Weld Inspection and Testing
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What is Weld Testing?
• Methods of weld testing and analysis are used
to assure the quality and correctness of the
weld after it is completed.
• This term generally refers to testing and
analysis focused on the quality and strength of
the weld
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Why to test the weld?
• To ensure development of quality weld
by collecting qualitative and quantitative data.
– Qualitative - Non destructive tests
– Quantitative - Hardness, tensile strength, ductility,
toughness, fracture toughness
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How to test the weld?
• Stages of Inspection
– Before Welding
– During Welding
– After Welding
• Testing Techniques
– Destructive
– Non Destructive
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Before Welding
Surface Oxides,
grease, oils
removal
[Link]:
Dimensions
and Quality of 2. Edge
Edge Preparation
Baking of
Removal of electrodes etc.
Moisture from
electrode coating
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During Welding
• Selection of input parameters like Current & Voltage, welding speed, shielding
gases, heat source temperature etc.
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After Welding
• Removal of the slag
• Peening
– Stress removal
• Post Welding Treatment
– Refinement of grain structure & stress removal
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Weld Testing
• Types
– Destructive
• Physical damage to w/p and welded join.
• Quantitative data obtained
– Non Destructive
• Without Physically damaging the workpiece and joint
• Qualitative data is obtained
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Destructive Weld Testing
• Destructive test, some sort of the damage takes
place in the component which is being tested,
the extent of damage may be more or less, but
most of the time it is observed that component,
which has been tested by the destructive test is
damaged to such as extent that it cannot be
used for further, for the targeted application.
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REASONS
Defects occur during welding which affect the
quality and hardness of the plate
Other defects occur through lack of knowledge
of and skill of the welder
For the training of welders
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Types of Destructive Weld Testing
MECHANICAL TEST
CHEMICAL TEST
METALLOGRAPHIC TEST
Types of Mechanical Testing
• Tensile Test
• Bend Test
• Hardness Test
• Toughness Testing
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Tensile Testing
• Tensile test is used to check how the weld joint
will perform under tensile loading and under
different environment.
• Modulus of elasticity, Yield strength, Ultimate
strength, kind of the deformation at the
different stages and the total elongation of the
weld joint, till the fracture.
• Most simple and common method.
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A machine which applies a tensile force (a
force applied in opposite directions) to
the specimen, and then measures that
force and also the elongation:
This machine usually uses a hydraulic
cylinder to create the force. The applied
force is determined by system
pressure, which can be accurately
measured.
HYDRAULIC UNIVERSAL TESTING
MACHINE
A universal testing machine (UTM), also known as a universal
tester, materials testing machine or materials test frame, is
used to test the tensile stress and compressive strength of
materials . It is named after the fact that it can perform many
standard tensile and compression tests on materials, components,
and structures.
Procedure
• Tensile Properties are
obtained in two ways
1. Taking specimen from
transverse direction of weld
joint consisting base metal –
heat affected zone
ASTM A370 Mechanical testing of steel products.
ASTM E8 Tension testing of metallic materials.
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[Link] weld metal specimen
• This test is used to determine the tensile
properties of a specimen that consists entirely of
weld metal.
• The test specimen is oriented parallel to the weld
axis, and is machined entirely from the weld
metal.
• There are two reasons for performing an all weld
metal test:
- to qualify a filler metal or
- determine the properties of the weld metal in
a particular weldment.
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• The following are typically properties that
are measured and reported in an all weld
metal tension test.
- tensile strength
- yield strength
- elongation
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Bend Test
• Bend test is one of the most important and
commonly used destructive test to determine,
– Ductility &,
– Soundness of the welded joints in terms of
porosity, inclusion, penetration & other macro size
weld discontinuities.
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How to Bend?
• Bending of the
weld joint canbe
Face
done orfrom root or side
depending Upon the
purpose
• i.e. whether face or root
side is assessed.
• ASTM - E190
Guided bend test
for ductility of welds
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Types of Bend Test
• Free bend
– In free bend test between
the two supports, the
weld joint is placed and
then the compressive
load is applied for the
bending to take place.
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Guided bend test
• In the guided bend
test guided
is performed by,
bending
placing weld
joint over the die.
the
• It offers, the
better controlled
conditions of
the specimen and of
the loading.
• Costlier than
free
bend test
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Guided Bend
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Loading in Bend Test
• Load keep on increasing until crack
starts appearing on face or root.
• Angle of bend is considered as measure
of ductility.
Good Bad
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Hardness Test
INTRODUCTION
Hardness can be defined as the resistance of a
material to indentation or abrasion by
another hard body.
Hardness is resistance of material to plastic
deformation caused by indentation.
Good hardness generally means that the
material is resistant to scratching and wear
Types of hardness test
Brinell Hardness Test
Vickers Hardness Test
Rockwell Hardness Test
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HARDNESS TESTING
A qualitative Moh’s scale, determined by the ability of a material to scratch another
material: from 1 (softest = talc) to 10 (hardest = diamond)
Diamond 10
Corundum 9
Topaz 8
Quartz 7
Orthoclase (Feldspar) 6
Apatite 5
Fluorite 4
Calcite 3
Gypsum 2
Talc 1
F
Brinell’s Hardness
ME101: Materials Science and
Technology
BRINELL HARDNESS TESTING
The Brinell hardness test consists in indenting the metal surface with a 10-mm
diameter steel ball at a load of 3,000 kg.
For soft metals the load is reduced to 500 kg to avoid too deep an impression.
For very hard metals Tungsten carbide ball can be used to minimize distortion of
the indenter.
The load is applied for a standard time, usually 30 sec.
The surface on which the indentation is made should be relatively smooth and free
from dirt or scale
BRINELL HARDNESS TESTING
Brinell Test Method
The indenter is pressed into the sample by an accurately controlled test force.
