DESTRUCTIVE TESTING

MECHANICAL METALLOGRAPHIC CHEMICAL

TESTING EXAMINATION ANALYSIS

1. TENSILE 1. MACRO 1. WET

ANALYSIS
2. BEND 2. MICRO 2. DRY
ANALYSIS
3. IMPACT 3. X-RAY -
4. HARDNESS FLORESCENCE
5. DROP WEIGHT 4. ATOMIC-
6. DROP WEIGHT TEAR
ABSORPTION
7. NICK BREAK
 PURPOSE OF TESTING
1. To determine the fundamental properties.

2. To determine Mechanical, Chemical and

Metallurgical properties in order to find out the
suitability for a specific purpose.

3. To record the data for a group of metals and alloys

for the purpose of design.

4. To check weather heat treatment imparted has

been carried out satisfactorily.

5. To investigate into defects and flaws of the material

so as to improve manufacturing techniques.
 PURPOSE OF TESTING

II. As for as welding is concerned

1. Qualification of welding procedure.

2. Qualification of welding and welding operation.

3. Qualification of welding consumables.

4. Quality control
 STANDARD TEST METODS
(For Mechanical Testing)
TYPE ASTM BS IS
Tensile E8 EN10002-1 1608,1521
Bend E190 EN287-1 1599
Impact E23 EN 10045-21757
Hardness E10(Brinell) BS 240-1 1500
E18(Rockwell) BS 891-1 1586
E 92(Vickers) BS 427 1501
 STANDARDS & CODES FOR DESTRUCTIVE
TESTING
ASTM-A370 : Mechanical Testing of Steels
AWS-B4 : Standard methods for Mechanical testing of welds
BS-709 : Destructive testing for fusion welded Boiler
drums.
IBR Ch.-V : Fusion Welded Boiler Drums.
IBR Ch.-Viii : Qualification test for Welders.
IBR Ch.-XII : Shell type Boiler construction
AWS 5.1,5.4,5.5 : Electrode Qualification Tests
IS 814,5206,1395 : Electrode Qualification Tests
ASME Sec.IX : Procedure & performance Qualification of welding

API-5L : For seamless and welded steel tubes & pipes .

 TEST PLATE FOR PERFORMANCE
QUALIFICATION (as per IBR)

B1 T2 B2
T1 B2 B1
weld
M
B
m
250 mm

16
406 mm mm
TEST PIPE & TUBE FOR PERFORMANCE
QUALIFICATION (as per IBR
Macro
Root
Face

weld

Root

250mm
Macro Face

PIPE Ø127x12.5mm, CS Tube Ø63.5x5.2mm, AS Tube Ø54x5mm

 PROCEDURE QUALIFICATION
(ASME SEC. IX)

Discard Discard
Reduced Sec. Tensile Specimen
Root Bend
Face Bend 300mm

Root Bend
Face Bend
Reduced Sec. Tensile Specimen
Discard Discard

250mm
QW-463.1(a) : Less than 3/4” PLATES
PROCEDURE QUALIFICATION
(ASME SEC. IX)

Discard Discard
Side Bend
Reduced Sec. Tensile Specimen
Side Bend
300
Side Bend
Reduced Sec. Tensile Specimen
Side Bend
Discard Discard

250
QW-463 1(b) :Over 3/4” PLATES
 WELDER QUALIFICATION TEST
(API 1104)
Top Pipe

Nick-break
Under
60.3
Top Pipe Root or
Root-bend Side Bend

Nick-break
Grater than 60.3
less than or equal to
114.3mm

Nick-break

Root or Side Bend Greater than

12.7 mm wall thickness
 WELDER QUALIFICATION
TEST (API 1104)
Face or Top Pipe
Side Bend tensile
Face or Side Nick-break
Bend

Greater than
114.3mm
but less or equal
to 323.8mm
Nick-break

Root or Root or
Side Bend Side Bend
 PROCEDURE QUALIFICATION
(API 1104)
Top Pipe

Nick-break
Under
60.3
Top Pipe Root or
Root-bend Side Bend

Nick-break
Greater than 60.3

less than or equal

to 114.3mm

Nick-break

Root or Side Bend Greater than

12.7 mm wall thickness
 PROCEDURE QUALIFICATION
(API 1104)

