Welding Inspection: Mechanical Testing Course Reference WIS 5

WI 3.
Welding Inspection
Mechanical Testing
Course Reference WIS 5
Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers
WI 3.1
WHAT IS
MECHANICAL
TESTING ?
The ultimate means by which the mechanical
strength and toughness of a prepared test
object can be determined by subjecting it to
mechanical forces beyond the limits of its own
mechanical resistance
WI 3.1
Mechanical Testing
Destructive testing of welded joints are
usually carried out to:
 Approve welding procedures

 Approve welders
 Production quality control

WI 3.1
Definitions
 Malleability  Can be deformed a

 Ductile great deal by
 Toughness compression before
cracking
 Hardness

WI 3.1
Definitions
 Malleability  Can be deformed

 Ductile considerably by
 Toughness tension before it
fractures
 Hardness

WI 3.1
Definitions
 Malleability  Ability to withstand

 Ductile bending without
 Toughness fracture
 Hardness

WI 3.1
Definitions
 Malleability  Measure of the

 Ductile resistance of a
 Toughness material to
indentation
 Hardness

WI 3.1
Mechanical Tests
The following mechanical tests have units and are
termed quantitative tests
 Tensile tests
 Toughness testing (Charpy, Izod)
 Hardness tests

WI 3.1
Definitions
The following mechanical tests have no units and
are termed qualitative tests
 Macro testing
 Bend testing
 Fillet weld fracture testing
 Butt weld nick-break testing

Mechanical Tests WI 3.1
Specimens
Tensile Specimen
CTOD Specimen
Charpy Specimen Bend Test Specimen
Fracture Fillet Specimen

WI 3.1
Hardness Testing
Various Methods
 Brinell
 Rockwell
 Vickers
 Equitip
Vickers Hardness WI 3.1
Testing
 Square based pyramid
 Indenter pressed into specimen with a load of between
1 and 100kg for 15 seconds
 Length of diagonals measured using adjustable
shutters and a built in microscope
Diamond
indentor Adjustable
shutters
Indentation

Brinell Hardness WI 3.1
Testing
 Hardened steel ball of given diameter is
subjected for a given time to a given load
 Load divided by area of indentation gives
Brinell hardness in kg/mm2
 More suitable for on site hardness testing

Equo Tip Hardness WI 3.1
Testing

WI 3.1
Charpy Impact Test

Object of Test
To determine the amount of energy absorbed in
fracturing a standardised test piece
1. Specimens are usually taken in groups of
three to allow for scatter results
2. Test temperature should be specified
3. Test results are give in joules
4. Tough specimens absorb more energy than
brittle specimens
WI 3.1
Charpy Impact Test

Direction of striker
45o
Root radius
0.25mm
2mm
10
10
55
WI 3.1
Izod Impact Test

Direction of impact
Test specimen
Vice type fixture
28mm
2mm
10mm
75mm

WI 3.1
Charpy Impact Test

22 I/2o
10 mm
100% Brittle
2 mm Machined
notch
Fracture surface
8 mm
100% bright
crystalline brittle
fracture
100% Ductile
Machined
notch
Large reduction
in area, shear
lips
Randomly torn,
dull gray fracture
surface

Ductile/Brittle WI 3.1
Transition Curve
Ductile fracture
Temperature range
47 Joules
Transition range Ductile/Brittle

transition point
28 Joules
Brittle fracture
- 50 - 40 - 30 - 20 - 10 0
Degrees Centigrade

Comparison of WI 3.1
Charpy Test Results

Impact Energy Joules
Room Temperature -20oC Temperature
1. 197 1. 49
2. 191 2. 53
3. 186 3. 51
Average = 191 Average = 51
The test results show the specimens carried out at room temperature
absorb more energy than than the specimens carried out at -20oC
WI 3.1
Charpy Impact Test

Reporting results
 Location and orientation of notch
 Testing temperature
 Energy absorbed in joules
 Description of fracture (brittle or ductile)
 Location of any defects present
 Dimensions of specimen

