TECHNOLOGY

Welding Inspection
Mechanical Testing
Course Reference WIS 5
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Mechanical Testing

Destructive testing of welded joints are

usually carried out to:

 Approve welding procedures

 Approve welders
 Production quality control

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Definition of 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

Copyright © 2003 TWI Ltd Faisal Yusof

 Properties of steel
Mechanical properties :–
TECHNOLOGY

Hardness – a measure of the resistance to penetration

Tensile strength – a metal’s ability to withstand stress
in tension
Compresive strength-a metal’s ability to withstand a
pressing or squeezing together
Shear strength - a metal’s ability to resist a sliding
past type of action
Fatigue strength – ability to take repeated loading
Toughness – ability to resist shock
Ductility – ability of a metal’s to stretches before it
breaks
Brittleness – metal does not stretches before it
fractures
Copyright © 2003 TWI Ltd Faisal Yusof
 Mechanical Tests
The following mechanical tests have units and are
TECHNOLOGY

termed quantitative tests

 Tensile tests

 Toughness testing (Charpy, Izod)

 Hardness tests

Copyright © 2003 TWI Ltd Faisal Yusof

 Mechanical Tests
The following mechanical tests have no units and
TECHNOLOGY

are termed qualitative tests

 Macro testing

 Bend testing

 Fillet weld fracture testing

 Butt weld nick-break testing

Copyright © 2003 TWI Ltd Faisal Yusof

 Mechanical Tests Specimens
Tensile Specimen
TECHNOLOGY

CTOD Specimen

Charpy Specimen Bend Test Specimen

Fracture Fillet Specimen

Copyright © 2003 TWI Ltd Faisal

M.S.Rogers
Yusof
TECHNOLOGY Hardness Testing

Hardness tests
 Measurements made by indenting the metal with
a penetrator under a known load

Determined by
 Load applied
 How load is applied
 Configuration of
penetrator

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Hardness Testing

Various Methods

 Brinell

 Rockwell

 Vicker

 Knoop
Copyright © 2003 TWI Ltd Faisal Yusof
 Brinell Hardness Testing
 Hardened steel ball of given diameter is
TECHNOLOGY

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

Copyright © 2003 TWI Ltd Faisal Yusof

 Rockwell Hardness Testing
 Measure the hardness by the depth on indentation made
TECHNOLOGY

by a constant load impressed upon the indentor

 Most common indentor is a diamond, ground to 120
degree cone with spherical apex that has 0.2 mm radius.
(hard materials)
 For soft steel and non ferrous, a hardened steel ball is
used with sizes of 1.6 mm,3.2 mm,5.0 mm and 12.5 mm.

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Rockwell Hardness Testing

Copyright © 2003 TWI Ltd Faisal Yusof

 Vickers Hardness Testing
 Square based pyramid
TECHNOLOGY

 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

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Vickers Hardness Testing

Copyright © 2003 TWI Ltd Faisal Yusof

 Knoop Microhardness Testing
 This test is similar principal to brinell and vickers.
TECHNOLOGY

 Utilised low load that less than 1 kg.

 Indentor is rhombic shape of base pyramid diamond
 The hardness is determine by measuring the size of
indentation with a microscope and then it dimension
in formula or conversion table.

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Knoop Microhardness Testing

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Charpy Impact Test

Copyright © 2003 TWI Ltd Faisal Yusof

 Charpy Impact Test
Object of Test
TECHNOLOGY

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
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Charpy Impact Test

10
10
55

45o

Root radius
0.25mm
2mm

Direction of striker
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Charpy Impact Test

Copyright © 2003 TWI Ltd Faisal Yusof

 Izod Impact Test
Direction of impact
TECHNOLOGY

Test specimen

Vice type fixture

28mm
2mm

10mm

75mm

Copyright © 2003 TWI Ltd Faisal Yusof

 Charpy Impact Test
22 I/2o
10 mm
100% Brittle
TECHNOLOGY

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

Copyright © 2003 TWI Ltd Faisal Yusof

 Ductile/Brittle Transition Curve
Energy
Transition Temperature range
TECHNOLOGY

Joule
200 Ductile fracture

150

100

50
Brittle fracture

Temperature 0
C
- 40 - 20 0 20 40
Degrees Centigrade

Copyright © 2003 TWI Ltd Faisal Yusof

 Comparison of Charpy Test Results

Impact Energy Joules

TECHNOLOGY

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 -20 oC

Copyright © 2003 TWI Ltd Faisal Yusof

 Charpy Impact Test
Reporting results
TECHNOLOGY

 Location and orientation of notch

 Testing temperature and soaking time

 Energy absorbed in joules

 Description of fracture (brittle or ductile)

 Lateral expansion

 Dimensions of specimen

Copyright © 2003 TWI Ltd Faisal Yusof

 Crack Tip Open Displacement
 To determine the fracture toughness or resistance towards crack
TECHNOLOGY

extension.

