TWI CMT. Destructive/Mechanical Testing: THE WCLDING INSTITUTE Destmuetive and/or mechanical tests are generally carried out to ensure that the required levels of certain mechanical properties have been achieved. When metals have been welded, the mechanical properties of the plates may have changed in the HAZ due to the thermal effects of the welding process. It is also necessary 10 establish that the weld metal itself reaches the minimum specified values, The mechanical properties or material characteristics most commonly evaluated include: Hardness The cbility of a material to resist indentation The opposite of Hard is Soft Toughness The ability of material ta resist fracture under impact loads ‘The opposite of Tough is Brittle Strength ‘The ability of a material to resist a force. (Normally tension} The opposite of Strong is Weak Duetility ‘The ability of @ material ta plastically deform under tension The opposite of Ductile is Un-ductile To camy out these evaluations we require specific tests. There are a number of mechanical tests available to test for these specific mechanical properties the most common of which are: 1) ‘Hardness testing. ers/Brinell/Rockwell) ~ 2) Toughness testing, (Charpy V/izod/CTOD) ‘Used to measure Quantity 3) Tensile testing, (Transverse/A weld metal) ‘Tests 1-3 have units and are termed quantitative tests We use other tests to evaluate the quality of welds 4) Macro testing Bend testing, (Side/FacefRoot) » et » Used to assess 6) Fillet weld fracture testing Quality 7) —_ Butt weld Nick-breaks testing Tests 4-7 have no units and are temed qualitative tests ‘Welding Inspaction of Steels WISS aL SPW wonocet ron Section 04 Mechanical and Destructive Testing TM ieeuonne Rev 09-09-06 Copyright © 2006 TWI Ltd TECHNOLOGYTWI CLM. 1) Hardness tests. (Used to measure the level of hardness across the weld) THE WELDING INSTITUTE Types of hardness test include: 2) Rockwell seale @iamond or steel ball) b) Vickers pyramid. HV (Diamond) ©) Brinell, BEN (S or 10 mm diameter steel ball) €) Shore Schlerescope (Measures resilience) 2ortable § used'ty assess hardnass site Most hardness tests are carried out by (1) impressing a ball. or a diamond into the surface of a material under a fixed loed, (2) then measuring the resultant indentation and comparing it to a scale of units (BHN/HV etc.) relevant to that type of test. Hardness surveys are generally carried out across the weld as shown below. In some applications it may also be required to takes hardness readings at the weld junction/fusion zone. A Shore Schlerescope measures resilience by dropping a weight from a height onta the surface then measuring the height of the rebound. The higher the rebound the higher is the resilience of the material. As resilience in materials may de direetly correlated 10 hardness then the hardness may be read in any or all sets of units. Early equipment was cumbersome, but still far more portable compared to other hardness testing methods available. Equipment is now available which works on the resilience principle and is the size of a ballpoint pen. This form of equipment may be used by the welding inspector to indicate hardiness values on site, and is scaled in all of the common hardness scales. 4 . + a fez at le ‘Welding Inspection of Sicels WIS 42 TW semana von ‘Section 04 Mechanics! and Destructive Testing MATRBIALS OND Rey 09-09-06 Copyright © 2006 TWH Ltd TmcngtoYTH \\E| DING INSTITUTE 2) Toughness tests. (Lisesi io measure resistance to fracture under Smpact Jonding) ‘Types of toughness test include: a) Charpy V. (Joules) Specimen held horizontally in test machine, notch to the reat. b) Izod. (FtIbs) Specimen held vertically in test machine, notch to the front. ©) CTOD or Crack Tip Opening Displacement testing, (mm) ‘There are many factors that affect the toughness of the weldment and weld metal. One of the important effects is that of testing temperature. In the Charpy V and Izod test the toughness is assessed by the amount of impact energy absorbed by a