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

STANDARD 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)
B
250 mm
406 mm
B1
T1 B2
M
m
B1
T2 B2
16
mm
weld
TEST PIPE & TUBE FOR PERFORMANCE
QUALIFICATION (as per IBR
Face
Face
Root
Macro
Macro
250mm
Root
PIPE 127x12.5mm, CS Tube 63.5x5.2mm, AS Tube 54x5mm
weld
PROCEDURE QUALIFICATION
(ASME SEC. IX)
QW-463.1(a) : Less than 3/4 PLATES
300mm
250mm


Discard Discard
Reduced Sec. Tensile Specimen
Root Bend
Face
Bend
Root Bend
Face Bend
Tensile Specimen
Discard Discard
Reduced Sec.
PROCEDURE QUALIFICATION
(ASME SEC. IX)
QW-463 1(b) :Over 3/4 PLATES
300
Discard

Discard

Discard

Discard

Reduced Sec.

Side
Side
Side
Side
Bend
Bend
Bend
Bend
Tensile Specimen
250
Reduced Sec.

Tensile Specimen
TENSILE SPECIMENS
TRANSEVERSE
TENSILE
ALL WELD
TENSILE
ELECTRODE QUALIFICATION TEST(AS PER AWS)
WELD
ALL WELD TENSILE
170mm min. (1No.)
25
25
15
IMPACT SPECIMEN
(5Nos.)
DISCARD
DISCARD
ALL WELD TENSILE SPECIMEN (as per IS)
R5
FOR SIZE 3.15 mm and BELOW






























































































































































































































































































































































































































































FOR SIZE 4mm AND ABOVE
G L 50
100.09
PL 60
12 min
70mm min
6.4 0.075
GL 32
44.8
38.9
9.5
THE SURFACE FINISH WIT THE PL SHALL BE 1.6
THE SURFACE FINISH WIT THE PL SHALL BE 1.6
ALL WELD TENSILE SPECIMEN (AWS)
THE SURFACE FINISH WITH THE PL SHALL BE 1.6

R 9.5
SIZE OF ELECTRODE 3.15 mm and BELOW






























































































































































































































































































































































































































































12.70.25
GL 50.8 0.13
PL 57.1
19.1
R 4.6
GL 25.4 0.13
GL 31.8
9.5
SL
SL
SL
SL
SIZE OF ELCTRODE 4 mm and ABOVE
6.40.13
UNIVERSAL TESTING MACHINE
CALIBRATION:
ASTM-E4,
BIS: 1828,
EN: 10002-2
CALIBRATION : EN 10045-2, BIS 3766
0.
TRANSEVERSE TENSILE SPECIMEN
W
PL
SL
SL
T
RECTANGULAR TENSILE TEST SPECIMEN
200
225
75
75
13 min
(FOR PLATE as per ASTM E8M )
ASTM
BS
IBR
IS


50 mm
5.65A
4 A
5.65 A


5min.
50
STANDARD ROUND TENSILE (GL)
FLAT TENSILE (GL)
5d
5d
4d
5d
GAUGE LENGTH AS PER VARIOUS STDS.& CODES.
40
BEND TEST METHODS
1. Guided bend
2. Free Bend
ROOT BEND TEST
t
ROOT BEND TEST
t
5.2t
1.5t
3t
FACE BEND TEST
t
5.2t
1.5t
3t
SIDE BEND TEST
W
5.2t
t
3t
CALIBRATION : EN 10045-2, BIS 3766
Specimen Supporter
Specimen
CALIBRATION : EN 10045-2, BIS 3766
STRICKER
TENIUS OLSON IMPACT TESTER
CAL : ASTM - E23
IMPACT TEST SPECIMEN
100.025


550.1
27.5
10 0.025
450.1
20.1

550.1
27.5
10 0.025
50.1

2

CHARPY VNOTCH TEST SPECIMEN
CHARPY UNOTCH TEST SPECIMEN
100.025


IZOD IMPACT TEST SPECIMEN
75 27.5 10
10
2
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.
BHN=APPLIED LOAD/AREA OF INDENTATION
BHN=P/[( D/2) X (D-D
2
- d
2
)]
WHERE P=LOAD IN Kg,
D=DIAMETER OF STEEL BALL IN mm, d= DIAMETER OF THE INDENTATION IN mm.
APPLICATION
FOR C.STEEL, CAST IRON,COPPERALLOYS, ALUMINIUM ALLOYS, LEAD AND TIN ETC.
POLISHED SURFACE
UNIVERSAL HARDNESS TESTER
TEST IS CARRIED OUT BY IN ACCORDENCE
ASTM E92 TEST IS CARRID OUT BY IN
ACCORDENCE ASTM E92
Minor Load Major Load
ROCKWELL HARDNESS TEST
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/ D
2

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
DROP WEIGHT TEST IS CONDUCTED IN ACCORDANCE WITH ASTM E208
SPECIMEN
SPECIMEN
SUPPORTER
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.
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.
THANK YOU