Welding Inspection Mechanical Testing Course notes section reference 4 GRE Copyright ©2004 Twn Lt Ms Rogere Copyright © 2004 Twa Li MS Rogers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 Copyright © 2004 TW Lis ms Rogers Destructive testing of welded joints are usually carried out to: = Approve welding procedures (BS EN 288) « Approve welders (BS EN 287) = Production quality control Copyrgnt © 2004 Tw" Lis Ms Ropers= Malleability = Can be deformed a = Ductile great deal by * Toughness compression before cracking = Hardness Copy @ 2004 TL ose « Malleability = Can be deformed = Ductile oe considerably by * Toughness tension before it fractures = Hardness Copyright ©2008 TW! Lis Ms.Rogees= Ability to withstand = Malleability = Ductile ge bending without = Toughness fracture = Hardness Copyright © 2008 TW Lid msnogers « Malleability = Measure of the = Ductile resistance of a * Toughness material to indentation = Hardness Copyright © 2008 TW Lia msRogesThe following mechanical tests have units and are termed quantitative tests = Tensile tests = Toughness testing (Charpy, Izod) : = Hardness tests Copyright @ 2008 TW Lis Ms Rovers 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 Copyright © 2004 TWI Lis Ms.RogersCopyright© 2008 TW Li Various Methods = Brinell = Rockwell = Vickers = EquitipTW. eH Hardness Testing Hardness tests * Measurements made by indenting the metal with a penetrator under a known load Determined by Various Methods + Load applied * Brinell * How load is applied + Rockwell * Configuration of + Vickers penetrator Copy © 2008 TW Lia wren a 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 < = 7 Adjustable shutters Indentation Copyright © 2008 TWiLid Ms Rogersalge Ae ATLL = 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 oo, Diamond Ye indentor Adjustable shutters Indentation Ein a Teka ings = 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/mm? = More suitable for on site hardness testing Copyngnt © 2008 TWA Li Us RopereCopyrght © 2004 TW Lis ms Rogers 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 Copyright ©2006 TW Lis Ms RogersRoot radius 0.25mm CCopymant © 2008 Tw Lid Ms.Rogers Direction of impact H Copynght © 2008 TW ts msnegee2a Machined notch zon Fracture surface 100% bright ‘orystalline brittle fracture 8mm 100% Ductile Machined notch Large reduction in area, shear lips Randomly torn, ‘dull gray fracture surface le Trans: Ductile fracture 47 Joules Transition range Ductile/Brittle transition point > - 28 Joules Brittle fracture 1 -50 -40 -30 -20 -10 0 Degrees Centigrade Copyright ©2008 TVA Lia Ms Roger49 53 51 2 3. Average = 51 The test results show the specimens carried out at room temperature absorb more energy than the specimens carried out at -20°C [Copyright © 2008 TW! Lis 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 Copyright© 2004 TWH Lid ms RogersDifferent tensile tests include: = Transverse tensile. = All-weld metal tensile test * Cruciform tensile test = Short tensile test (through thickness test) Copynght © 2008 Tw Lia MsRogers Transverse Tensile Specimen All-Weld Metal Tensile Specimen Copyrght © 2008 TW Let Ma.nogesObject of test: To measure the transverse tensile strength of a butt joint under a static load Beco. Seisienpetatee Reduced section specimen Radius reduced specimen None reduced section specimen Copyright ©2008 TWA Lia N.Rogers 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 Nimm2 ‘Copynght © 2004 TWI tc bsopereReporting results = Type of specimen e.g. reduced section = Whether weld reinforcement is removed = Dimensions of test specimen = The ultimate tensile strength in N/mm’, p.s.i or Mpa = Location of fracture = Location and type of any flaws present if any Copyright ©2008 TW Lie msKogere Object of test = Ultimate tensile strength = Yield strength i= —=In = Elongation % (ductility) Increased gauge length Copjight 2008 TI ws Ropers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% Copyright© 2008 TW Ls .ssRopers Reporting results = Type of specimen e.g. reduced section = Dimensions of test specimen = The u.ts, yield strength in N/mm2, p.s.i or Mpa = Elongation % * Location and type of any flaws present if any Copyrant © 2008 TW Lia Ms.Rovere* ~~ all-Weld Metal Tensile Tests Reporting results Type of specimen e.g. reduced section ® Dimensions of test specimen The u.t.s, yield strength in N/mm¢, p.s.i or Mpa Elongation % Location and type of any flaws present if any Copytight@ 2008 TWI Lis MeRogers oy 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 Copyight @ 2008 TN Lis wsoges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 ona welders approval test Copyngh © 2004 TWilts Ms Rogers 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 * Fillet weld leg and throat dimensions Copyright © 2008 TWA Lia ms Rogeeeaoe *Visual examination for defects *Cut transverse from the weld «Ground & polished P400 grit paper *Acid etch using 5-10% nitric acid solution "Wash and dry *Visual evaluation under 5x magnification «Report on results Copyright @ 2008 TW! Lid Visual examination for defects & grain structure Cut transverse from a weld *Ground & polished P1200 grit paper, 1pm paste «Acid etch using 1-5% nitric acid solution *Wash and dry «Visual evaluation under 100-1000x magnification *Report on results DEFECT TYPE 41. Lack of sidewall fusion + slag 2. Slag inclusion 3. Lack of sidewall fusion 4. Cap undercut Copyngnt © 2004 TW Lid DEFECT SIZE ACCEPT/REJECT 4mm Reject 3.5mm Reject 5.8mm depth Reject 0.6mm Accept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 Face bend Root bend Side bend Side bend tests are normally carried oul on welds aver 12mm in thickness Cenyrght ©2008 TW Lit msogere Copyright 2008 TW Lia MsnogeDefect indication Generally this specimen would be unacceptable Copyright © 2008 Ti Lid Ms Rogers Reporting results = Thickness and dimensions of specimen * Direction of bend (root, face or side) = Angle of bend (90°, 120°, 180°) = Diameter of former. (typical 4T) = Appearance of joint after bending e.g. type and location of any flaws. Conyright © 2004 TW Le Ne Roges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. Asaw 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 Fracture should break saw cut to root Copyright ©2008 TVA Lia MsRooereThis fracture has occurred saw Cut to root This fracture indicates lack of fusion Copyright © 2004 TW Lie ms.nogess 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 Copyright ©2004 TW Lic Ms.Rogere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 Copyight © 2004 TI Lts MSRooe Weld reinforcement may or may not be removed Alternative nick-break test specimen, notch applied all way around the specimen Copy © 2004 TWILis Me Rogersi] 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 Copyright ©2004 TW Lid Ms Rogere Any Questions Copyngnn © 2006 TW Les Ms RopersMechanical Testing 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 Copyright © 2004 TW Lis MsRooes