WIS10 M.Test

SWI 3.
Senior Welding Inspection

Mechanical Testing
Course Reference WIS 10
Copyright © 2003 TWI Ltd M.S.Rogers
SWI 3.2
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
SWI 3.2
Mechanical Testing
Destructive testing of welded joints are
usually carried out to:
 Approve welding procedures

 Approve welders
 Production quality control

SWI 3.2
Mechanical Tests
The following mechanical tests have units and are
termed quantitative tests
 Tensile tests
 Toughness testing (Charpy, Izod)
 Hardness tests

SWI 3.2
Mechanical Tests
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

SWI 3.2
Definitions
 Malleability  Can be deformed a

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

SWI 3.2
Definitions
 Malleability  Can be deformed

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

SWI 3.2
Definitions
 Malleability  Ability to withstand

 Ductile bending without
 Toughness fracture
 Hardness

SWI 3.2
Definitions
 Malleability  Measure of the

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

SWI 3.2
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

SWI 3.2
Bend Tests
Former (4t)
Weld dressed flush Support
Root bend Face bend

SWI 3.2
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
SWI 3.2
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.

SWI 3.2
Bend Tests
Different tensile tests include:
 Transverse tensile.
 All-weld metal tensile test
 Cruciform tensile test
 Short tensile test

SWI 3.2
Tensile Tests
Transverse Tensile
Specimen
All-Weld Metal Tensile

Specimen
SWI 3.2
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

SWI 3.2
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

SWI 3.2

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

SWI 3.2

Gauge length
Object of test
 Ultimate tensile
strength
 Yield strength
 Elongation %
(ductility)
Increased gauge length

SWI 3.2

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%

SWI 3.2

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

SWI 3.2
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

SWI 3.2
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
SWI 3.2
Charpy Impact Test

Direction of striker
45o
Root radius
0.25mm
2mm
10
10
55
SWI 3.2
Izod Impact Test

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

SWI 3.2
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

SWI 3.2
Comparison of 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
SWI 3.2
Ductile/Brittle 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

SWI 3.2
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

SWI 3.2
Fillet Weld 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
SWI 3.2

Hammer
Hammer
2mm
Notch
2mm
Notch
Fracture should break saw cut

to root

SWI 3.2
This fracture has occurred

saw cut to root
This fracture indicates lack

of fusion

SWI 3.2

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

SWI 3.2
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

SWI 3.2
Nick-Break Test 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

SWI 3.2
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

SWI 3.2
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

SWI 3.2
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
 Measure the leg length and throat thickness
SWI 3.2
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

P1200 grit paper
P400 grit paper
 Etched using 1-5%
 Etched using 10-15% nitric acid solution
nitric acid solution
 Wash and dry
 Wash and dry
 Visual inspection under
 Visual inspection under 100X-1000X magnification
5X magnification  Report on results
 Report on results
SWI 3.2
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
SWI 3.2
Hardness Testing
Various Methods
 Brinell
 Rockwell
 Vickers
 Equo tip
SWI 3.2
Vickers Hardness 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

SWI 3.2
Brinell Hardness 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

SWI 3.2
Equo Tip Hardness Testing

SWI 3.2
Any Questions

M.S.Rogers
SWI 3.2

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

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SWI 3.

Senior Welding Inspection

 Approve welding procedures

Copyright © 2003 TWI Ltd M.S.Rogers

 Toughness testing (Charpy, Izod)

Copyright © 2003 TWI Ltd M.S.Rogers

 Fillet weld fracture testing

 Butt weld nick-break testing

Copyright © 2003 TWI Ltd M.S.Rogers

 Malleability  Can be deformed a

Copyright © 2003 TWI Ltd M.S.Rogers

 Malleability  Can be deformed

Copyright © 2003 TWI Ltd M.S.Rogers

 Malleability  Ability to withstand

Copyright © 2003 TWI Ltd M.S.Rogers

 Malleability  Measure of the

Copyright © 2003 TWI Ltd M.S.Rogers

To determine the soundness of the weld zone.

Copyright © 2003 TWI Ltd M.S.Rogers

Weld dressed flush Support

Root bend Face bend

Copyright © 2003 TWI Ltd M.S.Rogers

Defect indication Minor ruptures on

 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

Copyright © 2003 TWI Ltd M.S.Rogers

 All-weld metal tensile test

 Cruciform tensile test

 Short tensile test

Copyright © 2003 TWI Ltd M.S.Rogers

All-Weld Metal Tensile

Transverse Tensile Tests

Weld metal area

Reduced section specimen

Radius reduced specimen

None reduced section specimen

Copyright © 2003 TWI Ltd M.S.Rogers

Transverse Tensile Tests

Maximum load applied = 220 kN.

U.t.s. = Maximum load applied

U.t.s = 733.33 N/mm2

Transverse Tensile Tests

 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

All-Weld Metal Tensile

Increased gauge length

All-Weld Metal Tensile

Elongation % = Increase of gauge length X 100

Copyright © 2003 TWI Ltd M.S.Rogers

All-Weld Metal Tensile

 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 M.S.Rogers

Short Tensile Tests

Friction Welded Caps

The results are given as a STRA value

Copyright © 2003 TWI Ltd M.S.Rogers

Charpy Impact Test

Charpy Impact Test