What is Mechanical Testing: Guía detallada

Mechanical testing is used to evaluate product designs. It is also used for validation, identification, and characterization of the products. Mechanical testing allows manufacturers to ensure that they are utilizing material appropriately and that the process is safe and cost-effective.

If you want to learn more about what is mechanical testing, the guide below is for you.

What is Mechanical Testing?

Mechanical testing consists of a series of standardized tests that help determine the properties of the material. It also helps in testing whether a particular material is suitable for the given applications or not.

Mechanical testing is a very important aspect of the manufacturing process to achieve some standards set by ISO and ASTM. These tests help manufacturers determine which materials are high quality and choose the appropriate ones.

How Does It Work?

Mechanical testing processes can help determine the material properties when the load is applied to them. It is a very crucial part of the manufacturing process. The material is subjected to load, and the deformation is assessed. Different types of tests are conducted to verify the material properties.

Types of Mechanical Testing

There are different types of mechanical tests to verify the material properties, and some of these are as follows:

Tensile Testing

Tensile testing helps determine the strength of the material and assess its properties, such as yield deformation, strain, and stress. The material is subjected to a given force and is pulled from the two ends till it breaks.

This testing is done in a testing machine that works either by electric or hydraulic system. The data is recorded at different forces. The standards for tensile testing are ASTM D412, ASTM D638, ASTM E8, ISO 37, ISO 527-2, etc.

Pruebas de dureza

Hardness testing assesses the hardness of a material. This test is conducted on the material only and not on the final product. The different types of hardness tests are the Brinell test, Rockwell test, and Vickers test. These tests help analyze surface hardness.

These tests are conducted with indenters to create an indentation on the material’s surface. The depth and force of the indentation help collect the data for the hardness test.

Pruebas de impacto

Impact testing is a type of mechanical testing that analyzes the amount of high-impact load a material can take. It allows the impact loads to be applied with a high force multiple times for a longer span of time to analyze the material’s strength.

Pruebas de fatiga

Fatigue testing is suitable for products that undergo cyclic loading. Components with dynamic mechanical loads need this type of testing, which changes their direction and magnitude now and then.

Fatigue testing helps to consider parameters consisting of the number of cycles and their frequency followed by the types of load.

Fracture Toughness Testing

Fracture toughness testing allows manufacturers to analyze the amount of energy required to break the material that has a crack already. The manufacturers can ascertain the ability of a material to resist the fracture using an intrinsic stress factor. The standards for this type of test are ASTM E1280 and EEMUA pub. 158, BS 7448, etc.

Compressive Testing

Compressive testing determines the material’s behavior, which is subjected to loads that end up crushing them. It is a very important manufacturing part as the material has to pass through different phases. This test is compatible with a wide range of materials, including plastics, metals, and ceramics.

Pruebas de torsión

Torsion testing carries out an evaluation of the way a material behaves when subjected to angular stress. It helps to measure properties like durability, shear yield strength, and shear modulus. There are different types of torsion tests, and these are as follows:

• The pure torsion test involves the application of a pure torsional load.
• The axial torsion compass is a combination of axial and torsional forces.
• Proof testing consists of applying the torsional load for a given period of time.
• Failure testing consists of twisting the material until it breaks.

Creep Testing

Creep testing is a test that consists of subjecting the material to consistent stress for extended temperature, and the data is recorded. This test helps to analyze the material’s ability to deform when subjected to constant stress at a given temperature. It is suitable for materials like soldered joints, metal workings, and springs.

Resistencia a la corrosión

Corrosion resistance tests are meant to determine the reaction of materials when subjected to different conditions, including saline and non-saline. These tests have different techniques, which are as follows:

• Salt spray is applied on coated and uncoated materials to consider their reaction.
• CASS exposure testing is an aggressive method that helps to test chromium and aluminum plating on materials made of steel and zinc. The components are exposed to copper-accelerated acetic acid salt spray to determine whether the material corrodes or not.
• Immersion corrosion testing involves immersing the material in an aggressive environment with moisture and determining the weight loss due to corrosion.

Non-destructive Testing

Non-destructive testing is conducted without causing any damage to the material. Some of these methods are the following:

• Acoustic emission testing detects the active defects by using ultrasound waves.
• Electromagnetic testing uses electromagnetic fields to identify the defects in the material.
• Leak testing detects the cracks and leaks in the materials.

Why Should You Invest in Mechanical Testing?

The success of the manufactured components depends on the quality of the materials used. The assessment of those materials relies on mechanical testing. Hence, there are many reasons to invest in mechanical testing, and some are discussed below:

Internal Audit

The internal audit in the process of manufacturing and product design helps manufacturers assess the material and processes and ensure it meets international standards.

The internal audit can detect whether the materials used in the manufacturing process pass the tests for international standards or not. If they don’t, the manufacturer can opt for an alternative solution.

External Audit

External audit is a process in which the organization conducts the testing of the products of another organization. It helps to test the quality of the product and ensure that it adheres to international standards. The materials that do not pass through the mechanical tests fail the external audit and lead to a waste of resources and time.

Increased Costs

The use of inferior quality materials leads to wastage, and the product’s authenticity is also questionable. Moreover, the products can be over-engineered, which increases production costs. Hence, the production cost can be reduced when the right material is chosen.

Product Failure

Product failure is one of the costly consequences of not considering mechanical testing. It leads to product damage and may also lead to legal consequences. It doesn’t take place if the internal and external audits are done, but there could be a problem during auditing.

Possibility of a Future Failure

In case the product fails during the testing process, the failure analysis can help predict that it will fail in the future as well. It helps to inspect the file aid part and think about its improvement.

Why is Mechanical Testing Important for Materials?

Mechanical testing is very important to understand the way materials will work when subjected to real world stress. By evaluating the material properties like ductility, toughness, strength, and hardness, the material can be assumed to adhere to specific standards.

Industries like automotive, aerospace, and construction are sensitive, and there is no margin for using inferior quality material.

Mechanical testing not only helps ensure the reliability of the product but also allows engineers to create product designs by analyzing their lifespan. The costly failures are prevented, and the performance of the parts is optimized.

Is Industrial Mechanical Testing Important?

Structural integrity testing is very important to ensure the cost-effectiveness and safety of the process. Manufacturers need mechanical testing to ensure the product’s quality, their reputation is preserved, and their production cost is reduced. The material dealers also adhere strictly to international standards so that their credibility is maintained.

The customers are also assured and relieved that the materials have undergone mechanical testing, which will prevent the risk of failure and ensure safety.

Ensuring Quality of Your Parts: DEK Can Help

The quality of components is crucial in every industry. If you are also looking to manufacture custom components that have passed mechanical testing, you can contact DEK. We always conduct mechanical tests for all the components we manufacture and ensure their materials are high quality.

Conclusión

Mechanical tests are important aspect of manufacturing. It is crucial to have a detailed understanding when it comes to conducting these tests. The information from this guide will help you make the most of the testing processes for your projects.

Preguntas frecuentes

Which is the most used mechanical test?

Tensile testing is a very common method. It allows the manufacturers to have an idea of the strain and stress that the material can handle.

What is material testing, and what is its role in the industry?

Material testing helps to differentiate between real and fake materials by testing their properties before using them in your products.

When should mechanical testing be done?

Mechanical testing is carried out to test the material quality and properties in a specific environment.