 CTOD test depends on

 Temperature

 Microstructure

 Loading rate

 Thickness

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Crack Tip Open Displacement

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Crack Tip Open Displacement

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Tensile Test

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Tensile Tests
Different tensile tests include:

 Transverse tensile.

 All-weld metal tensile test

 Cruciform tensile test

 Short tensile test

Copyright © 2003 TWI Ltd Faisal Yusof

 Tensile Tests
Transverse Tensile
TECHNOLOGY

Specimen

All-Weld Metal Tensile

Specimen
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Transverse Tensile 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

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Transverse Tensile 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

Copyright © 2003 TWI Ltd Faisal Yusof
 Transverse Tensile Tests
Reporting results
TECHNOLOGY

 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.

Copyright © 2003 TWI Ltd Faisal Yusof

 All-Weld Metal Tensile
Gauge length
TECHNOLOGY

Object of test

 Ultimate tensile
strength

 Yield strength

 Elongation %
(ductility)

Increased gauge length

Copyright © 2003 TWI Ltd Faisal Yusof
 All-Weld Metal Tensile Tests
Original gauge length = 50mm
TECHNOLOGY

Increased gauge length = 64

Elongation % = Increase of gauge length X 100

Original gauge length

Elongation % = 14 X 100
50

Elongation = 28%

Copyright © 2003 TWI Ltd Faisal Yusof

 All-Weld Metal Tensile Tests
Reporting results
TECHNOLOGY

 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 %

Copyright © 2003 TWI Ltd Faisal Yusof

 Short Tensile Tests
A test for a materials susceptibility to lamellar tearing
TECHNOLOGY

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

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY 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

Copyright © 2003 TWI Ltd Faisal Yusof

 Macro / Micro
Will Reveal
TECHNOLOGY

 Weld soundness
 Distribution of inclusions
 Number of weld passes
 Metallurgical structure of weld, fusion zone
and HAZ
 Location and depth of penetration of weld

Copyright © 2003 TWI Ltd Faisal Yusof

 Macro Micro
 Visual examination for  Visual examination for
defects & grain structure
TECHNOLOGY

defects
 Cut transversely from  Cut transversely from
the weld the weld
 Ground and polished
 Ground and polished
P1200 grit paper
P400 grit paper
 Etched using 2-5%
 Etched using 2 - 5%
nitric acid solution
nitric acid solution  Wash and dry
 Wash and dry
 Visual inspection under
 Visual inspection under 100X-1000X magnification
10 X magnification  Report on results
 Report on results
Copyright © 2003 TWI Ltd Faisal Yusof
 Macro Report
Sample Number MSR-1189
TECHNOLOGY

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
Copyright © 2003 TWI Ltd Faisal Yusof
 Bend Tests
Object of test
TECHNOLOGY

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)
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Plunger Type Bending Jig

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Wrap Around Bending Jig

Copyright © 2003 TWI Ltd Faisal Yusof

 Bend Tests
Former (4t)
TECHNOLOGY

Weld dressed flush Support

Copyright © 2003 TWI Ltd Faisal Yusof

 Bend Tests
Face bend
TECHNOLOGY

Side bend

Root bend

Defect indication Minor ruptures on

Generally this specimen tension surface
would be unacceptable Acceptance depends
upon code
requirements
Copyright © 2003 TWI Ltd Faisal Yusof
 Bend Tests
Reporting results
TECHNOLOGY

 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.

Copyright © 2003 TWI Ltd Faisal Yusof

 Fillet Weld Fracture Test
Object of test
TECHNOLOGY

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
Copyright © 2003 TWI Ltd Faisal Yusof
 Fillet Weld Fracture Test
Hammer
TECHNOLOGY

Hammer
2mm
Notch

2mm
Notch

Fracture should break saw cut

to root

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Fillet Weld Fracture Test

This fracture has occurred

saw cut to root

This fracture indicates lack

of fusion

Copyright © 2003 TWI Ltd Faisal Yusof

 Fillet Weld Fracture Test
Reporting results
TECHNOLOGY

 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

Copyright © 2003 TWI Ltd Faisal Yusof

 Nick Break Test
Object of test
TECHNOLOGY

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

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY Nick Break Test

Former

Excess weld
metal left
intact

Saw cuts

Support

Copyright © 2003 TWI Ltd Faisal Yusof

 Nick Break Test
Reporting results
TECHNOLOGY

 Thickness of parent material

 Width of specimen

 Appearance of joint after fracture

 Depth of penetration

 Defects present on fracture surfaces

Copyright © 2003 TWI Ltd Faisal Yusof

TECHNOLOGY

Any
Any Questions?
Questions?

Copyright © 2003 TWI Ltd Faisal Yusof

 Questions
QU 1. What mechanical properties can be measured in the all-
TECHNOLOGY

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. Macro.

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
Copyright © 2003 TWI Ltd Faisal Yusof