Smithells Metals Reference Book Part 13 pdf

Tensile testing 21-9 -, 1- Figure 21.1 BS 18:Part 2:1987 Test pieces of circular mrd rectangular cross-section Table 21.13 STANDARD TENSILE TEST PIECES FOR CAST IRON-BRITISH STANDARDS BS: 1452: 1977 Dimensions of machined tensile test piece Gauge diameter Minimum Minimum radius Plain ends Screwed ends D parallel R Nominal Machining P Nominal Machining Minimum Minimum diameter at Minimum value toleranee* value tolerance diameter length root ofthread length mm mm mmmmmm mm mm mm mm length Minimum B C E F - 20 f0.5 55 25 -0, +5 25 65 25 30 *If it is desired to calculate the tensile strength on the basis of the nominal diameter, the machining tolerance shall he 0.lOmm. Note: With screwed ends, any Corm of thread may be used provided that the diameter a1 the root of the thread is not Iess than that specified. Table 21.14 STANDARD TENSILE TEST PIECES FOR CAST IRON-AMERICAN STANDARDS ASTM E&88 AND BM-88 21-10 Mechanical testing Table 21.14 ASTM E848 AND E8M-SB-contiwzd STANDARD TENSILE TEST PIECES FOR CAST IRON-AMERICAN STANDARDS Dimensions Specimen I Specimen 2 Specimen 3 in G Length of parallel D Diameter 0.500i R Radius of fillet. min. 1 A Length of reduced section, min. 1$ L Overall length, min. 3: E Length of shoulder, min. 5 F Diameter of shoulder i* 0.010 B Length of end section, approximate 1 C Diameter of end section, approximate 3 1 1 64 ~~ ~ mm in mm in Shall be equal to or greater than diameter D 12.5i 0.750i 20.0+ 1.25f 0.2 0.015 0.40 0.02 25 1 25 2 32 I+ 38 4 95 4 100 6% 25 1 25 1; I+ 30 1' - 2 1 6 16 20 6 16.0k b* 24.0+ I$* 0.40 0.40 - 64 mm 30.0 i 0.60 50 60 160 45 48 8 36.5+ 0.40 Note: The reduced section and shoulders (dimensions A, D. E, F, G and R) shall be as shown. but the ends may be of any form to fit the holders of the testing machine in such a way that the load shall be axial. Commonly the ends are threaded and have the dimensions B and C given above. Imperial units are E8-88 and metric units are E8M-88. 21.3 Impact testing of notched bars 21.3.1 Id test The test consists of measuring the energy absorbed in breaking a notched test piece by one blow from a striker carried by a pendulum. The test piece is gripped vertically with the root of the notch in the same plane as the upper face of the grips. The blow is struck on the same face as the notch and at a fixed height above it. Tests are usually performed at the ambient temperature of the test house. TEST PIECES The standard test pieces are either lOmm square or 0.45 inches (11.4mm) diameter cross-section. Complete dimensions are shown in Table 21.15. The notch profile is shown in Figure 21.2. Table 21.15 AND AMERICAN STANDARD ASTM ED-86 Item Square section Circular section DIMENSIONS OF IZOD IMPACT TEST PIECES-BRITISH STANDARD BS 131:PART 1:1961 (1989) Nominal dimension mm in equivalent in mm equiualent Minimum overall length of test piece 1 Notch 2 Notch 3 Notch Width Thickness Root radius of notch Maximum depth below notch Distance of plane of symmetry of notch from free end of test piece and from the adjacent notch Angle of notch 70' 98 126* 10 10 0.25 8 28 45" 2.75 3.86 4.96 ti;:} 0.010 0.315 1.1 2.8' 71 3.9 99 5.03 127 0.45 dia. 11.48 dia 0.010 0.25 0.32 8.1 1.1 28 45" Notes: (1) American Standard overall length 75 mm (2.952 in). (2) American Standard overall length 131 mm (5.157 in). (3) American Standard overall length 137 mm (5.375 in). Impact testing of notched bars 21-1 1 PRESENTATION OF RESULTS When standard test pieces