Welding Inspector

Destructive Testing
 Qualitative and Quantitative Tests 4.1
The following mechanical tests have units and are termed
quantitative tests to measure Mechanical Properties
Tensile tests (Transverse Welded Joint, All Weld Metal)
Toughness testing (Charpy, Izod, CTOD)
Hardness tests (Brinell, Rockwell, Vickers)

The following mechanical tests have no units and are termed

qualitative tests for assessing joint quality
Macro testing
Bend testing
Fillet weld fracture testing
Butt weld nick-break testing
 Mechanical Test Samples 4.1
Tensile Specimens
CTOD Specimen

Bend Test
Specimen
Charpy Specimen

Fracture Fillet
Specimen
 Destructive Testing 4.1
WELDING PROCEDURE QUALIFICATION TESTING

top of fixed pipe

2 Typical Positions for Test
Pieces
Specimen Type Position
•Macro + Hardness 5
3
•Transverse Tensile 2, 4
•Bend Tests 2, 4
•Charpy Impact Tests 3

4 •Additional Tests 3

5
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to

withstand deformation
• Ductility
under static compressive
• Toughness loading without rupture
• Hardness
• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material

undergo plastic
• Ductility
deformation under static
• Toughness tensile loading without
• Hardness rupture. Measurable
elongation and reduction
• Tensile Strength in cross section area
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to

withstand bending or the
• Ductility
application of shear
• Toughness stresses by impact loading
• Hardness without fracture.

• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of a
materials surface
• Ductility
resistance to indentation
• Toughness from another material by
• Hardness static load

• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of the

maximum force required to
• Ductility
fracture a materials bar of
• Toughness unit cross-sectional area in
• Hardness tension

• Tensile Strength
Transverse Joint Tensile Test 4.2

Weld on plate

Multiple cross joint

Weld on pipe specimens
 Tensile Test 4.3

All-Weld Metal Tensile

Specimen

Transverse Tensile
Specimen
STRA (Short Transverse Reduction Area)
For materials that may be subject to Lamellar Tearing
UTS Tensile test 4.4
 Charpy V-Notch Impact Test 4.5

Objectives:
• measuring impact strength in different weld joint areas
• assessing resistance toward brittle fracture
Information to be supplied on the test report:
• Material type
• Notch type
• Specimen size
• Test temperature
• Notch location
• Impact Strength Value
Ductile / Brittle Transition Curve 4.6

Ductile fracture
Temperature range

47 Joules

Transition range Ductile/Brittle

transition
point

28 Joules
Energy absorbed
Brittle fracture
- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees Centigrade
Three specimens are normally tested at each temperature
Comparison Charpy Impact Test Results 4.6

Impact Energy Joules

Room Temperature -20oC Temperature

1. 197 Joules 1. 49 Joules

2. 191 Joules 2. 53 Joules
3. 186 Joules 3. 51 Joules

Average = 191 Joules Average = 51 Joules

The test results show the specimens carried out at room
temperature absorb more energy than the specimens carried
out at -20oC
Charpy V-notch impact test specimen 4.7
Specimen dimensions according ASTM E23

ASTM: American Society of Testing Materials

Charpy V-Notch Impact Test 4.8

Specime Pendulu
n m
(striker)

Anvil (support)
 Charpy Impact Test 4.9

22.5o
2 mm 10 mm 100% Brittle

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
 Hardness Testing 4.10

Definition
Measurement of resistance of a material against
penetration of an indenter under a constant load
There is a direct correlation between UTS and
hardness

Hardness tests:
Brinell
Vickers
Rockwell
 Hardness Testing 4.10

Objectives:
• measuring hardness in different areas of a welded joint
• assessing resistance toward brittle fracture, cold cracking
and corrosion sensitivity within a H2S (Hydrogen Sulphide)
environment.

Information to be supplied on the test report:

• material type
• location of indentation
• type of hardness test and load applied on the indenter
• hardness value
 Vickers Hardness Test 4.11

Vickers hardness tests:

indentation body is a square based diamond pyramid
(136º included angle)
the average diagonal (d) of the impression is
converted to a hardness number from a table
it is measured in HV5, HV10 or HV025
Adjustable
Diamond Indentation shutters
indentor
Vickers Hardness Test Machine 4.11
 Brinell Hardness Test 4.11