small specimen of 10 mmr during fracture by a swinging hammer. A tempereture transition curve can be produced from the results. The Charpy V test 10x 10 mm specimen Machined notch ‘The notch may be machined either in the Weld metal, Fusion zone or HAZ depending ‘on which area/zone is to be evaluated during the test. The standard notch is 2mm deep, 0.25 mm root radius, and included angle 45 * though other shapes of notches exist ie. “U” with all relevant dimensions given in the standard. A smaller version of this test is also available. i. J Release lever Pendulum locked in position Graduated scale of Joules absorbed energy ‘Notch placed to the rear of the strike Specimen Welding inspection of Steels WIS 5 43 ~ TW] tens comeroe Section 04 Mechanlest and Destructive Testing Og saraunsions Rev 09-09-06 Copyright © 2006 TWI Ld [Link]TWI LLM. A Ductile/Brittle transition curve for a typical C/Mn Structural Steel “Temperature range °C ke THE WEI DING INSTITUTE, Ductile fracture ~ 47 Joules Ductile/Brittle transition point Brittle fracture ~ 28 Joules Energy absorbed (Joules) 40 30 20 -10 oO 10 20 30 Degrees Centigrade The uansition tempereture of welded steels can be affected by many factors including 4) Alloying (Chemical composition) The curve can effectively be moved to the left by additions of manganese of up to 1.6 % maximum as this has a positive effect on improving the toughness of plain ferritic steels at cryogenic temperatures. Nickel also bas a very positive effect on low temperature toughness of steels, however nickel is a very expensive metallic element and is only used were low temperatures are severe. Steels containing 5-9% nickel have excellent low temperature toughness with fully austenitic stainless stcels having measurable toughness down to ~ 270°C. b) Heat input ‘The above curve can effectively be moved to the right by using a high heat input during the welding cycle, where Time at Temperatures spent above the Critical Temperatures of the steel allows grains to grow and fuse together to form larger grains. (Grain Growth) Energy required in fracturing a large or a coarser grained steel is comparatively lower than finer grained steel, hence the need to control heat input and/or limit maximum inter-pass temperatures, A fine grain structure will effectively move the curve to the leit i.e. Increase the relative toughness values of a steel. ©) Chemical cleaning ‘The cleanliness of the weld metal will also greatly affect its level of toughness. Welding fluxes containing high amounts of basic compounds give much higher éoughness & strength weld metal values than welds made using lower amounts of these compounds. ‘Welding, Inspestion of Steely WIS aa aaa Section 04 Mechanical and Destructive Testing asTERIALS YON Rey 09-05-06 Copyright © 2006 TWI Ltd eepicesaTHE WELDING INSTITUTE 3) Tensile Tests. (Used to measure teusile strength and ductility) ‘Types of tensile test: 2) ‘Transverse reduced section Used to measure the tersile strength of the weldment. 5) Longitudinal all weld metal tensile test Used to measure tensile strength, yield point and E% of deposited weld metal. A transverse tensile test specimen prior to testing ‘Test gripping area weld . Plate material Reduced Section Jn a transvéines test failure is generally expected in the base material, though faifure in the weld or HAZ is not reason to fail the test if minkioum specified stress has been met. An all weld metal tensile test is carried out to determine the deposited weld metal strength in N/oum® and weld matal dnctility as elongation (E%). A weld is made in a plate and the tensile spesimen is cut along the length of the weld, which would contain mainly undiluted weld metal. Prior to the test 2 marks are made 50 mm apart along the length of the specimen. As the test is carried out the yield load and fracture load are recorded and dociracnied, After fracture, the pieces are placed back together and the clongation is measured from the original gauge length with the result is given as E% A longitudinal all weld metal tensile test specimen after testing ' Elongation marks * If load at yield was 8,500 N and the CSA Cross Sectional Area was 25 mm” the resultant, calculation of Foree/CSA the yield stress (Re) would be 8,500N/2Smmt" = 340N/mm” The calculation of the tensile stress of the metal can be similarly ealeulated on fracture. E% If the original gauge length was 50mm and the final length on fracture is 61mm this indicates a linear extension of I1mm on the original gauge length «. If 100%/S0mm = 2 2. 