BTEC Assignment Brief
Pearson BTEC Level 3 National Extended Diploma in Engineering
Qualification
Unit number
Unit 25: Mechanical Behaviour of Metallic Materials
and title
Learning B: Explore safely the mechanical properties of metallic materials and the
aim(s) (For NQF impact on their in-service requirements
only)
Assignment Destructive and non-destructive testing of metal samples
title
Oga I.O
Assessor
19 /01 /2023
Issue date
Hand in 03 /02 /2023 {23:59pm}
deadline
You are working as an apprentice technician for a large company that
manufactures hydraulic systems and airframe components for the
aerospace industry. It is now time for you to spend a few weeks in the
quality assurance department where you will assist with quality checks
Vocational
on incoming raw materials.
Scenario or
The quality manager asks you to assist a technician in preparing and
Context
mechanically testing samples taken from bar stock. You will also help
with the inspection of cast, weld and forged components to determine if
they are free from surface and internal defects.
You are going to carry out a range of destructive and non-destructive
tests on metal samples. Use a log book to record all data, information
and images.
Destructive testing
To do this:
You have been provided with a selection of unlabelled ferrous and non-
ferrous samples which are ready to mount into the test equipment. You
will be determining the mechanical properties of the test pieces.
You need to:
Task 1
• Safely set-up and carry out tensile tests by pulling to destruction, recording
load/elongation and the condition of the fracture surface. Properties to be
determined - limit of proportionality/elastic limit, yield point, tensile strength,
Young's Modulus of Elasticity, percentage elongation and percentage
reduction in cross-sectional area
• Safely set-up and carry out tests, recording results - include energy transfer at
fracture and condition of fracture surface (to establish if brittle or ductile
fracture).
Non-destructive testing
To do this:
, You have been provided you with one processed and one non-processed
material sample that have surface flaws (e.g. cracks) or internal faults
(e.g. inclusions).
You need to either:
• Use a visual technique such as dye penetrant to identify surface flaws in the
two material samples, recording findings as annotated images
Or
• Use a technique such as ultrasound to identify internal flaws in the two
samples, recording findings, images and notes.
You then need to:
Produce an organised technical report that includes data and
information from the above tests that has two sections:
Destructive testing
• A comparison of the mechanical properties found by experimentation
with those in an accredited data source.
• A determination of what materials were tested and whether they
have been processed.
• A discussion about how the mechanical properties of metals affect
their behaviour and suitability for different applications supported by
case study examples, for example, the use of mild steel for products
that involve press work in their manufacture.
• A discussion about the testing methods used, given the mechanical
properties being measured, making reference to features such as
reliability and accuracy of results taken.
Non-destructive testing
• Images and written commentary that identify the defects in the
components/materials tested.
• Discussion about what has caused the defects and how they could be
avoided in the future.
Checklist of A written report containing annotated images, extracts from an
evidence accredited materials data source, materials identification evidence, phase
required diagrams and a learner observation record
Criteria covered by this task:
Unit/Criteria
To achieve the criteria you must show that you are able to:
reference
Evaluate, using the results from safely conducted tests and an accredited
data source, how the mechanical properties of processed and non-
25/B.D2 processed metallic materials affect their behaviour and suitability for
different realistic applications, justifying the validity of the test methods
used.
Analyse, using the test results and an accredited data source, how the
25/B.M3 mechanical properties of metallic materials affect their behaviour and
suggest a realistic application.
2
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Conduct/describe destructive and non-destructive tests accurately on
25/B.M2
different non-processed and processed metallic samples.
Explain, using the test results, how the mechanical properties of
25/B.P5
metallic materials affect their behaviour and suggest an application.
Conduct/describe non-destructive tests safely on at least two non-
25/B.P4
processed and processed metallic samples.
Conduct/describe destructive tests safely on different non-processed and
25/B.P3
processed metallic samples.
25/B.P
Sources of Books
information to
support you Materials for Engineers and Technicians 6th Edition; Bolton W, Higgins R
with this A; Routledge, 2014; ISBN 978-1138778757
Assignment
Websites
http://www.matweb.com/
http://www.makeitfrom.com/
Other
assessment
materials Mechanical properties data base
attached to Prepared test specimens
this Components for non-destructive testing + Dye penetrant chemicals
Assignment
Brief
3
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, The Mechanical Properties of metallic materials and the
impact on their in-service requirements
Tensile Test - Destructive testing
For our tensile test we got two specimens:
TS1021 TL1040
Before we carried out the
tensile test, we had to measure the
original length of both materials.
Then we had to measure the test
length of both materials which is the
interior part.
Then we had to measure diameter of
both parts
Now we must safely set up the tensile
test machine:
We must connect the elongation display on the
tensile test machine to the digital load meter
which then we must connect to the versatile data
acquisition system which is also connected to the tensile
test machine Also it is connected to a computer where the
VIDAS system is operated where all our data is gathered
and plotted into a graph.