WI 3.1
Tensile Tests
Different tensile tests include:
 Transverse tensile.
 All-weld metal tensile test
 Cruciform tensile test
 Short tensile test

WI 3.1
Tensile Tests
Transverse Tensile
Specimen
All-Weld Metal Tensile

Specimen
Transverse Tensile WI 3.1
Tests
Object of test:
To measure the transverse tensile strength of a
butt joint under a static load
Weld metal area
Reduced section specimen
Radius reduced specimen
None reduced section specimen

Tests
Maximum load applied = 220 kN.
Least cross sectional area = 25 mm X 12 mm
U.t.s. = Maximum load applied

Least c.s.a.
U.t.s = 220000 N
25mm X 12mm
U.t.s = 733.33 N/mm2

Tests
Reporting results
 Type of specimen e.g. reduced section
 Whether weld reinforcement is removed
 Dimensions of test specimen
 The ultimate tensile strength in N/mm2, p.s.i or

Mpa
 Location of fracture.
 Location and type of any flaws present if any

All-Weld Metal WI 3.1
Tensile Test
Gauge length
Object of test
 Ultimate tensile
strength
 Yield strength
 Elongation %
(ductility)
Increased gauge length

Tensile Test
Original gauge length = 50mm
Increased gauge length = 64
Elongation % = Increase of gauge length X 100

Original gauge length
Elongation % = 14 X 100
50
Elongation = 28%

Tensile Test
Reporting results
 Type of specimen e.g. reduced section
 Dimensions of test specimen
 The u.t.s, yield strength in N/mm2, p.s.i or Mpa
 Elongation %
 Location and type of any flaws present if any

WI 3.1
Short Tensile Tests

A test for a materials susceptibility to lamellar tearing
Friction Welded Caps

Short Tensile Specimen
Sample of Parent Material
Through
Thickness
Ductility
The results are given as a STRA value

Short Transverse Reduction in Area

WI 3.1
Macro / Micro
Object
 Macro/microscopic examinations are used to give
a visual evaluation of a cross-section of a welded
joint
 Carried out on full thickness specimens
 The width of the specimen should include HAZ,

weld and parent plate
 They maybe cut from a stop/start area on a

welders approval test

WI 3.1
Macro / Micro
Will Reveal
 Weld soundness
 Distribution of inclusions
 Number of weld passes
 Metallurgical structure of weld, fusion zone
and HAZ
 Location and depth of penetration of weld
 Fillet weld leg and throat dimensions
WI 3.1
Macro Micro
 Visual examination for  Visual examination for
defects defects & grain structure
 Cut transversely from  Cut transversely from
the weld the weld
 Ground and polished  Ground and polished
P400 grit paper P1200 grit paper
 Etched using 5-10%  Etched using 1-5%
nitric acid solution nitric acid solution
 Wash and dry  Wash and dry
 Visual inspection under  Visual inspection under
5X magnification 100X-1000X magnification
 Report on results
 Report on results
WI 3.1
Macro Report
Sample Number MSR-1189
3
4
2
DEFECT TYPE DEFECT SIZE ACCEPT/REJECT

1. Lack of sidewall fusion + slag 4mm Reject
2. Slag inclusion 3.5mm Reject
3. Lack of sidewall fusion 5.8mm depth Reject
4. Cap undercut 0.6mm Accept
WI 3.1
Bend Tests
Object of test
To determine the soundness of the weld zone.
Bend testing can also be used to give an
assessment of weld zone ductility.
There are three ways to perform a bend test
1. Face bend
2. Root bend
3. Side bend (Generally for materials above
12mm thickness)
WI 3.1
Bend Tests
Former (4t)
Weld dressed flush Support
Root bend Face bend

WI 3.1
Bend Tests
Face bend
Side bend
Root bend
Defect indication Minor ruptures on

Generally this specimen tension surface
would be unacceptable Acceptance depends
upon code
requirements
WI 3.1
Bend Tests
Reporting results
 Thickness and dimensions of specimen
 Direction of bend (root, face or side)
 Angle of bend (90o, 120o, 180o)
 Diameter of former. (typical 4T)
 Appearance of joint after bending e.g. type

and location of any flaws.