are used the following symbols are used in reporting the results of Izod tests: I for Izod S for square section Rs for circula cross-section with straight notch E.G. 1120s x ft Ibf An energy of x ft Ibf was obtained from an hod test with a striking energy of 120 ft lbf using a square section test piece.7 9 3 5 Enlarged view of U-notch (three depths) Enlarged view of keyhole notch (two depths) 0) Enlarged view .of V-notch (All dimemions in millimetres unless otherwise stated) Fq 21.2 Standard notch profiles for impact test pieces-see Table 21.15 and 21.16 21.3.2 cbprpytest The test consists of measuring the energy absorbed in breaking by one blow from a pendulum a test piece notched in the middle and supported at each end. TEST PIECES The standard test piece has a lOmm square cross-section with one of the. three notch profiles shown in Figure 21.2. The test piece dimensions are shown in Table 21.16 Sub-standard test pieces are used where material thicknesses do not permit full-size specimens. It should be noted that the values obtained from subsidiary specimens cannot be compared with full-size specimens nor can the values obtained from different notches be compared. PRESENTATION OF RESULTS The report of the tests should include the following information: Type of test: Charpy V or U notch; striking energy of the machine; size of test piece if sub- Standazd. Nominal depth of notch and form ('W or 'keyhole'). The energy absorbed (J) and the test temperature: e.g. C16OV: x J at y "C tBS 13l:Part 21972 uses SI units with 1 Js4/3 It Ibf for striking energies (1 ft Ibf=1.35582 J). 21-12 Mechanical testing An energy of x J was recorded from a Charpy V notch specimen tested at y "C with a striking energy of 160 J: e.g. C320U2: x J at y "C In this case the specimen was a Charpy with a U notch 2 mm deep and the striking energy was 320 J. Table 21.16 DIMENSIONS OF CHARPY IMPACT TEST PIECES-BRITISH STANDARDS BS 131:PART 2:1972; BS 131:PART 3:1972 (1982); AMERICAN STANDARD ASTM E23-86 Nominal dimension Item mm inch equivalent Length Width standard test piece subsidiary test piece' subsidiary test piece subsidiary test piece Thickness Root radius of V notch Depth below V notch Root radius of U notch Depth below U notch Distance of notch from one end of test piece Angle between plane of symmetry of notch and longitudinal axis of test piece Angle of V notch 55 10 7.5 5.0 2.5 10 0.25 8 1 8 (2 mm notch)', 7 (3 mm notch)z. 5 (5mm notch) 27.5 90" 45" 2.165 0.394 0.295 0.1 97 0.098 0.394 0.010 0.315 0.039 0.315 0.276 0.197 1.083 Mores: (1) Additional subsidiary test pieces are permitted by ASTM ED-86 as follows: Smm thick with 4mm depth below the notch and 5.10 or 20 mm width and 3 mm thick with 0.094 in (2.39 mm) depth below notoh and 10 mm width. (2) Not specified in ASTM E23-86. (3) The 2, 3 and 5 mm notches are sometimes referred to as 'Mesnager', 'DVM' and 'Charpy', respectively. 21.4 Fracture toughness testing 21.4.1 Plane strain &) Standards: British BS 5447:1977 (1987) The method involves the loading to faiiure in tension or three point bend of notched specimens which have been precracked by fatigue loading. The load versus displacement across the notch at the specimen edge is recorded autographically. The load corresponding to a 2% increment of crack extension is established by a specified deviation from the linear portion of the record. The fracture toughness, K,,, value is calculated from this load by equations which have been established on the basis of