It is important to choose the combination of load and ball size carefully so that the
indentation is free from distortion and suitable for measurement.
The force is maintained for a specific time (max 30Sec.).
After this time period, the indenter is removed leaving a round indent in the sample.
The size of the indent is determined optically by measuring two diagonals of the
round indent using a optical microscope.
The Brinell hardness number is a function of the test force divided by the curved
surface area of the indent.
P from 500 - 3000 kg
D= 10 mm
BHN 2P D D
ME101: Materials Science and
D 2
d 2
Technology
BRINELL HARDNESS TESTING
HB = The Brinell hardness number
F = Applied load in kg
D = Diameter of the spherical indenter in
mm
d = Diameter of the resulting indenter
impression in mm
UNIT OF BHN (HB)
kilograms per square millimeter.
ME101: Materials Science and
Technology
ROCKWELL HARDNESS TESTING
This test utilizes the depth of indentation, under constant load, as a measure of
hardness.
A 120° diamond cone with a slightly rounded point, called a Brale indenter, and
1/16 and 1/8 inch -diameter steel balls are generally used as indenters.
Major loads of 60, 100, and 150 kg are used.
The Rockwell hardness is dependent on the load and indenter, it is necessary to
specify the combination which is used.
The hardness number is expressed by the symbol HR and the scale designation
A Rockwell hardness number without the letter prefix is meaningless
ROCKWELL HARDNESS TESTING
Rockwell Scales
There are 30 different scales. The majority of applications are covered by the
Rockwell C and B scales for testing steel, brass, and other metals.
A Scale diamond penetrator, 60-kg major load, which is usable for materials from
annealed brass to cemented carbides
B Scale 1/16 inch. diameter steel ball and a 100-kg major load, Softer materials
are usually tested .the range of this scale is from RB to RB 100.
C Scale 120° diamond cone indenter and a 150-kg major load. Hardened steel is
tested the useful range for this scale is from about RC20 to RC 70.
ROCKWELL HARDNESS TESTING
Types of the Rockwell hardness Test
Rockwell: The minor load is 10 kg, the major load is 60, 100, or 150 kg.
Superficial Rockwell: The minor load is 3 kg and major loads are 15, 30, or 45
kg.
In both tests, the indenter may be either a diamond cone or steel ball.
The standard Rockwell test can not be used for very thin sheet and foils
and for these the Rockwell superficial hardness test is used.
Select Scale - load and
indentor depending
on the scale
Press a point
into material
- Diamond
Point (Brale)
- 1/16" ball
- 1/8" ball
- ¼” ball
DPH/VHN/VPH/VH = 2PSin(/2)/L 2
P
P: applied load in kg, 5-120 kg
L: average diagonal length, mm
(typically from a few µm to 1
mm)
: angle between opposite faces of
indenter; 136°
L
Range: 5 (extremely soft metals) -
1500 (extremely hard materials) A
1.854P
HV 2
L Vickers Hardness = F/A = 3
VICKERS HARDNESS TESTING
The Vickers hardness test uses a square-base diamond pyramid as the indenter.
This test is preferable to the Brinell test where hard materials are concerned, as it
uses a diamond indenter.
The included angle between opposite faces of the pyramid is 136°
The loads ordinarily used with this test range from 1 to 120 kg .
Standard loads are 5, 10, 20, 30, 50 and 100 kg
It is necessary to state the load when specifying a Vickers hardness number
For example, if the hardness number is found to be 200 when using a 50 kg
load,
VICKERS HARDNESS TESTING
Vickers Hardness method
The included angle between opposite faces of the pyramid is 136°.
Because of the shape of the indenter this is frequently called the diamond-
pyramid hardness test.
The diamond-pyramid hardness number (DPH), or Vickers hardness number
(VHN, or VPH), is defined as the load divided by the surface area of the
indentation,
This area is calculated from microscopic measurements of the lengths of the
diagonals of the impression.
ME101: Materials Science and
Technology
What is Impact or Impact Force ?
In mechanics, an impact is a high force or shock applied over a short time
period when two or more bodies collide. Such a force or acceleration
usually has a greater effect than a lower force applied over a
proportionally longer period.
Example : car crush, wind force, earthquake etc.
Toughness Test
• Toughness is the ability of a material to resist
both fracture and deformation.
• Can be determined by calculating energy
absorbed by material before fracture.
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Methods of toughness testing
• Charpy Impact test
• Izod impact test
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Charpy Impact Test
• The Charpy vee-notch impact test is the most
common fracture toughness test used by industry.
• A notched specimen is broken by a swinging
pendulum and the amount of energy required to
break the specimen is recorded in foot-pounds or
joules.
• This is determined by measuring how far the
pendulum swings upwards after it fractures the
specimen.
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The specimen is set like a
simply
supported
beam.
It can be seen that at low temperatures the
material is more brittle and impact toughness is
low. At high temperatures the material is more
ductile and impact toughness is higher.
The transition temperature is the boundary
between brittle and ductile behavior and this
temperature is often an extremely important
consideration in the selection of a material.
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Izod Impact Test
• Testing is generally carried out with the
specimens at room temperature since the time
required to accurately place it in the machine
allows its temperature to increase.
• This can introduce a significant error when
conducting tests at various temperatures.
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Calculation
Impact energy
= mgH-mgh ;
Where,
m=mass of
pendulum.
g=acceleration due to gravity.=9.81ms-2
The absorb energy in Joule Unit.
Fig : Impact energy
The curve represents a change in
fracture behaviour from ductile at high
temperature to brittle at lower
temperature
Ductile to Brittle Transition
Upper shelf
Lower shelf
Transition –
mixed
mode
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