Experiment 3

Title: Measurement of hardness values

1. Introduction (Background and theory)

Hardness is a indicator of a metal's tolerance to withstand (plastic) deformation. The

metal's hardness is determined by applying an intender to its back. The more intense material can
be found in a variety of ball, pyramid, or cone shapes. The intender substance must be thicker
than the content being checked. A defined charge is added gradually with most conventional
hardness checks by moving the indenter perpendicular to the metal sheet. The intender is taken
back from the top upon pushing. An empirical number of hardness is then measured or read from
a dial (or digital display) and is centered on the indentation's cross-sectional depth area. There
are three specific measurements focused on intender forms widely developed and implemented
by Brinell, Vickers and Rockwell approaches of engineering practices.

This requires a diamond intensder in the shape of a square-based pyramid with an apex
angle of 136 degrees for Vickers study. The intender is pushed into the surface of the specimen
under examination for 10 to 15 seconds under load. The effect is an indentation between
rectangular forms. The diagonals of the indention d (mm2) are calculate after the load and
indenter are separated from the air. The Vickers hardness number HV is obtained by measuring
the load size F (kgf) of the indentation, multiplied by the surface region A (mm). Moreover, the
HV is convey to

F
HV =
¿¿
The load added depends on the substance and is special. The normal load for a given content is
as follows

Load (kg) Material

30 Steels and Cast irons
10 Copper alloy
5 Pure copper and aluminium alloy
2.5 Pure aluminium
1 Lead, tin and tin alloys

,The hardness value value given by the Vickers test is the same as that provided by the Brinell
test up to a hardness value of approx, 300 HV.

Figure 1: Vickers indenter

2. Apparatus and Experimental Procedure

The 300 mm x 100 mm x 12 mm of High Yield (HY-80) steel is used as the base metal for this
experiment. Table 1 lists the chemical composition of HY-80 steel This experiment includes 4
tests, which is 2 out of 4 sample is butt welded with V-type weld groove to achieve a weld joint
of 300 mm x 200 mm x 12 mm, and two other tests have been welded with fillet (Figure 1). The
samples were welded using a process named Gas Metal Arc Welding (GMAW). In the horizontal
role, 90 per cent Ar + 10 per cent CO2 is used for the shielding material. The ER100S rigid wire
with a diameter of 1.2 mm was used to weld the piece. In Table 2 is given the chemical
composition of the filler material.

C Mn P S Si Ni Cr Mo
0.14 0.29 0.004 0.002 0.22 3.03 1.49 0.437
Table 1: Chemical composition of existing steel plates HY-80 (wt%)

C Si Mn Cr Mo Ni
0.08 0.6 1.7 0.2 0.5 1.5
Table 2: Composition of a filler material (welding wire) for GMAW application (wt%)

a) Butt joint b) fillet joint

Figure 1: Test HY-80 arc welded steel gas joint (GMAW)

During the welding cycle the key parameters including voltage ( V), current (I), and welding
speed (v) were measured and managed. Calculation of heat input using corresponding
 U × I ×60
E=
v

Where

E= Heat input (J/mm)

U= Arc voltage (V)
I= Current (A)
v= Welding speed (mm/min)

Fig 2 displays the HY-80 Steel cross section. Until welding process, the welded plate had been
preheated at 50 °C. During the welding process, Welded joint, Weld Metal (WM) and Heat
Affected Zone (HAZ) of the specimen were machined from welded plate for improved
consistency. The DNV Norm applied to the preparing of the weld samples and welding procedures.
The research specimens were split to weld bead perpendicular.
Sequence Pass Current (A) Voltage (V) Welding Heat input
speed
(kj/mm)
(mm/min)

1 root 100 15 137 0.66

2 Hot pass 170 18 286 0.64

3 Filler 170 18 295 0.62

4 Filler 170 18 295 0.62

5 Capping 170 18 305 0.60

6 Capping 170 18 273 0.67

7 Back weld 170 18 353 0.52

Table 3: Welding of butt weld specifications HY-80 steel plates

Sequence Pass Current (A) Voltage (V) Welding Heat input

speed
(Kj/mm)
(mm/min)

1 1st 190 20 346 0.66

2 2nd 190 20 400 0.57

3 3rd 190 20 375 0.61

Table 4: Welding variables for HY-80 steel fillet weld plates

 a) Butt joint b) fillet joint

Figure 2: HY-80 Steel Plates Joint Design:

Microstructural Analysis

The specimens were cut into the weld joint for microstructural studies. In order to achieve mirror
finish using normal metallographic methods, this specimen was polished in cross-sectional area
and then engraved with nital solution. Microstructure of the specimen was examined through the
aid of an optical microscope.