elastic stress analysis of the two specimen types. Stress-intensityfactor K,: A measure of the stress-field intensity near the tip of a crack in a linear elastic body when deformed so that the crack faces are displaced apart, normal to the crack plane (Opening Mode or Mode I deformation). K, is directly proportional to the applied load and depends on the specimen geometry. Plain strain fracture toughness K,: A material toughness property-the critid value of the stress intensity factor at which rapid propagation of a crack occurs during static loading. American ASTM E399-83 TEST PIECES The particular type of test piece used depends upon the form, the strength and the toughness of the material under test. Fracture toughness testing 21-13 The basis of the test piece size requirements* is that both the crack length, a, and the thickness, B, shall be not less than 2.5[(Krc)/(uy)]2 where uy is 0.2% proof stress of the material under the conditions of test, i.e. orientation, temperature and loading rate. In the first place, the test piece size has to be based on an approximate estimate of the KIc of the material, it is better to overestimate the K, value initially and subsequently use a more conservative test piece if possible, on the basis of the first test results. Alternatively, the ratio of yield strength to Young's modulus given in Table 21.17 can be used a a guide for selecting the initial test piece size. Tab 21.17 RECOMMENDED THICKNESS AND CRACK LENGTH FOR FRACTURE TOUGHNESS TEST PIECES Minimum recommended thickness and crack length up to 0.0050 100 4.0 0.005 0-0.005 I 15 3.0 0.005 1-0.006 2 63 2.5 0.006 2-0.006 5 50 2.0 0.006 5-0.007 1 38 1.5 0.007 1-0.008 0 25 1 .o 0.008 0-0.009 5 13 0.5 0.0095 or greater 6.5 0.25 If, however, it is not possible to produce a test piece having both crack length and thickness not less than 2.5 [(Krc)/(uY)lz then it is not possible to obtain a valid K,c determination according to the standard procedures. See Section 21.4.2 for an alternative measure of fracture toughness. Minimum thickness for plane strain Cmml '"1 250' 100'75'50' 25' lo' 7.5/ 0 400 800 I200 1600 EOOO 2400 2800 3203 3600 Yield strength, cry (MPa) I 0 400 800 I200 1600 EOOO 2400 2800 3203 3600 Yield strength, cry (MPa) Figure 21.3 Yield strength versus fracture toughness data for several alloy systems at 20 "C. The upper scale of the diagram indicates the minimum thickness requirement for a given strength and toughness by projection of the line joining the origin and data point. (Source: Fulmer Materials Optimizer, Fulmer Laboratories Ltd, Buckinghamshire, UK). 'For graphical assessment see Figure 21.3. 21-14 Mechanical testing 5~71 Sectior through t Lw + Srnm(min ~W+5mm(minbl _t notch Single-notch bend test piece -+IN t MuLti-notch bend test piece Test piece. Proportion, dimensions and limits Width =W Thickness =B=$ W Crack length a=0.45 W-0.55 W Notch length J = 0.25 W-0.45 W i.e. 0.25 W when W= 13 mm 0.45 W when W=150 mm Notch width not greater than W (when W is equal to or less than 25 mm N may be up to 1: mm). Faces parallel and perpendicular to 0.02 mm taper per 10 mm run. Figure 21.4 Standard bend test piecefrom BS 5447: 1977 (1987) Fracture toughness testing 21-15 I D dia. tt Proportional dimensions and lim'ts Net width W Crack length a=0.45 W4.55 W Thickness B=0.5 W Total width C=1.25 W Hole diameter D =0.25 W Half hole centres E =0.275 W G=not less than 0.55 W J=see Figure 21.4 N = not greater than & W Hole centres F=0.55 W H=0.6 W Notch