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Welding Inspection
Mechanical Testing
Course Reference WIS 5
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Mechanical Testing
Destructive testing of welded joints are
usually carried out to:
Approve welding procedures
Approve welders
Production quality control
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Properties of steel
Mechanical properties :
Hardness
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Mechanical Tests
The following mechanical tests have units and are
termed quantitative tests
Tensile tests
Toughness testing (Charpy, Izod)
Hardness tests
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Mechanical Tests
The following mechanical tests have no units and
are termed qualitative tests
Macro testing
Bend testing
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Charpy Specimen
Tensile Specimen
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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
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Hardness Testing
Various Methods
Brinell
Rockwell
Vicker
Knoop
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Diamond
indentor
Adjustable
shutters
Indentation
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3.
4.
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Root radius
0.25mm
2mm
Direction of striker
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Direction of impact
Test specimen
28mm
2mm
10mm
75mm
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22 I/2o
2 mm
10 mm
8 mm
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100% Ductile
Machined
notch
Large reduction
in area, shear
lips
Randomly torn,
dull gray fracture
surface
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Joule
Ductile fracture
200
150
100
50
Brittle fracture
- 40
- 20
20
40
Temperature
Degrees Centigrade
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-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
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Tensile Test
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Tensile Tests
Different tensile tests include:
Transverse tensile.
All-weld metal tensile test
Cruciform tensile test
Short tensile test
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Tensile Tests
Transverse Tensile
Specimen
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220000 N
25mm X 12mm
U.t.s = 733.33 N/mm2
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Object of test
Ultimate tensile
strength
Yield strength
Elongation %
(ductility)
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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
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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
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Macro
Visual examination for
defects
Cut transversely from
the weld
Ground and polished
P400 grit paper
Etched using 2 - 5%
nitric acid solution
Wash and dry
Visual inspection under
10 X magnification
Micro
Visual examination for
defects & grain structure
Cut transversely from
the weld
Ground and polished
P1200 grit paper
Etched using 2-5%
nitric acid solution
Wash and dry
Visual inspection under
100X-1000X magnification
Report on results
Report on results
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Macro Report
Sample Number MSR-1189
1
3
4
2
DEFECT TYPE
1. Lack of sidewall fusion + slag
2. Slag inclusion
3. Lack of sidewall fusion
4. Cap undercut
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DEFECT SIZE
4mm
3.5mm
5.8mm depth
0.6mm
ACCEPT/REJECT
Reject
Reject
Reject
Accept
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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 (Generally for materials above
12mm thickness)
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Bend Tests
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Former (4t)
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Bend Tests
Face bend
Side bend
Root bend
Defect indication
Generally this specimen
would be unacceptable
Minor ruptures on
tension surface
Acceptance depends
upon code
requirements
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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.
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2.
3.
4.
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Hammer
2mm
Notch
2mm
Notch
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2.
3.
Fracture is usually made by striking the
specimen with a single hammer blow
4.
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Former
Excess weld
metal left
intact
Saw cuts
Support
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Width of specimen
Depth of penetration
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Any
Any Questions?
Questions?
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Questions
QU 1. What mechanical properties can be measured in the allweld 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
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