2.x Ilmm = 22%E. This is typical value for and C/Mn steal weld metal. Any adition of carbon to steels will reduce its ductility. Occasionally, where insufficient material is available a short transverse test indicating a % reduction in area may be used and calculated as STRA (Short Transverse Reduction ia Arca) i.c. a) mm?~b) mm? %_ ‘This method js often used in assessing steel plates susceptibility to Lamellar Tearing. ‘Welding inopecten of Sela WISS $5 Section 04 Mechanical and Destructive Teatlng fatenac3son0 Rey 09-09-06 Copyright © 2000 1 WI Lid CEM Sesoxoce wort cer: FORTWI VM. 4) Macro examination tests. (Used to assess the internal quality of the weld) THE WELDING INSTITUTE A macro specimen is normally cut from a stop/start position in the root, or hot pass of a welder approval test. The star/stop position is marked out during a welder approval test by the welding inspector. Once ut, the specimen is polished using progressively finer grit papers and polishing at 90° to previous polishing direction, until all the scratches caused by the previous polishing direction have been removed. It is then etched in an acid solution which is normally 5 -10% Nitric acid in alcohol (plain carbon steels). Care must be taken not to under-etch or over-etch as this could mask the elements that can be observed on a correctly etched specimen. After etching for the eorrect time the specimen is then washed in acetone and water, tborougtly dried, and may also be preserved. A visual examination should be carried out at all stages of production to observe any imperfections that are visible. Finally, a report is then produced on the visual findings then compared and assessed to the levels of acceptance in the application standard. Macro samples may be sprayed with clear lacquer after inspection, for storage purposes. Macro of a Butt Welded Butt Joint Macro Assessment Table 1) Excess weld metal height 2) Slag with lack of sidewall fusion 3) Slag with Jack of inter-run fusion 4) Angular misalignment 5) — Root penetration bead height $) Segregation bands 7) Lack of sidewall fusion/UIndercut? ‘A Macrograph is a qualitative method of mechanical testing/examination as it is only weld quality that is being observed in this test. “Welling Inspection of Steels WISS 46 ‘WORLD CENTRE FOR Section 04 Mechanical and Destructive Testing MATERIALS ONG Rev 09-09-06 Copyright © 2006 TW1 Let TeapiorosyLe THE VE DING INSTITUTE 5) Bend tests, (Used to assess weld ductility & fusion in the area under siress) The former is moved through a guide (guided bend test), or rollers, and the specimen is bent to the desired angle. Types of guided bend test include: ) Facebends b) Root bends) Side bends d) Longitudinal bends A guided side bend A clear indication of both lack of sidewall and inter-run fusion Any areas containing a lack of fusion become visible as the stress is applied. This cay also result in tearing of the specimen, caused by local stress concentration, as shown above. Bend tests are carried out for welder approval tests, and procedure approval to establish good sidewall, roat, or weld face/root fusion. Inspection of the test face is made after the bending to cheek the integrity of the area under test. Face, root, side and Jongicudinal tests may be carried out in thickness below 12mm For materials greater than 12mm thickness, a slice of 10-12mm is normally eut out along the length and the ‘material is side bend tested. Bend testing is a qualitative method of mechanical