Face or Top Pipe

Side Bend tensile
Face or Side Nick-break
Bend

Greater than Root or

114.3mm Side Bend
but less or equal
to 323.8mm
Nick-break

tensile Face or
Side Bend
 PROCEDURE QUALIFICATION
(API 1104)

Top Pipe
Root or Send Bend Face or Side Bend
Tensile
Nick-Break
Root or Send Bend
Tensile
Nick-Break
Face or Side Bend

Greater than
323.8mm
Face or Side Bend
Root or Side Bend
Nick-Break
Nick-Break
Tensile
Tensile
Face or Side Bend Root or Send Bend
 WELDER QUALIFICATION
TEST (API 1104)
Top Pipe
Root or Side Bend
Tensile
Nick-Break
Nick-Break
Tensile
Face or Side Bend

Greater than
323.8mm

Face or Side Bend

Tensile
Nick-Break
Nick-Break
Tensile
Root or Side Bend

LOCATION OF TEST SPECIMENS FOR WQ : TEST BUTT WELD

TENSILE SPECIMENS

TRANSEVERSE
TENSILE

ALL WELD
TENSILE
ELECTRODE QUALIFICATION TEST(AS PER AWS)

15 IMPACT SPECIMEN
(5Nos.)
WELD

ALL WELD TENSILE

170mm min. (1No.)

25
25
DISCARD DISCARD
ALL WELD TENSILE SPECIMEN (as per IS)
R5

10±0.09 12 min
G L 50
PL 60
70mm min
FOR SIZE 4mm AND ABOVE

6.4 ±0.075 9.5

GL 32
38.9
44.8
FOR SIZE 3.15 mm and BELOW

THE SURFACE FINISH WIT THE PL SHALL BE 1.6

ALL WELD TENSILE SPECIMEN (AWS)
R 9.5

Ø12.7±0.25 Ø19.1

GL 50.8 ±0.13

SL PL 57.1 SL

SIZE OF ELCTRODE 4 mm and ABOVE

R 4.6

Ø6.4±0.13 Ø 9.5

GL 25.4 ±0.13
SL GL 31.8 SL

SIZE OF ELECTRODE 3.15 mm and BELOW

THE SURFACE FINISH WITH THE PL SHALL BE 1.6
CALIBRATION : EN 10045-2, BIS 3766
0.
TRANSEVERSE TENSILE SPECIMEN

W
SL PL SL T
RECTANGULAR TENSILE TEST SPECIMEN
(FOR PLATE as per ASTM E8M )
13 min

40 50

200
75 75 5min.
225

GAUGE LENGTH AS PER VARIOUS STDS.& CODES.

STANDARD ROUND TENSILE (GL) FLAT TENSILE (GL)

ASTM 5d 50 mm
BS 5d 5.65A
IBR 4d 4A
IS 5d 5.65  A
NICK-BREAK TEST SPECIMEN
AS PER API 1104
3.17mm

19mm,
min. 25mm

230mm
NICK-BREAK TEST SPECIMEN
AS PER API 1104

Notch in depth 3.17mm

1.59 mm

19mm Weld

Wall thickness

FOR AUTOMATIC & SEMI AUTOMATIC WELDING

REQUIREMENTS :
1. Specimen shall show complete penetration and
fusion
2. Any gas pocket shall not exceed1/16” (1.59mm)
3. Combined area of all gas pockets shall not exceed
2% of exposed surface
4. Slag inclusion shall not be more than 3.17mm or one
half the wall thickness in length, whichever is smaller
5. There shall be 12.7mm of sound weld metal between
adjacent slag inclusions
BEND TEST METHODS

1. Guided bend
2. Free Bend
ROOT BEND TEST

t
BEND SAMPLE OF 40 mm THICK PLATE
IN COLD WIRE ADDITION SAW
ROOT BEND TEST

3t

t
1.5t
5.2t
FACE BEND TEST

3t

t
1.5t
5.2t
SIDE BEND TEST

3t

W
t
5.2t
 STRICKER

Specimen
Specimen Supporter

CALIBRATION : EN 10045-2, BIS 3766

TENIUS OLSON IMPACT TESTER

CAL : ASTM - E23

IMPACT TEST SPECIMEN

10±0.025
2±0.1
10 ±0.025
45°±0.1°
27.5
55±0.1

CHARPY ‘V’NOTCH TEST SPECIMEN

5±0.1 10±0.025
2 10 ±0.025
27.5
55±0.1

CHARPY ‘U’NOTCH TEST SPECIMEN

IZOD IMPACT TEST SPECIMEN

10
2
75 27.5 10
 IMPACT TEST SPECIMEN
AS API 5L (SR 5.3)
Max.13.5 mm Min. 28 mm Max.13.5 mm

