Quiz

What is the main difference between destructive

DBT 204 test and nondestructive test?
Technology of Metal Welding I
Destructive Test

2
Azmi Kamardin
2015-2016 S01

Destructive Tests Tensile Test

To measure quality, strength, ductility,
toughness & hardness of welded joints.

Materials preparation, welding cutting,
machining, test, interpretation  expensive!

Welding process, filler metals, welding technique
 fabrication codes

Standard sizes, shapes, specific test
 standard requirements.

Tensile, shear, bend, hardness, toughness &
break tests.
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Measure the effects of a tensile force.

Universal Testing Machine (UTM) apply loads in
tension & compression.

Load is applied hydraulically or by means of a
screw & gears.

The specimen is hold inside the UTM by using
mechanical grippers.
Tensile Test Tensile Test

GOTECH GT-7001 50kN 5 INSTRON 5569 5kN 6

Tensile Test Tensile Test

Specimen should conform to specific dimensions

The reduced area contains only weld metal.

The transition from ends of specimen to reduced
section is shouldered or made with a fillet
 minimize stress concentration.

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Tensile Test Tensile Test

Data recorded from tensile tests are max load,
tensile strength, failure location, %elongation &
%reduction of area.

Quantitative test results can be used in the
design of welded structure.

Fracture surface appearance at the failure
location provided information on the presence
and/or effects of discontinuities such as
incomplete fusion, incomplete penetration,
porosity, inclusions & cracking.

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Tensile Test Tensile Test

Tensile specimen are usually dog-bone shape
 test specimen fail at narrow central portion

Specimens have a round or rectangular cross
section.

The shape of the specimen-ends is determined
by gripping device that is used.

Round  plain, shouldered or threaded

Rectangular  plain or pin

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Tensile Test
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Tensile Test

A proportional limit: max
stress is to strain.

B elastic limit: max stress
at which specimen will
return to initial length when
load is removed.

Beyond B, strain is
permanent plastic strain.
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Tensile Test

Extensometer is fitted to the
specimen across its gauge
length to measure the
elongation of the specimen.

Specimen is stretched to
failure at steady rate
0.05-0.5.

ASTM E8: Tensile Testing
of Metallic Materials.

Stress-strain curve is plotted
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Tensile Test

C yield point: strain
increases without stress
increases.

Yield point behavior leads
to Luders bands (ripples)
- only exhibited by low &
medium carbon steels.

Curve fall between C-D
plastic strain.

E lowest yield point before
curving upward. 16
Tensile Test Tensile Test

F ultimate tensile strength:
The differences between stress-strain curve of

max stress (load) a metal low-medium carbon steels and other metals.
can withstand.

Neck down between F-G

G point of failure: Fracture
occurs.

Brittle materials fail between
point E-F

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Tensile Test Tensile Test

%elongation can be calculated by fitting both
%reduction in area of a round specimen is given
broken ends and measure the new gauge length by:

Indicate the amount of plastic deformation prior
to fracture. %RA = Di - Df x 100
Di
%E = Lf Li x 100
Li Di = initial diameter
Df = final diameter
Lf = final gauge length
Li = initial gauge length 19 20
Tensile Test Shear Test

Failure location region of the specimen at
Determine the shear strength of fillet welds,
which final failure occurs. brazed joints & spot welds.

3 categories: base metal, HAZ or weld
Materials separate parallel to load

Fabrication code &
Acceptable shear strength ~ 60% of tensile
standard require failure strength of base metal.
location to be in the
Types: tension shear test & peel test
base metal.

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Shear Test Shear Test

Tension shear test:
Brazed joint tension shear test:

Specimen is pulled to failure under tensile
Fillet welded, brazed joint & spot welded
 Shear strength is calculated from load at
failure
 Brazed joint & spot-weld tension shear tests
Strength of filler metal in brazed joint
Two 1/8 thick specimens joined by brazing
with a filler metal
Shear strength = tensile load at failure /
brazed area.

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Shear Test Shear Test

Spot-weld tension shear test:
Peel test:

Determine strength of arc welds & spot welds.
Suitable for thin & low
strength base metal.
Specimen is made of overlapping materials.

Inexpensive alternative
to the spot-weld tension
2 mm 4 mm
shear test.
50 mm

30 mm

100 mm Spot welded

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Bend Test Bend Test

Determine the ductility of a weld by bending a
Guided bend test:

welded specimen around a standardized
mandrel.

