Destructive Testing
Section 4
Copyright © TWI Ltd
Destructive testing Objective
When this presentation has been completed you
should be able to recognise a wide range of
mechanical tests and their purpose. You should
also be able to make calculations using formulae
and tables to determine various values of
strength, toughness, hardness and ductility.
Copyright © TWI Ltd
Destructive Testing Definitions
What is destructive testing?
The destruction of a welded
unit or by cutting out
selected specimens from the
weld, is carried out to check
the mechanical properties of
the joint materials.
They can be produced to
Approve welding procedures (BS EN 15614).
Approve welders (BS EN ISO 9606).
Production quality control.
Copyright © TWI Ltd
Destructive Tests
Destructive tests include:
3x
Bend test. Toughness
(Charpy V
Impact test. notch)
Tensile test.
2 x Ductile
Hardness test. (Bend test)
Macro/micro
examination. 2 x Strength
(transverse
tensile)
Copyright © TWI Ltd
Qualitative and Quantitative Tests
The following mechanical tests have units and are termed
quantitative tests to measure mechanical properties of
the joint.
Tensile tests (transverse welded joint, all weld metal).
Toughness testing (Charpy, Izod, CTOD).
Hardness tests (Brinell, Rockwell, Vickers).
The following mechanical tests have no units and are
termed qualitative tests for assessing weld quality.
Macro testing.
Bend testing.
Fillet weld fracture testing.
Butt weld nick-break testing.
Copyright © TWI Ltd
Definitions
Mechanical properties of metals are related to the
amount of deformation which metals can
withstand under different circumstances of force
application.
Malleability.
Ductility. Ability of a material to
Toughness. withstand deformation
under static compressive
Hardness. loading without rupture.
Tensile Strength.
Copyright © TWI Ltd
Mechanical Test Samples
Tensile specimens
CTOD specimen
Bend test
specimen
Charpy
specimen
Fracture fillet specimen
Copyright © TWI Ltd
Destructive Testing
Welding procedure qualification testing
Top of fixed pipe
2 Typical positions for test
pieces and specimen
type position
Macro + hardness. 5
3
Transverse tensile. 2, 4
Bend tests. 2, 4
Charpy impact tests. 3
Additional tests.3
4
5
Copyright © TWI Ltd
Mechanical Testing
Hardness Testing
Copyright © TWI Ltd
Hardness Testing
Definition
Measurement of resistance of a material against
penetration of an indenter under a constant
load.
There is a direct correlation between UTS and
hardness.
Hardness tests:
Brinell.
Vickers.
Rockwell.
Copyright © TWI Ltd
Hardness Testing
Objectives:
Measuring hardness in different areas of a
welded joint.
Assessing resistance toward brittle fracture, cold
cracking and corrosion sensitivity.
Information to be supplied on the test
report:
Material type.
Location of indentation.
Type of hardness test and load applied on the
indenter.
Hardness value.
Copyright © TWI Ltd
Hardness Testing
Usually the hardest region
1.5 to 3mm
Fusion
line or
HAZ
fusion
boundary
Hardness test methods Typical designations
Vickers 240 HV10
Rockwell Rc 22
Brinell 200 BHN-W
Copyright © TWI Ltd
Vickers Hardness Test
Typical location of the indentations
Butt weld from
one side only
Butt weld from
both side
Copyright © TWI Ltd
Vickers 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.
Adjustable
Diamond Indentation shutters
indentor
Copyright © TWI Ltd
Vickers Hardness Test Machine
Copyright © TWI Ltd
Brinell Hardness Test
Hardened steel ball of given diameter is
subjected for a given time to a given load.
Load divided by area of indentation gives
Brinell hardness in kg/mm2.
More suitable for on site hardness testing.
30KN
Ø=10mm
steel ball
Copyright © TWI Ltd
Rockwell Hardness Test
Rockwell B Rockwell C
1KN
1.5KN
Ø=1.6mm 120° diamond
steel ball cone
Copyright © TWI Ltd
Portable Hardness Test
Dynamic and very portable hardness test.
Accuracy depends on the the condition of the
test/support surfaces and the support of the test
piece during the test.
For more details, see ASTM E448.