width When W is equal to or less than 25 mm N may be up to It mm. Surfaces parallel and perpendicular as applicable to 0.02 mm taper/per 10 mrn run. Size 18 W C a max. N max. E F H D G min. 13 13 26 32.5 14.5 1.5 7.2 14.3 15.6 6.5 14.3 25 25 SO 62.5 27.5 3.1 13.8 27.5 30 12.5 27.5 75 75 150 188.5 82.5 9.4 41.3 82.5 90 37.5 825 100 100 200 2% 110 12.5 55 110 120 50 110 Hence: 50 50 100 125 55 6.3 27.5 55 60 25 55 Finish to be 0.8 unless otherwise specified. The dimensions given above are for a resonunended series of test piece sizes. Figure 21.5 Standard tension test piece from BS 5447: 1977 (1987) CALCULATION AND INTERPRETATION OF RESULTS Unlike most other forms of mechanical test, plane strain fracture toughness testing has to be completed and the results analysed before it is known if a valid measurement has been made. It is necessary to calculate a provisional result Kq, which involves a construction from the test record, and then to determine whether this result is consistent with the test piece size requirements for the proof stress of the material. 21-16 Mechanical testing OFFSET PROCEDURE A secant line through the origin is drawn with a slope 5% less than the slope of the tangent to the initial linear part of the record. The force PQ is defined as the intersection of the secant line with the test record or any higher recorded value of force preceding the intersection. CALCULATION OF KQ KQ is calculated from PQ using one of the following relationships. For the bend test However, L=2 hence KQ=PQY,/BW1‘2 Values for Yl for specific values of a/W are given in Table 21.18. For tension test piece Hence KQ=% Values of Y, for specific values of a/W are given in Table 21.19. CALCULATION OF K,, The factor 2.5 [(K~)/(ay)]’ shall be &lculated and if this is less than both the thickness and the crack length of the test piece then KQ is equal to K,. Otherwise, it is necessary to use a larger test piece to determine K,,, such that both thickness and crack length are not less than 2.5 [(KIc)/(ay)12. The new dimensions can be estimated on the basis of KQ. Table 21.18 SPAN TO TEST PIECE WIDTH RATIO 41 VALUES OF Y, AGAINST a/w FOR BEND TEST PIECE THREE-POINT LOADED OVERALL 0.OOO 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 am Y, Stress intensity coe@ient 0.450 9.10 9.13 0.460 9.37 9.40 0.470 9.66 9.69 0.480 9.96 9.99 0.490 10.28 10.31 0.500 10.61 10.65 0.510 10.96 11.00 0.520 11.33 11.37 0.530 11.71 11.75 0.540 1212 12.16 0.550 12.55 9.15 9.43 9.72 10.03 10.34 10.68 11.03 11.40 11.79 12.20 9.18 9.21 9.23 9.26 9.46 9.49 9.52 9.54 9.15 9.78 9.81 9.84 10.06 10.09 10.12 10.15 10.38 10.41 10.44 10.48 10.71 10.75 10.78 10.82 11.07 11.11 11.14 11.18 11.44 11.48 11.52 11.56 11.83 11.87 11.91 11.96 12.25 12.30 12.33 12.37 9.29 9.57 9.81 10.18 10.51 10.85 11.22 11.60 12.00 12.42 9.32 9.35 9.60 9.63 9.90 9.93 10.21 10.25 10.54 10.58 10.89 10.93 11.25 1129 11.64 11.67 12.04 1208 12.46 12.50 Fracture toughness resting 21-17 Table 28.19 VALUES OF Yz AGAINST a/W FOR TENSION TEST PIECE O.Oo0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 Y, Stress intensity co&cient alW 0.433 8.34 8.36 8.38 8.41 8.43 8.45 8.47 8.50 8.52 8.54 0.460 8.57 8.59 8.61 8.64 8.66 8.69 8.71 8.13 8.76 8.78 0.470 8.81 8.83 8.86 8.88 8.91 8.93 8.96 8.98 9.01 9.03 0.480 9.06 9.09 9.11 9.14 9.16 9.19 9.22 9.24 9.27 9.30 0.490 9.32 9.35 9.38 9.41 9.43 9.46 9.49 9.52 9.55 9.57 QSOO 9.60 9.63 9.66 9.69 9.72 9.75 9.78 9.81 9.84 9.87 0.510 9.90 9.93 9.96 9.99 10.02 10.05 10.08 10.11 10.15 10.18 0.520 10.21 10.24 10.27 10.31 10.34 10.37 10.40 10.44 10.47 10.50 0.530 10.54 10.57 10.61 10.64 10.68 10.71 10.75 10.78 10.82 10.85 0.540 10.89 10.92 10.96 11.00 11.03 11.07 11.11 11.15 11.18 11.22 0.550 11.26 RECORDING OF TEST RESULTS The following data are usually recorded for each test: 1. Thickness: E in metres. 