Provide info on the plastic deformation capability
of a welded joint.

Plastic deformation capability is shown through
the ability of the weld to resist tearing.

May reveal discontinuities on the surface &
expose incomplete fusion and delamination.

Guided & Wraparound guided bend tests.
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Rectangular specimen is bent into a U-shape.
Most commonly used ductility test for groove
welds, surface welds and fillet welds.
Test fixtures can be bottom guided or bottom
ejecting.
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Bend Test Bend Test

Guided bend test:
Guided bend test:

Bottom guided bend fixture is designed to
Bottom ejecting bend fixture allows the specimen to
support the specimen in the die as it is bent. be ejected from the die after it is bent.

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Bend Test Hardness Test

Wraparound Guided bend test:
Determine the resistance of a material against

Specimen is bent around a stationary indentation or scratches.
mandrel.
Less commonly used to test welds because the
critical HAZ area requires special preparation.

Do not provide adequate information on the
physical quality of the weld as compared to other
tests.

Provide info on metallurgical changes caused by
welding, i.e. high hardness value on HAZ might
indicate insufficient preheating or postheating.
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Hardness Test Hardness Test

Provide bulk properties of the metal thru Brinell,
Brinell hardness test:
Rockwell and Vickers tests. Determine hardness of base metal

Provide info on the weld and HAZ of the metal
thru microhardness test.

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Hardness Test Hardness Test

Brinell hardness test:
Rockwell hardness test:

test lever

10 mm hardened steel ball

Deepest & widest indentation

Provide average hardness value

Not suitable for thin metal

Soft aluminum cast anvil holder screw

- 500 kg load
electronic unit

Hard ferrous metal (display &
handwheel
programming
(to regulate rising
- 3000 kg load keyboard)
screw)

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Hardness Test Hardness Test

Rockwell hardness test:
Vickers hardness test:

1/16 steel ball & 120-diamond cone

Minor load of 10 kg

Major load 60-150 kg

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Hardness Test Hardness Test

Vickers hardness test:
Microhardness hardness test:

136 degree square-base diamond cone

Applied load 1-120 kg

Accuracy depends on the specimen surface
finishing

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Hardness Test Hardness Test

Microhardness test:

Light load < 200g

Polished surface is required

A series of regularly spaced indentations across the
base metal, HAZ and weld metal.

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Toughness Test Toughness Test

Measure the ability of
A dynamic test: metal is broken by a single blow

material to absorb
Energy is measured in foot-pound (ft-Ib)
energy at high strain
Compare the toughness of weld & base metal
rates and deform
plastically rather than
Charpy V-notch test, plain-strain fracture
fracture in a brittle toughness test & nil-ductility transition
manner temperature test

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Toughness Test Toughness Test

Charpy V-notch test:

Square-shaped bar with a V-notch
Universal pendulum impact tester
Tough material absorbs high energy
- short travel distance
Brittle material absorbs low energy
- long travel distance

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Toughness Test Toughness Test

Plain-strain fracture toughness test
Measure the resistance of metals to brittle
fracture propagation in the presence of stress
raiser such as weld defects.
Determine the allowable internal size of
discontinuity that might lead to a catastrophic
failure
Pressure vessels, storage tanks, airplanes &
ships

Nil ductility transition (NDT) temperature test
Measure the temp at which the fracture
behavior of a metal changes from ductile to
brittle in the presence of a stress raiser.
Carbon & low alloy steels show sharp
transition in toughness when temperature
decreases cold weather.

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Toughness Test Break Test

Drop weight test
Rapid & convenient method of evaluating certain

A weld bead is laid down
as the center of the plate

The plate is brought to
test temperature

Drop weight & cause plate
to bend

Below NDT temp, plate
breaks in two
types of welds.

Nick-break test:
Cutting a small notch in the weld specimen
Break it with a hammer blow
Check fracture surface for porosity, slag
inclusions, overlaps, etc
Used primarily in the pipeline industry

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Break Test Break Test

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Break Test

Fillet weld break test:

Specimen is tested with the
weld root in tension.

Qualify tack welding

The specimen is pressed
and bent to produce fracture
at or neat the weld.

Fracture surface is
examined for evidence of
incomplete fusion or
porosity

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