Copyright © TWI Ltd
Mechanical Testing
Impact Testing
Copyright © TWI Ltd
Charpy V-Notch Impact Test
Weld metal Fusion Line (FL) FL+2mm FL+5mm Parent material
Objectives:
Measuring impact strength in different weld joint areas.
Assessing resistance toward brittle fracture.
Information to be supplied on the test report:
Material type.
Notch type.
Specimen size.
Test temperature.
Notch location.
Impact strength value.
Copyright © TWI Ltd
Charpy V-Notch Impact Test
Pendulum
Specimen (striker)
Anvil (support)
Copyright © TWI Ltd
Charpy V-Notch Impact Test Specimen
Specimen dimensions according ASTM E23
ASTM: American Society of Testing Materials.
Copyright © TWI Ltd
Charpy Impact Test
10 mm
22.5° 2 mm 100% Brittle
Machined notch.
8 mm
Fracture surface
100% bright
crystalline
brittle fracture.
100% Ductile
Machined notch.
Large reduction
in area, shear
lips.
Randomly torn,
dull gray
fracture surface.
Copyright © TWI Ltd
Ductile/Brittle Transition Curve
Mn < 1.6 % Temperature range
Ductile fracture
increases toughness
in steels, and lower
energy input used. 47 Joules
Transition range Ductile/Brittle
transition point
28 Joules
Brittle fracture Energy absorbed
- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees centigrade
Three specimens are normally tested at each temperature
Copyright © TWI Ltd
Comparison Charpy
Impact Test Results
Impact energy joules
Room Temperature -20°C Temperature
1. 197 Joules 1. 49 Joules
2. 191 Joules 2. 53 Joules
3. 186 Joules 3. 51 Joules
Average = 191 Joules Average = 51 Joules
The test results show the specimens carried out at room
temperature absorb more energy than the specimens carried
out at -20°C.
Copyright © TWI Ltd
Charpy Impact Test
Reporting results
Location and orientation of notch.
Testing temperature.
Energy absorbed in joules.
Description of fracture (brittle or ductile).
Location of any defects present.
Dimensions of specimen.
Copyright © TWI Ltd
Mechanical Testing
Tensile Testing
Copyright © TWI Ltd
Tensile Testing
Copyright © TWI Ltd
UTS Tensile Test
Rm
ReH
ReL
Copyright © TWI Ltd
Tensile Tests
Copyright © TWI Ltd
Tensile Test
Rp 0.2% - Proof stress. Refers to materials
which do not have a defined yielding such as
aluminium and some steels.
Copyright © TWI Ltd
Tensile Tests
Different tensile tests:
Transverse tensile.
All-weld metal tensile test.
Cruciform tensile test.
Short tensile test (through thickness test).
Copyright © TWI Ltd
Tensile Test
All weld Metal
All-Weld metalTensile
tensile
specimen
Specimen
Transverse
TransverseTensile
tensile
Specimen
specimen
Copyright © TWI Ltd
Transverse Joint Tensile Test
Objective:
Measuring the overall strength of the weld joint.
Information to be supplied on the test report:
Material type.
Specimen type
Specimen size (see QW-462.1).
UTS.
Location of final rupture.
Copyright © TWI Ltd
Transverse Joint Tensile Test
Weld on plate
Multiple cross joint specimens
Weld on pipe
Copyright © TWI Ltd
Transverse Tensile Test
Maximum load applied = 220 kN
Cross sectional area = 25 mm X 12 mm
UTS = Maximum load applied
csa
UTS = 220 000
25mm X 12mm
UTS = 733.33 N/mm2
Copyright © TWI Ltd
Transverse Tensile Test
Reporting results:
Type of specimen eg reduced section.
Whether weld reinforcement is removed.
Dimensions of test specimen.
The ultimate tensile strength in N/mm 2, psi or
Mpa.
Location of fracture.
Location and type of any flaws present if any.
Copyright © TWI Ltd
All-Weld Metal Tensile Test
BS 709/BS EN 10002
All Weld Metal Tensile Testing
Direction of the test *
Tensile test piece cut along weld specimen.
Copyright © TWI Ltd
All-Weld Metal Tensile Test
Original gauge length = 50mm
Increased gauge length = 64
Elongation % = Increase of gauge length X 100
Original gauge length
Elongation % = 14
X 100
50
Elongation = 28%
Copyright © TWI Ltd
All-Weld Metal Tensile Test
Gauge length
Object of test:
Ultimate tensile
strength.
