MACRO EXAMINATION

Macro etch testing allows the tester to see a cross section of the weld, and see the
arrangement of the grains in the parent metal and the weld material. This is known as
its Macrostructure. Its can also show up defects such as porosity, inclusions and poor
fusion. You need minimal equipment to perform a macro etch test. Firstly, it involves
cutting a sample from the welded joint. Cold cutting methods are best for this, such
as a bandsaw.

Then the surface needs to be polished. File away any burrs and rough marks, then use
progressively finer grades of emery until a smooth even polish is obtained.

Once prepared, an acid solution is applied with a soft clean cloth, wiping over the
test piece. The acid used is nitric acid, dissolved in distilled water. The solution is
10% Nitric acid, and 90% water. Nitric acid is used because of its rapid oxidising
properties. After a short time, the parent metal and weld areas will begin to discolour.
If it doesn't, it is possible to clean and re-apply the acid solution. If it discolours too
much, it may require re-polishing and reapplication of the acid. Once results are
visible, the sample is rinsed off and carefully dried.

The results should show distinctive colour difference between the actual weld metal
and the parent metal in the immediate area. The weld will show up lighter, and the
darker material next to it is the rearranged grain structure, due to the heating and
cooling cycle. In multiple run welds, the one that is done first shows up slightly
darker, due to the root run being reheated during the second pass.
Macroscopic examination, also called macro test or macro examination, evaluates the
quality and homogeneity of a test sample indicating the flow of material during the
forming or welding process. Information on macrostructural features can be used to
assess internal quality, presence of hydrogen flakes, chemical segregation, hard
cases, flow lines and welds.

STANDARDS/SPECIFICATIONS

ASME Sect. IX
ASTM E340
ASTM E381
MIL Specifications
A common macro test is weld cross section examination to reveal internal
discontinuities, weld profile, weld passes and sequence, extent of penetration and the
quality of weld. The macrostructural properties of a weldament can then be used as a
component of weld procedure qualification or welder qualification.

THE TEST PROCESS

After receipt of the sample, macroscopic examination begins with the cutting,
grinding and etching of the test sample. Etching is a chemical reaction on the surface
of the test sample that allows viewing of the flow properties of the material. The
samples can be ingots, castings, plates, bars, sheets or finished products.
The macro examination is performed on the cross section, longitudinal section or
through the thickness (Z direction) of the test sample. The sample is viewed with
the unaided eye or at low magnification, usually no greater than 10 times.
Macroetch to ASTM E340 is the controlled surface etching of a metal or alloy
sample to reveal a structure such as grain flow lines and ingot patterns that are visible
at the low magnification. Grain flow lines are the resulting fiber pattern observed in a
hot or cold worked material, showing the manner in which the metal flowed during
the forming process.

These examples are magnified samples that shows the grain structure quite clearly. The first is
steel, the second is stainless steel.
 These ones show very high levels of penetration.

Macro photograph of the section A-A' of box square pillar welding which board
thickness is 40 mm

Macro photograph of plates which thickness is 45 mm, where SESNET welding

is applied - Courtesy of Nippon Steel & Sumikin Welding
Macro photograph of plates which thickness is 60 mm

Macro photograph of plates which thickness is 20 mm where NS One-Side MAG

welding is applied
(Courtesy of Nippon Steel & Sumikin Welding)

MICRO EXAMINATION

The microstructural study of a material can provide information regarding the

morphology and distribution of constituent phases as well as the nature and pattern of
certain crystal imperfections. Optical metallography is a basic tool of material
scientists, since the equipment is relatively inexpensive and the images can be
obtained and interpreted easily. Distribution and morphology of the phases can be
studied and, if their properties are known, a quantitative analysis of the micrographs
provides some information about the bulk properties of the specimen. A limited study
of line and surface informations is also possible with the optical microscope. In order
to obtain reproducible results, with good contrast in the image, the specimen surface
is polished and subsequently etched with appropriate reagents before microscopic
examination. In a polished specimen, the etching not only delineates grain
boundaries, but also allows the different phases to be distinguished by differences in
brightness, shape, and color of the grain. Differences in contrast may result from
differences in light absorption characteristics of the phases. Etching results in
preferential attack or preferential colouring of the surface. The preferential attack is
electrochemical corrosion; it is well known that different materials corrode at
different rates.
Grain boundaries are often anodic to the bulk metal in the interior of the grain and so
are etched away preferentially and delineated. Staining is produced by the deposition
of solid etch product on the specimen surface. This is formed by chemical reaction
between the etchant and the specimen. Under favorable conditions the use of a
proper etchant enables the identification of constituents. Failure analysis depends a
great deal on metallographic examination.

A carefully prepared specimen and magnification are needed for microscopic

examination. Proper preparation of the specimen and the materials surface requires
that a rigid step-by-step process be followed. The first step is carefully selecting a
small sample of the material to undergo microstructure analysis with consideration
given to location and orientation. This step is followed by sectioning, mounting,
grinding, polishing and etching to reveal accurate microstructure and content.
Detailed viewing of samples is done with a metallurgical microscope that has a
system of lenses (objectives and eyepiece) so that different magnifications (typically
50X to 1000X) can be achieved. Scanning Electron Microscopes (SEMs) are capable
of much higher magnifications and are utilized for highly detailed microstructural
study.
EFFECTS OF INDUSTRIAL PROCESSES AND TREATMENTS

Industrial processes and treatments such as casting, welding and heat treating are
often applied to metals to prepare them for particular applications or to improve their
characteristics and properties. There may be residual effects of these processes and
treatments such as inclusion or contaminants that can be explained by microstructure
analysis. In many cases, the investigation centers on the correlation between the
resulting microstructure and the material properties.
THE TEST PROCESS

A carefully prepared specimen and magnification are needed for microscopic

examination. Proper preparation of the specimen and the materials surface requires
that a rigid step-by-step process be followed. The first step is carefully selecting a
small sample of the material to undergo microstructure analysis with consideration
given to location and orientation. This step is followed by sectioning, mounting,
grinding, polishing and etching to reveal accurate microstructure and content.
Detailed viewing of samples is done with a metallurgical microscope that has a
system of lenses (objectives and eyepiece) so that different magnifications (typically
50X to 1000X) can be achieved. Scanning Electron Microscopes (SEMs) are capable
of much higher magnifications and are utilized for highly detailed microstructural
study.

Investigation on the influence to micro structure by welding heat

input of IS Z 3212 YGW18 and interpass temperature.
Micro tissue of unaffected area

Micro tissue of reheated area