Hardness Tests

Hardness checking was performed using a Vickers hardness measuring tool with a load of 10kgf.
The testing and hardness experiment for the specimen was carried out in accordance with the
ASTM E92-82 standard. The toughness measurements are carried out on the bead weld cross-
section in a section 2 mm along the top and bottom surfaces of the plates. The hardness
calculations were performed to achieve the hardness distribution around the (BM), (HAZ) and
(WM).
 Figure 3: Vickers hardness testing machine

3. Expected Result & Data Analysis

Results and Discussion

Microstructural Analysis

Figure 4 displays butt weld and fillet weld macrographs, while Figure 5 and Figure 6
display micrographs of BM, HAZ, and butt weld and filet weld WM respectively. The diameter of
HAZ is approx. 2 mm. A mixture of granular bainite (GB), ferrite (F) and martensite (M) is shown
in the microstructure of BM and HAZ while the WM reveals acicular ferrite (AF) as seen in figure
5. This result is comparable to the main microstructure of welded joint of high strength low alloy
steel (HSLA), which is the microstructure of the HAZ granular bainite and martensite were
observed while the WM showed acicular ferrite.

During welding the evolution of the microstructure influences the mechanical properties.
The HAZ and WM micro-hardness is heavily dependent on the microstructure. The toughness of
the HAZ and WM has been due to lath martensite and bainite formation.

a) Butt joint b) fillet joint

Figure 4: BM, HAZ, and WM Optical Microscopy (OM) macrographs

 (a) Base metal (b) HAZ (c) weld metal

Figure 5: Optical HY-80 welding micrographs for butt welding: (a) base metal, (b) HAZ, (c) weld
metal (1000x magnification)

(a) base metal (b) HAZ (c) weld metal

Figure 6: HY-80 fillet welding optical micrographs: (a) base metal, (b) HAZ, (c) weld metal
(1000x magnification);
Hardness test

Hardness profile was observed around the butt weld bead weld and fillet weld (Figure 4). Butt
weld form indicates that the BM had a toughness value of 250-253 HV while the WM and HAZ
vary greatly from line 1 (near upper surface) to line 2 (near lower surface area). At Line 2 the HAZ
and WM stiffness were greater than Line 1. The maximum toughness value for both Line 1 (394
HV) and Line 2 (431 HV) was found in the HAZ.

-----Line 1 (upper)-----Line 2 (lower)

Figure 7: Hardness measure outcomes of evaluating to the position in Figure 3(a) in BM, HAZ and
WM of butt weld joint

The butt type hardness test shows HAZ and WM at line 2 (near lower surface) where the
root hardness is greater than line 1 (near upper surface) (Figure 5). Since the heat intake applied at
the bottom surface (back weld) is smaller than the top surface (capping), this has an impact on the
higher cooling intensity, martensite has resulted in the hard phases.
 In the HAZ field, it was noticed that the hardness of the affected zone of fine grain heat
(FGHAZ) near BM is lower than the affected zone of coarse grain heat (CGHAZ) near the fusion
line (FL). CGHAZ 's strength became higher by using a lower welding heat supply than the
FGHAZ. Although the BM has the hardness values of 240-251 HV for fillet weld form whereas
the WM and HAZ are higher than BM. Highest hardness value at HAZ (397 HV) was observed. It
is not much different from the line 1 (upper surface) butt joint style HAZ which has a capacity at
394 HV. It will allow specific heat input to be added (averaging 0.6 kJ / mm).

Figure 8: Hardness evaluation findings of filet weld joint in BM, HAZ and WM with position
relation in Figure 3(b)
Conclusion

Since conducting the HY-80 high-resistance steel plate hardness check, few assumptions
can be made which is the average hardness in line 2 (near bottom surface) is higher than line 1
(near upper surface) for category of butt weld. The BM hardness rating indicates 250-253 HV
while the WM and HAZ vary greatly from line 1 to line 2. The HAZ and WM hardness at line 2
is, as described, a higher than line 1. That is because the heat intake applied at the bottom surface
is smaller than at the top surface, thereby leading to a higher cooling rate and martensite forming
occurs. In the HAZ (394 HV at line 1 and 431 HV at line 2) the maximum hardness was found.
While, the BM hardness value for fillet is 240-251 HV whereas the WM and HAZ hardness is
higher than BM. Highest hardness value at HAZ (397 HV) was observed. Last but not least, both
butt weld and fillet weld had the highest hardness value at coarse grain heat (CGHAZ) affected
site.
 Experiment 4

Title: Destructive Tests -Bend Test to evaluate quality on Butt Weld.