Yield strength.
Elongation %
(ductility).
Increased gauge length
Copyright © TWI Ltd
All-Weld Metal Tensile Test
Two marks are made
Gauge length 50mm
During the test, yield and tensile strength are recorded
The specimen is joined and the marks are re-measured
Force Applied
Increased gauge length 75mm
A measurement of 75mm will give Elongation of 50%.
Copyright © TWI Ltd
All-Weld Metal Tensile Test
Two marks are made
Gauge length 50mm
During the test, yield and tensile strength are recorded
The specimen is joined and the marks are re-measured
Increased gauge length 75mm
A measurement of 75mm will give Elongation of 50%.
Copyright © TWI Ltd
All-Weld Metal Tensile Test
Reporting results:
Type of specimen eg reduced section.
Dimensions of test specimen.
The UTS, yield strength in N/mm2, psi or Mpa.
Elongation %.
Location and type of any flaws present if any.
Copyright © TWI Ltd
STRA (Short Transverse
Reduction Area)
Copyright © TWI Ltd
STRA Test
Original CSA
Reduced CSA
Copyright © TWI Ltd
UTS Calculation
A welded sample has undergone a transverse tensile test.
The specimen before testing 120mm long and after testing
had a length 150mm, the maximum load applied was
140Kn. The cross sectional area before testing was 10mm
in depth and 40mm in width.
Please calculate the elongation % and UTS.
Change in
length (150 – 120) = 30
= 0.25 x 100 = 25%
Original 120
length
Load 140 Kn 14,000 n
= 350 n/mm²
CSA 10 x 40 400
Copyright © TWI Ltd
Mechanical Testing
Macro/Micro Examination
Copyright © TWI Ltd
Macro Preparation
Purpose
To examine the weld cross-section to give assurance
that:
The weld has been made in accordance with the
WPS.
The weld is free from defects.
Copyright © TWI Ltd
Macro Preparation
Specimen preparation
Full thickness slice taken from the weld (typically ~10mm
thick).
Width of slice sufficient to show all the weld and HAZ on
both sides plus some unaffected base material.
One face ground to a progressively fine finish (grit sizes
120 to ~400).
Prepared face heavily etched to show all weld runs and all
HAZ.
Prepared face examined at up to x10 (and usually
photographed for records).
Prepared face may also be used for a hardness survey.
Copyright © TWI Ltd
Macro Preparation
Purpose
To examine a particular region of the weld or HAZ
in order to:
To examine the microstructure.
Identify the nature of a crack or other
imperfection.
Copyright © TWI Ltd
Macro Preparation
Specimen preparation
A small piece is cut from the region of interest (typically
up to ~20mm x 20mm).
The piece is mounted in plastic mould and the surface
of interest prepared by progressive grinding (to grit size
600 or 800).
Surface polished on diamond impregnated cloths to a
mirror finish.
Prepared face may be examined in as-polished
condition and then lightly etched.
Prepared face examined under the microscope at up to
~100 – 1000X.
Copyright © TWI Ltd
Macro/Micro Examination
Object:
Macro/microscopic examinations are used to
give a visual evaluation of a cross-section of a
welded joint.
Carried out on full thickness specimens.
The width of the specimen should include HAZ,
weld and parent plate.
They maybe cut from a stop/start area on a
welders approval test.
Copyright © TWI Ltd
Macro/Micro Examination
Will reveal:
Weld soundness.
Distribution of inclusions.
Number of weld passes.
Metallurgical structure of weld, fusion zone and
HAZ.
Location and depth of penetration of weld.
Fillet weld leg and throat dimensions.
Copyright © TWI Ltd
Macro Macro/Micro Examination
Macro Micro
Visual examination for Visual examination for
defects. defects and grain
Cut transverse from the structure.
weld. Cut transverse from a
Ground and polished weld.
P400 grit paper. Ground and polished P1200
Acid etch using 5-10% grit paper, 1µm paste.
nitric acid solution. Acid etch using 1-5% nitric
Wash and dry. acid solution.
Visual evaluation under Wash and dry.
5x magnification. Visual evaluation under
Report on results. 100-1000x magnification.
Report on results.
Copyright © TWI Ltd
Metallographic Examination
Macro examination Micro examination
Copyright © TWI Ltd
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.