2. Width Win metres. 3. Half loading span: Lin metres for bend test only. 4. Fatigue precracking. (a) The fatigue stress intensity, K, , during the last 1.25 mm (or 2.5% W whichever is the greater) increment of crack growth. This stress intensity should not exceed 0.7 KQ. @) The maximum fatigue stress intensity, used to initiate the crack. This stress intensity should not exceed 0.15 KQ. (c) Temperature of the test piece during precracking. When fatigue cracking is conducted at a temperature Ti and the testing carried out at a temperature T2, K, during the final stages of cracking should be. less than [(20yl)/(3uy2)] K,, where oyl and uytare the proof stresses at the temperatures and q. (d) The R ratio, i.e. the ratio of the minimum to the maximum fatigue load. It is recommended that R should not be greater than 0.1. 5. Crack length n in metres. The crack length is measured from the fractured test piece at 25%, 50% and 75% of the specimen thickness and the average of these three values quoted. The crack is regarded as unsatisfactory if any of these measurements differ by more than 2.5% W or if any two possible crack length measurements differ by more than 5% W. 6. Test temperature. 7. Environment. 8. Loading rate in terms of 9. 0.2% proof stress in MPa. (change in stress intensity factor per unit time) if outside the standard range of 0.5-2.5 MNm-3/2s-'. 10. K1,: in MN m-3'2. Note Kl,=KQ if the size requirements are satisfied, 21.4.2 PlanestressCOD Standards: BS 5762:1979 (1986) This standard extends the fracture toughness test beyond the linear elastic behaviour in the plane strain regime, covered by BS 5447 and E399, into the elastic-plastic regime of plane stress. The crack opening displacement, COD, at the crack tip is determined as a measure of the stress intensity. This test method is used for full thickness test pieces of material not thick enough to give valid IClc values, but which, nevertheless, fail by crack propagation before general yield. The critical COD is not a material property; it is only valid for the thickness of material under the conditions of the test. See Figures 21.6 and 21.7. [...]... 240 195 145 110 70 40 290 285 235 175 110 70 40 330 310 270 155 110 70 40 Elong % on5Omm or 5.656 - - 30 35 50 65 80 100 130 14 16 25 40 80 100 130 8 9 20 40 80 100 130 25 30 40 55 70 100 130 12 16 25 35 70 100 130 8 13 20 35 70 100 130 continued overleaf 22-18 Mechanical propenies of metals and alloys TaMe 22.3 ALUMNKJM AND AUlMINRlM A!LOYS -MECHANICAL PROPERTIES AT ELEVATED TEhPERATWR!B - continued... 0.6 Mn 0.5 Cu 0.4 T5 T6510 T451 T651 T6 T4 T 6 T4 T6 T4 T 6 T4 T 6 155 180 245 115 180 230 310 200 240 loo 30 30 20 130 160 - - 22 12 12 230 20 310 13 385-430 380-415 310 13 340 260 285 150 289 285 160 300 315 240 315 315 240 15 11 19 12 12 25 285 160 285 130 215 130 325 310 245 325 13 20 - 35 52 75 - 50 70 129 50 117 65 78 152 Architectural exlrusions (fast exrnding) 60 160 m 9 0 - - - 205 'Ransport,... creep rate %per lO00h Total extension % in lOOOh Reference 0. 013 0.022 0.046 0.126 0.147 0.107 0.273 0.04 0.09 0.14 0.69 0 .13 0.29 0.01 0.11 0.12 0.43 0.99 0.016 0.06 0.016 0.054 0.14 0. 