• 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
30KN

Ø=10mm
steel ball
Rockwell Hardness Test

Rockwell B Rockwell C
1KN
1.5KN

Ø=1.6mm 120°Diamond
steel ball Cone
 Hardness Testing 4.12

usually the hardest region

1.5 to 3mm
fusion line
or
fusion HAZ
boundary

Hardness Test Methods Typical Designations

Vickers 240 HV10
Rockwell Rc 22
Brinell 200 BHN-W
Hardness specimens can also be used for CTOD samples
Crack Tip Opening Displacement testing 4.12

Test is for fracture toughness

Square bar machined with a notch placed
in the centre.
Tested below ambient temperature at a
specified temperature.
Load is applied at either end of the test
specimen in an attempt to open a crack at
the bottom of the notch
Normally 3 samples
 Fatigue Fracture 4.13

Location: Any stress concentration area

Steel Type: All steel types

Susceptible Microstructure: All grain structures

Test for Fracture Toughness is CTOD

(Crack Tip Opening Displacement)
 Fatigue Fracture 4.13

• Fatigue cracks occur under cyclic stress conditions

• Fracture normally occurs at a change in section, notch
and weld defects i.e stress concentration area
• All materials are susceptible to fatigue cracking
• Fatigue cracking starts at a specific point referred to as
a initiation point
• The fracture surface is smooth in appearance
sometimes displaying beach markings
• The final mode of failure may be brittle or ductile or a
combination of both
 Fatigue Fracture
Precautions against Fatigue Cracks
• Toe grinding, profile grinding.
• The elimination of poor profiles
• The elimination of partial penetration welds and weld
defects
• Operating conditions under the materials endurance limits
• The elimination of notch effects e.g. mechanical damage
cap/root undercut
• The selection of the correct material for the service
conditions of the component
 Fatigue Fracture
Fatigue fracture occurs in structures subject to repeated
application of tensile stress.
Crack growth is slow (in same cases, crack may grow
into an area of low stress and stop without failure).
 Fatigue Fracture
Secondary mode of failure Fatigue fracture surface
ductile fracture rough fibrous
appearance smooth in appearance

Initiation points / weld defects

 Fatigue Fracture
Fatigue fracture distinguish features:
Crack growth is slow
It initiate from stress concentration points
load is considerably below the design or yield stress level
The surface is smooth
The surface is bounded by a curve
Bands may sometimes be seen on the smooth surface –
”beachmarks”. They show the progress of the crack front from the
point of origin
The surface is 90° to the load
Final fracture will usually take the form of gross yielding (as the
maximum stress in the remaining ligament increase!)
Fatigue crack need initiation + propagation periods
 Bend Tests 4.15

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:

Face bend
Root bend Side bend
Side bend tests are normally carried out on welds over 12mm in thickness
 Bending test 4.16

Types of bend test for welds (acc. BS EN 910):

“t” up to 12 mm Root / face

bend

Thickness of material - “t”

“t” over 12 mm Side bend

 Fillet Weld Fracture Tests 4.17

Object of test:
To break open the joint through the weld to permit
examination of the fracture surfaces
Specimens are cut to the required length
A saw cut approximately 2mm in depth is applied
along the fillet welds length
Fracture is usually made by striking the specimen
with a single hammer blow
Visual inspection for defects
Fillet Weld Fracture Tests 4.17

Hammer

2mm
Notch

Fracture should break weld saw cut to root

Fillet Weld Fracture Tests 4.17

This fracture indicates This fracture has

lack of fusion occurred saw cut to root

Lack of Penetration
 Nick-Break Test 4.18

Object of test:
To permit evaluation of any weld defects across
the fracture surface of a butt weld.
• Specimens are cut transverse to the weld

• A saw cut approximately 2mm in depth is applied

along the welds root and cap
• Fracture is usually made by striking the specimen with
a single hammer blow
• Visual inspection for defects
 Nick-Break Test 4.18

Notch cut by hacksaw

2 mm
19 mm

2 mm
Approximately 230 mm

Weld reinforcement
may or may not be
removed
 Nick Break Test 4.18

Alternative nick-break test

specimen, notch applied all
way around the specimen

Lack of root penetration Inclusions on fracture

or fusion line
 Summary of Mechanical Testing 4.19
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint

We divide tests into Qualitative & Quantitative methods:

Quantitative: (Have units/numbers) Qualitative: (Have no units/numbers)

To measure mechanical properties
Hardness (VPN & BHN)
Toughness (Joules & ft.lbs)
Strength (N/mm2 & PSI, MPa)
Ductility / Elongation (E%)
For assessing joint quality
Macro tests
Bend tests
Fillet weld fracture tests
Butt Nick break tests