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
8. FATIGUE
9. CREEP
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 10045-2 1757
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.-xiii : 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 [Link] : Procedure & performance Qualification of welding
API-5L : For seamless and welded steel tubes & pipes.
TEST PLATE FOR PERFORMANCE
QUALIFICATION (as perIBR)
B1 T1 B2 B1 T2 B2
weld
m
250 mm M
16
406 mm mm
TEST PIPE & TUBE FOR PERFORMANCE
QUALIFICATION (as perIBR
Macro
Root
Face
weld
Root
250mm
Face
Macro
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
Top Pipe
(API 1104)
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
Face or
TEST (API 1104)
Top Pipe
Side Bend tensile
Face or Side Nick-break
Bend
Greate than
r 114
3m . m
but or equal
less to mm
Nick-break 323.8
Root or Root or
Side Bend Side Bend
PROCEDURE
QUALIFICATION
Top Pipe
(API 1104)
Nick-break
Under
60.3
Top Pipe Root or
Root-bend Side Bend
Nick-break
Greater than
60.3
less than or
to
114.3mm
equal
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
Great than
er 114 Root or
3m Side Bend
. m
but or equal
less to 8mm
Nick-break 323.
tensile Face or
Side Bend
PROCEDURE
QUALIFICATION
(API 1104)
Top Pipe
Root or Send Bend Face or Side Bend
Tensile
Nick-Break
Tensile Root or Send Bend
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
Tensile Nick-
Break
Root or Side Bend
LOCATION OF TEST SPECIMENS FOR WQ : TEST BUTT
TENSILE SPECIMENS
TRANSEVERSE
TENSILE
ALL WELD
TENSILE
ELECTRODE QUALIFICATION TEST( AS PER AWS)
IMPACT SPECIMEN
15 (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
70mmmin
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
UNIVERSAL TESTING MACHINE
CALIBRATION:
ASTM-E4,
BIS: 1828,
EN: 10002-2
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
5min .
75 225 75
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-BREK TEST
SPECIMEN
AS PER API 1104
3.17mm
Notch in depth
1.59 mm
Weld
19mm
Wall thickness
FOR AUTOMATIC & SEMI AUTOMATIC
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
45°±0.1 ° 1 ±0.025
27.5 0
55±0.1
CHARPY ‘V’NOTCH TEST SPECIMEN
5±0.1 10±0.025
2 1 ±0.025
27.5 0
55±0.1
CHARPY ‘U’NOTCH TEST SPECIMEN
IZOD IMPACT TEST SPECIMEN
1
0
2
75 27.5 1
0
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
[Link] HARDNESS 2. ROCKWELL HARDNESS
[Link] 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/[( ΠD/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
ROCKWELL HARDNESS TEST
Minor Load Major Load
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
MICROSTRUCTURE : F + P
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)
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