TWI CSWIP 3.
1 WIS 5 WELDING INSPECTION DESTRUCTIVE TESTS
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Destructive tests
Involve the destruction of a welded unit or selected specimens cut out from the weld
Destructive tests include: tensile test bend test impact test
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hardness test metallographic examination creep test, etc.
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Tensile test
Objective:
measuring the overall strength of the weld joint
Informations to be supplied on the test report: material type UTS specimen type specimen size (see QW-462.1)
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location of final rupture
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Bending test
Objectives: check if lack of fusion type of defects are present assessing ductility of the weld joint Informations to be supplied on the test report: bend radius/angle material type
specimen type and orientation (see QW-462.2;3)
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test result (pass/fail)
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Bending test
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Charpy V-notch impact test
Objectives: measuring impact strength in different weld joint area assessing resistance toward brittle fracture Informations to be supplied on the test report: material type notch type specimen size
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test temperature
notch location impact strength value
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Charpy V-notch impact test specimen
Specimen dimensions acc. ASTM E23
10 mm
2 mm 10 mm
R 0,25 mm = 55 mm = 45
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Charpy V-notch impact test
Charpy impact test Pendulum (striker)
Specimen
Anvil (support)
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Charpy V-notch impact test
h1
h2
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Charpy V-notch impact test
To define the type of failure, we can also measure: lateral expansion amount of crystalinity
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Charpy V-notch impact test
Mn < 1.6 % increases toughness in steels* Transition Zone Joules absorbed
Brittle Fracture
Ductile Fracture Three specimens are normally tested at each temperature. 47 Joules 28 Joules Transition Temperature Range
-40
-30 -20 -10 0 +10 +20 +30 Testing temperature
+ 40
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Hardness
Definition - is the resistance of a material against penetration It is measured by indentation by a penetrator under a constant load Between UTS and hardness is a direct correlation Hardness tests:
Brinell Vickers Rockwell
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Hardness test
Objectives: measuring hardness in different areas of a weld joint assessing resistance toward brittle fracture, cold cracking and corrosion sensitivity in H2S Informations to be supplied on the test report: material type location of indentation type of hardness test and load applied on the indenter hardness value
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Weld joint hardness test
Vickers hardness tests: indentation body is a square based diamond pyramid (136 included angle) the average diagonal (d) of the impression is converted to a hardness number from a table it is measured in HV5, HV10 or HV025
d2 d = (d1+ d2)/2 d1
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Vickers hardness test
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Metallographic examination
Macro examination
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Micro examination
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Metallographic examination
Objectives: detecting weld defects (macro) measuring grain size (micro) detecting brittle structures, precipitates, etc
assessing resistance toward brittle fracture, cold cracking and corrosion sensitivity
Informations to be supplied on the test report: material type location of examined area
etching solution
magnification grain size
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weld imperfections (macro)
phase, constituents, precipitates (micro)
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Hydrostatic test
Is a test for leakage under pressure
Vessel configuration: the test should be done after any stress relief components that will not stand the pressure test (e.g. flexible pipes, diaphragms) must be removed the ambient temperature MUST be above 0C (preferably 1520C)
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Hydrostatic test procedure
blank off all openings with solid flanges use correct nuts and bolts, NOT G clamps two pressure gauges on independent tapping points should be used for safety purposes bleed all the air out pumping should be done slowly (no dynamic pressure stresses) test pressure - see relevant standards (PD 5500, ASME VIII). Usually 150% design pressure hold the pressure for minimum 30 minutes
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Hydrostatic test - what to look for
leaks (check particularly around seams and nozzle welds!) dry off any condensation with a compressed air-line watch the gauges for pressure drop check for distortion of flange faces, etc
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