

Magnesium vs. Aluminum Identification

Aluminum can be differentiated from Magnesium by using silver nitrate, which will leave a
black deposit on magnesium, but not on aluminum.

Numerical Index System

One of the most widely known steel numbering systems for steel specifications and
compositions is the one established by the Society of Automotive Engineers (SAE), known as
SAE designations. The specifications were originally intended for use in the automotive
industry; however, their use has spread into all industries where steel and its alloys are used. As
the title implies, this is a numerical system used to identify the compositions of the SAE steels.
With only a few exceptions, plain steels and steel alloys are identified by a four-digit numbering
system. With this procedure, shop drawings use numbers and blueprints to partially describe
the composition of the materials referred to in the drawings.

Numbers use 4 or 5 digital codes for ferrous metals.

 First digit: Type of alloy (e.g.; 1 = steel)

 Second and third digits indicate the main alloy in whole percentage numbers.
 The last two or three numbers is the carbon content in hundredths of 1 percent.

To provide a better understanding of the SAE system, assume that a shop drawing indicates the
use of 2340 steel. The primary alloying element or type of steel is the first digit to which it
belongs; in this case, a nickel alloy. In the simple alloy steels, the second digit indicates the
approximate percentage of the predominant alloying element (3 percent nickel).

The last two digits always indicate the carbon content in points, or hundredths of 1 percent
(i.e., 0.40 hundredths of 1 percent carbon). From this explanation, it can be seen that a 2340
designation indicates a nickel steel of approximately 3 percent nickel and 0.40 hundredths of
percent carbon.

Steel Bar Color Coding

A color code established by the Bureau of Standards of the United States Department of
Commerce for making steel bars. Markings are applied by painting the ends of metal bars.

The work of preparing this color code was undertaken initially at the request of the National
Association of Purchasing Agents.

 Solid colors: usually mean carbon steel

 Twin colors: designate alloy and free-cutting
Metal Identification Color Codes