Copyright © TWI Ltd
Metallographic Examination
Information to be supplied on the test report:
Material type.
Etching solution.
Magnification.
Grain size.
Location of examined area.
Weld imperfections (macro).
Phase, constituents, precipitates (micro).
Copyright © TWI Ltd
Mechanical Testing
Bend Testing
Copyright © TWI Ltd
Bend Tests
Object of test:
To determine the soundness of the weld zone. Bend testing
can also be used to give an assessment of weld zone
ductility.
There are three ways to perform a bend test:
Root bend Face bend Side bend
Side bend tests are normally carried
out on welds over 12mm in thickness.
Copyright © TWI Ltd
Bending Test
Types of bend test for welds
(acc BS EN ISO 5173+A1):
Root/face
t up to 12 mm
bend
Thickness of material - t
t over 12 mm Side bend
Copyright © TWI Ltd
Bending Test Methods
Guided bend test Wrap around bend test
Copyright © TWI Ltd
Bend Testing
Face bend Side bend Root bend
Defect indication generally this
specimen would be unacceptable.
Acceptance for minor ruptures
on tension surface depends
upon code requirements.
Copyright © TWI Ltd
Bend Tests
Reporting results:
Thickness and dimensions of specimen.
Direction of bend (root, face or side).
Angle of bend (90°, 120°, 180°).
Diameter of former (typical 4T).
Appearance of joint after bending eg type and
location of any flaws.
Copyright © TWI Ltd
Bend Testing
Copyright © TWI Ltd
Mechanical Testing
Fillet Weld Fracture Testing
Copyright © TWI Ltd
Fillet Weld Fracture Tests
Object of test:
To break open the joint through the weld to
permit examination of the fracture surfaces.
Specimens are cut to the required length.
A saw cut approximately 2mm in depth is
applied along the fillet welds length.
Fracture is usually made by striking the
specimen with a single hammer blow.
Visual inspection for defects.
Copyright © TWI Ltd
Fillet Weld Fracture Tests
Hammer
2mm
notch
Fracture should break weld saw cut to root
Copyright © TWI Ltd
Fillet Weld Fracture Tests
This fracture indicates This fracture has occurred
lack of fusion saw cut to root
Lack of penetration
Copyright © TWI Ltd
Hammer
2mm
notch
Fracture should break weld saw cut to root
Copyright © TWI Ltd
Hammer
This fracture indicates
lack of fusion
Copyright © TWI Ltd
Fillet Weld Fracture Tests
Reporting results:
Thickness of parent material.
Throat thickness and leg lengths.
Location of fracture.
Appearance of joint after fracture.
Depth of penetration.
Defects present on fracture surfaces.
Copyright © TWI Ltd
Mechanical Testing
Nick-Break Testing
Copyright © TWI Ltd
Nick-Break Test
Object of test:
To permit evaluation of any weld defects across
the fracture surface of a butt weld.
Specimens are cut transverse to the weld.
A saw cut approximately 2mm in depth is
applied along the welds root and cap.
Fracture is usually made by striking the
specimen with a single hammer blow.
Visual inspection for defects.
Copyright © TWI Ltd
Nick-Break Test
Notch cut by hacksaw
3 mm
19 mm
3 mm
Approximately 230 mm
Weld reinforcement
may or may not be
removed
Copyright © TWI Ltd
Nick-Break Test
Alternative nick-break test
specimen, notch applied all
way around the specimen
Lack of root Inclusions on fracture
penetration or fusion line
Copyright © TWI Ltd
Nick-Break Test
Reporting results:
Thickness of parent material.
Width of specimen.
Location of fracture.
Appearance of joint after fracture.
Depth of penetration.
Defects present on fracture surfaces.
Copyright © TWI Ltd
Summary of Mechanical Testing
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint
We divide tests into qualitative and quantitative
methods:
Quantitative: (Have Qualitative: (Have no
units) units)
Hardness (VPN & BHN). Macro tests.
Toughness (Joules & Bend tests.
[Link]). Fillet weld fracture tests.
Strength (N/mm2 & PSI, Butt Nick break tests.
MPa).
Ductility/Elongation (E
%).
Copyright © TWI Ltd
Any Questions
?
Copyright © TWI Ltd