IMPACT SPECIMENS WITH TAPERED END

 HARDNESS TEST
1.BRINELL HARDNESS 2. ROCKWELL HARDNESS
3.VICKERS HARDNESS 4. MICRO HARDNESS
BRINELL HARDNESS TEST
•HARDENED STEEL BALL IS USED FOR
MEASURING UPTO 500 BHN
•FOR 500 BHN TUNGSTON STEEL BALL IS USED F
• FOR IRON AND STEEL 3000Kg OF LOAD IS APPLIED
•FOR INTERMEDIATE HARD MATERIALS 1500Kg, 500Kg
OF LOADS ARE USED.
•FOR SOFT MATERIALS 100 Kg OF WEIGHT IS USED.
•RATE OF LOADING IS AN IMPORTANT CRITERIA,
RAPID RATE OF LOADING AFECTS THE INDENTATION.
POLISHED SURFACE

BHN=APPLIED LOAD/AREA OF INDENTATION

BHN=P/[( D/2) X (D-D2 - d2)]
WHERE P=LOAD IN Kg,

D=DIAMETER OF STEEL BALL IN mm, d= DIAMETER OF THE INDENTATION IN mm.

APPLICATION
UNIVERSAL HARDNESS TESTER

TEST IS CARRIED OUT BY IN ACCORDENCE

ASTM E92 TEST IS CARRID OUT BY IN
ACCORDENCE ASTM E92
 ROCKWELL HARDNESS TEST

Minor Load Major Load

TEST IS CARRIED OUT BY IN ACCORDENCE

ASTM E92 TEST IS CARRID OUT BY IN
ACCORDENCE ASTM E92
VICKERS HARDNESS TEST
 VICKERS HARDNESS TEST

Angle between faces of the

pyramid is 136°
VHN=1.854 P/ D2
P=Load in Kgf
D= Average of measured
diagonals of impression in
mm

TEST IS CARRIED OUT BY IN ACCORDENCE WITH ASTM E92

 DROP WEIGHT TEST

STANDARD DROP WEIGHT TEST SPECIMEN

P1=25X90X360
P2=19X50X130
P3=16X50X130
 DROP WEIGHT TEST

SPECIMEN

SPECIMEN
SUPPORTER

DROP WEIGHT TEST IS CONDUCTED IN ACCORDANCE WITH ASTM E208

 MACRO EXAMINATION
It involves the visual observation of the gross structural
details of materials after preparation of the surface,
either by unaided or with the aid of low power
microscope . Usually under 10X.
When macroscopic examinations appropriately carried
out, some important metallic characteristics are
determined by such studies.
Example : As for as welding is concerned macro will
reveal
Undercut, Excess penetration, Incomplete penetration,
Dilution lack of fusion pores and cracks etc.
 DC: 700A,30V/AC: 600A,32 V,0.5m/min

MACRO STRUCTURE OF BEAD IN COLD

WIRE ADDITION SAW
MACRO STRUCTURE OF 25mm THICK
WELD PLATE
MACRO STRUCTURE OF 40 mm THICK
SAW PLATE
 MICRO EXAMINATION
The most important part of metallography deals with the
microscopic examinations of a prepared metal
specimen,employing magnification with the optical
microscope from 100X to as high as 2000X.
Such microscopic studies are of much broader scope than
macro examinations.
It will reveal clear picture of structural characteristics as
grain size, shape, distribution secondary phases, non
metallic inclusions, segregation and other heterogeneous
conditions.
Microstructure reflects almost complete history of the
mechanical and thermal treatment that a metal has
received.
MICROSTRUCTURE
MICROSTRUCTURE :: FF ++ PP

200x
MICRO STRUCTURE OF BASE METAL
MICRO STRUCTURE OF SAW
WELD METAL
MICRO STRUCTURE OF HAZ IN SAW
MICRO PHOTOGRAPH AT THE CRACK
ORIGIN (200 x)
THANK YOU