testing/examination as it is only the weld quality that is being observed, (Although ductility is very often observed, it cannot be measured in this test.) ‘Welding Inspection of Seels WIS 5 47 TWI vowcemeron Section 04 Mectianteal and Destructive Testing MATERIALS IONING Rey 09-09-06 Copyright © 2006 TWI Lia EMT exisTHE WELDING INSTITUTE Fillet weld fracture tests, (Used to assess root fusion in fillet welds) AA fillet weld fracture test is normally only carried out during a welder approval test. ‘The specimen is normally cut by hacksaw through the weld face io a depth (usually 1-2 mm) stated in the standard, 114s then held in a vice and fractured with a haminer blow from the rear. Aer fracture has heen made both surfaces are then carefully inspected for imperfections. Finally the vertical plate X is moved through 90° and the line of root fusion is observed for continuity. Any straight Kine would indicate a lack of root fusion. In most standards this is sufficient to fail the welder. Saw cut 1 2 Hammer blow Producing a stress concentration 1 to sid and ease fracture Ling of fusion A Fracture line Cc B xX ’ 1 “Lack of root fusion” After inspection of both fractured surfaces for imperfections, turn fracture picce X through 90° vertically and inspect the line of root fusion, (Line 2) A Fillet weld fracture test is a qualitative method of mechanical testing/examination as it is only the weld quality that is being observed in this test. Welding inspection oF Steels WIS 48 Section 04 Mechanical and Destructive Testing FOND vatncnsne Rev 09-08-06 Copyright © 2006 TWILid VIM cco.Ls TH VVi:1 ING INSTITITE 7; Nick-break tests. (Used to assess toot fusion in double butt welds) Used to assess mot penetration and fusion in double-sided butt welds, and the internal faces of single sided butt welds. A Nick-break test is normally carried out during 4 welder approval test. The specimen is normnally cut by hacksaw through the weld faces 10 a depth stated in the standard. It may then be held in a vice and fractured with a hammer blow fram above, or placed in tension and stressed too fracture. Once fracture has ‘occurred both fracture faces are then tured horizontally through 90° and may then be inspected for imperfections along the fracture faces, as shown below in C. Hammer blow or tensile stress Saw cut Producing, stress cnnrentrations to aid and ease fracture a Lack of root penetration, or fusion Any inclusions on the fracture line A butt mickbreak test is a qualitative method of mechanical testing/examination as only the weld quality is being observed, Welding Inspection of Steels WIS 5 49 \WORLDOENTRE FOR Section 04 Mechanical and Destructive ‘Testing OWE senso Rey 05-09-06 Copyright © 2006 TWI Lad VLA recxxciosyTWI CEM. Quantitative and Qualitative Destructive Testing THE WELDING INSTITUTE. Quantitative ‘We test weldments mechanically to establish the level of various mechanical properties The following types of tests are typical: 1) Hardness Vickers (VPN) —_Brincll (BEEN) Rockwell (Seale € for steels) 2) Toughness Charpy V Goules) Izod (USA) (Ftlbs) CTOD (mm) 3) Tensile Strength ‘Transverse reduced & radius reduced. Longitudinal all weld metal ‘Nimm’ (PSI In the USA) Allthe above tests 1 —3 have units and are thus termed quantitative tests. Ductili Elongation E% or as % Reduction in Area For weld metal this property is generally measured as E% during tensite testing. Quantitative tests are mainly used in welding procedure approvals tests and generally would not be used in a welder approval test, Qualitative We also test weldments mechanicelly to establish the level of quality in he weld. In sucha case we may use the following types of test: 4) Macro testing 5) Bend testing. (Face, Root. Side. & Longitudizal) 6) Fillet weld fracture testing 1) Butt nick-break testing All the above tests 47 have no units and are thus termed qualitative tests. Qualitative tests are mainly used in welder approvals tests though some of the qualitative tests may also be used during welding