013 0.047 0.223 0.001 0.022 0.040 0.060 0 .13 0.15 0.73 0.007 0.39 0.03 0.045 0.325 0.035 0.1 0.040 0.02 0.07 2.36 10.0 1.0 10.0 1.0 10.0 1.0 10.0 0.126 0.107 0.174 0. 413 0.647 0.341 0.658 3 - 5 - 5 0.190 0.675 0.096... 40 6 6 14 16 - 22 10 8 20 10 22 10 17 1 0 ' 95 240 240 - 260 290 108 139 140 125 260 295 250 260 115 135 I30* 130 * 95* 95* 140 124 100 - - - - 115 135 18 19 - 285 285 120 120 140 135 115 135 140 2 b E; Free machining alloy 2 & ! Heavy duty applications in transport and aerospace, e.g large parts, wings Aircraft applications (cladding when wed 1070A) - 115 a P r - 3 - - % 9 45* 23 21 34 32 95 100 70... 300 300 300 245 215 130 95 60 240 215 145 fi0 _ 30 20 17 330 290 185 lo00 145 loo0 145 loo0 145 loo0 135 lo00 111 lo00 75 50 lo00 20 lo00 loo00 215 loo00 195 10000 135 innno 4s - - 10000 25 17 10000 14 10000 loo00 230 loo00 270 10000 175 innno - fis _ loo00 loo00 35 30 1OooO loo00 275 260 213 loo00 80 50 io000 io? loo00 35 1Oo00 17 loo00 14 100 230 100 100 220 100 185 100 135 100 110 100 45... 1050A A199.5 135 0 AI995 1200 AI 99.0 - I- Sheet Hlll H14 H18 Hlll Sheet HI4 HI8 Wire HI11 H14 H18 Sheet Hlll HI4 H18 Bars and sectionsas extruded Rivet stock H15 Tubes Hlll H18 e 75mm Hl8 > 75mm Wire HI11 H 14 HI8 Wire Hlll H 14 H18 Sheet HI11 HI3 HI4 HI6 H18 - 90 110-140 55 85 110 70 100 135 70 105 130 -160 35 105 80 110 130 50 125 145 75 140 15 125 115 75 115 140-195 83 110 186 90 105 120 135 160 20... Mn 0.6 -80 (2024) -196 Rolled and 24 drawnrod T8 -28 -80 - 196 40 40 so 60 180 185 195 220 97 99 97 115 235 230 236 215 115 11s 115 135 275 280 325 370 130 130 145 90 105 11s 115 215 220 22s 250 300 3 10 305 330 270 280 290 3 15 300 305 320 400 400 405 415 460 110 11s 130 220 195 20s 21s 290 199 201 210 330 275 280 290 400 240 240 250 350 330 340 455 645 290 290 420 175 190 200 260 240 250 260 330... 60 35 20 14 505 430 145 80 60 45 30 400 310 155 75 40 Elong % on50mm or 5.656 13 14 15 35 45 64 20 10 - - - - 8 - 13 - 380 345 255 90 55 35 25 570 455 175 95 75 60 45 9 9 9 30 50 70 160 160 130 95 30 340 350 270 185 90 45 4 3 3 4 4 16 10 0 42 85 100 90 11 15 30 60 65 80 65 continued overleaf 22-20 Mechanical properties of metals and alloys Table 223 ALUMINIUM AND ALUMINIUM ALLOYS -MECHANICAL PROPERTIES... Zn 1.0 Si 23.0 Cu 1.0 (LM29) Mg 1.0 Ni 1.0 (LM28) Si 19.0 Cu 1.5 Mg 1.0 Ni 1.0 Si 11.0 cu 1.0 (LM13) Mg 1.0 Ni 1.0 MPa - - - (P=5$) 60 60 75 85 65 70 105 105 115 115 55 75 60 95 so* - - 110* 1.5 4.5 - - - - 85 90 - - - - 0.3 0.3 - 120 - - - 130 210 190 0.3 0.3 0.5 - 120 120 120 - 120 170 0.5 0.5 1 - - 130 200 220 120 120 105 - 190 280 200 290 0.5 Ni 2.0 Al-Si-CuMg-Zn Shear Brinell strength haniness... Hlll HI4 HI8 Hlll HI4 HI8 Hlll H 14 HI8 Hlll HI8 65 125 140 I60 185 60 135 170-200 55 150 195 70 200 250 50 270 Hlll 40 HI2 125 H 14 145 HI6 170 Physical properties 1IO 130 155 I80 200 40 17 11 8 80 90 95 30 40 50 34 55 - - 60 70 70 29 - - 20 - 7 - I IO - 44 41 51 30 45 55-65 24 5 3 20 9 5 23 85 105 115 - 110 125 145 45 63 77 - - 30 130 10 150 8 175 5 as for 3003 clad with 4343 75 85 95 105 - 5 - I I5 . 19 285 23 21 34 32 95 100 108 139 - - 115 135 - - 115 135 115 135 115 135 - - 120 120 45* - - - - - - 140 125 - I30* 130 * 95* 95* 140 1 24 - - - -. J. Table 21.16 DIMENSIONS OF CHARPY IMPACT TEST PIECES-BRITISH STANDARDS BS 131 :PART 2:1972; BS 131 :PART 3:1972 (1982); AMERICAN STANDARD ASTM E23-86 Nominal dimension Item mm. Size 18 W C a max. N max. E F H D G min. 13 13 26 32.5 14.5 1.5 7.2 14.3 15.6 6.5 14.3 25 25 SO 62.5 27.5 3.1 13. 8 27.5 30 12.5 27.5 75 75 150 188.5 82.5 9.4