Fillet Weld WI 3.1
Fracture Test
Object of test
To break open the joint through the weld to permit
examination of the fracture surfaces
1. Specimens are cut to the required length

2. A saw cut approximately 2mm in depth is
applied along the fillet welds length
3. Fracture is usually made by striking the
specimen with a single hammer blow
4. Visual inspection for defects
Fillet Weld WI 3.1
Fracture Test
Hammer
Hammer
2mm
Notch
2mm
Notch
Fracture should break saw cut

to root

Fillet Weld WI 3.1
Fracture Test
This fracture has occurred

saw cut to root
This fracture indicates lack

of fusion

Fillet Weld WI 3.1
Fracture Test
Reporting results
 Thickness of parent material
 Throat thickness and leg lengths
 Location of fracture
 Appearance of joint after fracture
 Depth of penetration
 Defects present on fracture surfaces

WI 3.1
Nick-Break Test
Object of test
To permit evaluation of any weld defects across
the fracture surface of a butt weld.
1. Specimens are cut transverse to the weld

2. A saw cut approximately 2mm in depth is
applied along the welds root and cap
3. Fracture is usually made by striking the
specimen with a single hammer blow
4. Visual inspection for defects

Nick-Break Test WI 3.1
Specimens
Notch cut by hacksaw
3 mm
19 mm
3 mm
Approximately 230 mm
Weld reinforcement may or

may not be removed
Alternative nick-break test specimen,

notch applied all way around the
specimen

WI 3.1
Nick-Break Test
Reporting results
 Thickness of parent material
 Width of specimen
 Location of fracture
 Appearance of joint after fracture
 Depth of penetration
 Defects present on fracture surfaces

WI 3.1
ny Questio
Copyright © 2003 TWI Ltd Section

Section Ref
Ref 44 M.S.Rogers
M.S.Rogers
WI 3.1
Questions
QU 1. What mechanical properties can be measured in the all-
weld metal tensile test
QU 2. What is the purpose of a charpy V-notch test and what

units are the test results give in.
QU 3. Give a brief description of the following tests

a. Bend test
b. Nick-break test
c. Marco.
QU 4. From a transverse tensile test the following information is

known, calculate the ultimate tensile strength
Maximum load applied 235 Kilo Newtons
Least cross sectional area 25.20mm x 17.52mm

Welding Inspection: Mechanical Testing Course Reference WIS 5

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WI 3.

 Approve welding procedures

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Malleability  Can be deformed a

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Malleability  Can be deformed

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Malleability  Ability to withstand

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Malleability  Measure of the

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Toughness testing (Charpy, Izod)

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Fillet weld fracture testing

 Butt weld nick-break testing

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Charpy Specimen Bend Test Specimen

Fracture Fillet Specimen

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Charpy Impact Test

Charpy Impact Test

Izod Impact Test

Vice type fixture

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Charpy Impact Test

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Transition range Ductile/Brittle

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Charpy Test Results

Charpy Impact Test

 Energy absorbed in joules

 Description of fracture (brittle or ductile)

 Location of any defects present

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 All-weld metal tensile test

 Cruciform tensile test

 Short tensile test

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

All-Weld Metal Tensile

Weld metal area

Reduced section specimen

Radius reduced specimen

None reduced section specimen

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

U.t.s. = Maximum load applied

U.t.s = 733.33 N/mm2

 Whether weld reinforcement is removed

 Dimensions of test specimen

 The ultimate tensile strength in N/mm2, p.s.i or

 Location and type of any flaws present if any

Increased gauge length

Elongation % = Increase of gauge length X 100

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

 Dimensions of test specimen

 The u.t.s, yield strength in N/mm2, p.s.i or Mpa

 Location and type of any flaws present if any

Copyright © 2003 TWI Ltd Section Ref 4 M.S.Rogers

Short Tensile Tests

Friction Welded Caps

The results are given as a STRA value