procedural approval tests i.e. to establish good fusion/penetration ete, Welding Inspection of Steels WIS 5 41D "EWI vomocomeron Section 04 Mechaaieal and Destructive Testing Caer asses Rey 09-09-06 Copyright © 2036 TW LidTWwI MT. Summary of Destructive/Mechanical Testing: THE WELDING INSTITUTE ‘Name of test Properyor — | Qualitative Units Used mainly for Characteristic or I applicable { ____|_sfappticabte_| Quantitative _| Rockwell seale Hardness Quantitative | Seale Cis used | Welding Procedure for Steels tests Vickers pyramid Hardness Quantitative |HV Welding Procedure | tests Brinell Hardness Quantitative | BHN- Welding Procedure tests Shore Schlerescope | Hardness Quantitative | Measures | Assessing Hardness (Through Resilience) of stock materials ‘Charpy V Toughness — | Quantitative | Joules. Welding Procedure Energy absorbed | tests Tod Toughness ~ | Quantitative | Ftlbs. AWS Consumables Energy absorbed | Materials roo "| Notch Ductility | Quantitative | 0.0000mm-+ | Welding Procedure Toughness | Detailed report | tests Transverse Reduced Strength | Quantitative | N/mm? or PSI | Welding Procedure Tensile Ductility. STRA + %STRA tests | All Weld Metal Tensile Strength | Quantitative | N/mm’ or PSI_| Welding Tensile Ductility Elongation % | Consumable tests Radius Reduced Tensile Strength | Quantitative | N/mm® or PSI_ | Welding Procedure Transverse Tensile of weld metal tests Macrograph Visual Qualitative NA ‘Welder Approval No direct units | or Procedure tests Bends Visual Ductility | Qualitative NA Welder Approval Face Root or Side | may be observed No direct units | or Procedure tests Fillet Weld Fracture | Visual Qualitative NA Welder Approval T & Lap Joints No direct units | or Procedure tests Nick Break Test Visual Qualitative NIA Welder Approval Butt Joints No direct units | or Procedure tests Welding Inspection of Steels WISS 4.1 WORLD CENTRE FOR, Section 04 Mechanical and Destructive Testing Rev 09-09-06 Copyright © 2006 WI Ltd MATERIALS ORIN TECHNOLOGYTWI LN 7} | VWVEL ING INSTITUTE WIS 5 Section 4 Exercises: Study the following macrographs and report any observations in the tables given below. Use the levels of acceptance yiven in the Practical Inspection Section to make your assessment; Take actual sizes as measurements for this training exercise only. Weld Details: Welding Process: FIG (141) Root MMA (111) Fill and Cap Material: Stainless Steel Pipe (Argon purged) Welding Position: SG/PE # Imperfection Size Accept/Reject 1 2 — 3_| _—| 3 1 | 5 6 7 8 | _ ae 10 11 | Excess Weld Metal (Weld Face) 12 | Excess Weld Metal (Weld Root) _ Comments: Welding Inspection of Sec WIS S a2 SS Section 04 Mechanical and Destructive Testing TW taocs ene Rey 09-09-06 Coayright © 2006 TWILL CLM rescoTWI ULM. THE WELDING INSTITUTE Weld Detail Welding Process: MMA (111) SMAW Material: C/Mn Structural Steel Plate Welding Position: 3G/PF # Imperfection __—_—'|_—‘Size Accept/Reject 1 { 7 — 3 4 5 = 6 7 8 9 10 11_| Excess Weld Metal (Weld Face) 12_| Excess Weld Metal (Weld Root) Comments: ‘Welding Inspection of Steels WIS 5 413 TW] wousceme son Section 04 Mechanical and Destructive Testing AATENALS IODC ‘Rev 09-09-06 Copyright © 2006 TWH Ltd TECENOLOSYTHE WELDING INSTITUTE Complete the table given below: Name of test Property or Qualitative Units Used mainly for Characteristic or If applicable |_ sf applicable | Quantitative Rockwell seale Hardness Vickers pyramid ‘Quantitative Brinell BHN Shore Assessing Hardness Schlerescope of stock materials Charpy V ‘Joules. Energy absorbed [Izod - a Quantitative | CTOD Notch Ductility ‘Toughness Transverse Quantitative Reduced Tensile All Weld Metal Nimmo PSI Tensile Elongation % Radius Reduced Welding Procedure Transverse Tensile ae Macrograph | NA No direct units Bends Qualitative Face Root or Side Fillet Weld Fracture | Visual T & Lap Joints Nick Break Test Qualitative Butt Joints Welding Inspection of Stes WISS 414 ae Section 04 Mechanical and Destructive Testing MATRIAS JONG Rev 09-09-06 Copyright © 2006 TWI Ltd TENANCY