1. Introduction (background and theory)

Throughout the welding area, the welding feature is determined by means of a test that
can also be classified into two: Destructive Test (DT) and Non-Destructive Test (NDT). Tension
testing, bent testing, charpy impact tests, Pellini drop weight tests, peel tests, smash tests, strain
and crack tests were used in the Destructive Experiment. The bend test is a clear and economical
qualitative check which can be used to determine both a material's ductility and hardness. It is
often used as a quality assurance measure for butt-welded joints, and has the benefit of both the
test component and the equipment being plain. The research does not involve a expensive
laboratory machine and test specimens are quickly prepared and the study can be carried out on
the shop floor as a quality assurance measure to maintain accuracy of manufacturing if
necessary. The bend check essentially uses a coupon which is bent to a defined angle in three
points.

During the bend examination, the specimen undergoes plastic deformation, such that any flaw or
embrittlement of the specimen may be observed by the coupon's premature failure. The specimen
can be bended into free form or driven by mold or holder design. The directed bend measure is
the location where the coupon is wound around a defined diameter former. Samples or samples
may be broken down to be tested, for example, to assess the strength of a weld is adequate to
endure intense pressure or to check the material's properties.
2. Apparatus and Experiment Procedure

Apparatus

Specimen

 2 Butt weld (for Face and Root Nick Break Test)

Machine

 50 Tons Press Machine

 Specimen’s holder for bending tests

Procedure

1. Two specimens were prepared for bending testing

2. The fatigue failure check was conducted with 50 t pressing device for
a. Face test

b. Root test

3. An internal defect such as porosity, inclusion of slag and so on was observed and
recorded before, during and after the test.
3. Expected Results & Data Analysis

i. Face Bend Test for Butt Weld

ii. Root Bend Test for Butt Weld

4. Discussion of Results and Answer of Questions

By referring to the image for face bend test in the result section, the test shows that no
defect was found on the welding surface. The face bend test was conducted to check whether
visual inspection after the test could detect any defect. The face bent examination focussed on
the weld surface image. During face bent check the region of the specimen 's face welding
undergoes plastic deformation. The face weld region extend through bent checking. When some
deformation of the weld face happens, visual examination will reveal the defect. This is because
any defects like cracking or porosity will increase as the force is applied during the test. The
force exerted should remain on the region of fault, because force appears to concentrate on the
weld face at each tension level. Furthermore, because the visual examination on the welding face
did not show any evidence, it can be inferred that the welding face of the specimen is suitable for
application as no defect was detected during the face bent check

Whereas for the root bend analysis, the visual analysis reveals certain defects that place
on the specimen sheet. The red box is the product of visual testing carried out on the item. The
test generates a linear indication that is in the red box on the root of the weld. When in yellow
boxes s crack that existed on the specimen 's root emerges. Since the specimen is forced to bend,
the stress created by the bending should focus on any defected region or focused point of stress
in which any failure may occur. Flat sign and cracks were visualized on the welding root region
for this event. These types of defects are caused by lack of fusion, incorrect speed during the
welding process and rapid refrigeration rate. Failure to fuse is caused by incorrect voltage used
for welding process and improper techniques. Lack of fusion is the key element leading to
longitudinal signal and splitting, because the weld metal and base metal are not fully fused.
Despite of this, it produces a void that can trigger accumulation of tension that causes loss. In
addition to lack of fusion, welding speed often plays a critical function, as quick welding speed
disrupts base metal melting and fusion. The cooling rate is also an significant consideration, as
welding is usually performed in passes

.
5.Conclusion and Recommendation

Conclusion

The bending analysis conducted was able to determine the specimen 's consistency for
butt weld joints. The mechanical properties of the substance such as durability and stiffness may
be calculated by bend research. The students had already been introduced to the damaging facial
and root bent test process. The aims of this experiment had been achieved in conclusion.

Recommendation

There are a few ideas that come out after implementing the bending test to improve the
student's comprehension of the bending process. Besides the face and root bend examination, it is
also important to conduct side bend tests which will help the pupil to learn more about the bend
test process. First, perform the examination using additional tools and advance specimen.
Because of this, the defect and non-defect can be seen during the bend test.