CSWIP 3.

1 Welding Inspection

Destructive Testing
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 Destructive testing Objective

When this presentation has been completed

you should be able to recognise a wide
range of mechanical tests and their purpose.
You should also be able to make
calculations using formulae and tables to
determine various values of strength,
toughness, hardness and ductility.

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 Destructive Testing Definitions

What is Destructive Testing ?

The destruction of a welded
unit or by cutting out selected
specimens from the weld is
carried out to check the
mechanical properties of the
joint materials. They can be
produced to:

• Approve welding procedures (BS EN 15614).

• Approve welders (BS EN 287).
• Production quality control.
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 Destructive Tests

3 x Toughness
Destructive tests include: (Charpy V
notch)
• Bend test.
• Impact test. 2 x Ductile (Bend
• Tensile test. test)

• Hardness test.
• Macro/micro examination. 2 x Strength
(transverse
tensile)

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 Qualitative and Quantitative Tests

The following mechanical tests have units and are termed

quantitative tests to measure mechanical properties of the
joint.
• Tensile tests (transverse welded joint, all weld metal).
• Toughness testing (Charpy, Izod, CTOD).
• Hardness tests (Brinell, Rockwell, Vickers).

The following mechanical tests have no units and are

termed qualitative tests for assessing weld quality.
• Macro testing.
• Bend testing.
• Fillet weld fracture testing.
• Butt weld nick-break testing.

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 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Ductility Ability of a material undergo

plastic deformation under static
• Toughness tensile loading without rupture.
• Hardness Measurable elongation and
reduction in cross section area
• Tensile Strength

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 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Ductility Ability of a material to withstand

bending or the application of
• Toughness shear stresses by impact
• Hardness loading without fracture.
• Tensile Strength

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 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Ductility Measurement of a materials

surface resistance to
• Toughness indentation from another
• Hardness material by static load
• Tensile Strength

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 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Ductility Measurement of the maximum

force required to fracture a
• Toughness materials bar of unit cross-
• Hardness sectional area in tension
• Tensile Strength

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 Mechanical Test Samples

Tensile Specimens
CTOD Specimen

Bend Test

Specimen

Charpy Specimen
Fracture Fillet
Specimen
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 Destructive Testing
Welding Procedure Qualification Testing
Top of fixed pipe
2 Typical positions for test pieces
Specimen type position

• Macro + hardness. 5
3
• Transverse tensile. 2, 4
• Bend tests. 2, 4
• Charpy impact tests. 3
• Additional tests. 3
4
5
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Mechanical Testing

Hardness Testing

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 Hardness Testing

Definition
• Measurement of resistance of a material against
penetration of an indenter under a constant load.
• There is a direct correlation between UTS and hardness.

Hardness tests:
• Brinell.
• Vickers.
• Rockwell.

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 Hardness Testing

Objectives:
• Measuring hardness in different areas of a welded joint.
• Assessing resistance toward brittle fracture, cold
cracking and corrosion sensitivity.

Information to be supplied on the test report:

• Material type.
• Location of indentation.
• Type of hardness test and load applied on the indenter.
• Hardness value.

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 Hardness Testing
Usually the
hardest region
1.5 to 3mm
Fusion
line HAZ

Hardness test methods Typical designations

• Vickers 240 HV10
• Rockwell Rc 22
• Brinell 200 BHN-W

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 Vickers Hardness Test

Typical location of the indentations

Butt weld from one side only

Butt weld from both side

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 Vickers Hardness Test
Vickers hardness tests:
• Indentation body is a square based diamond pyramid (136º
included angle).
• The average diagonal (d) of the impression is converted to a
hardness number from a table.
• It is measured in HV5, HV10 or HV025.
Adjustable
Diamond Indentation shutters
indentor

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Vickers Hardness Test Machine

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 Brinell Hardness Test
• 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.

30KN

Ø=10mm
steel ball

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 Rockwell Hardness Test

Rockwell B Rockwell C
1KN
1.5KN

Ø=1.6mm 120°Diamond
steel ball Cone

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 Portable Hardness Test

• Dynamic and very portable hardness test.

• Accuracy depends on the the condition of the test/support
surfaces and the support of the test piece during the test.
• For more details, see ASTM E448.

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Mechanical Testing

Impact Testing

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 Charpy V-Notch Impact Test

Weld metal Fusion Line (FL) FL+2mm FL+5mm Parent material

Objectives:
• Measuring impact strength in different weld joint areas.
• Assessing resistance toward brittle fracture.
Information to be supplied on the test report:
• Material type.
• Notch type.
• Specimen size.
• Test temperature.
• Notch location.
• Impact Strength Value.
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Charpy V-Notch Impact Test

Pendulum
Specimen (striker)

Anvil (support)

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Charpy V-Notch Impact Test Specimen

Specimen dimensions according ASTM E23

ASTM: American Society of Testing Materials.

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 Charpy Impact Test
10 mm
22.5° 2 mm 100% Brittle
Machined notch.
8 mm

Fracture surface
100% bright
crystalline brittle
fracture.

100% Ductile
Machined notch.

Large reduction in
area, shear lips.
Randomly torn,
dull gray fracture
surface.

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 Ductile/Brittle Transition Curve
Temperature range Ductile fracture
Mn < 1.6 % increases
toughness in steels,
and lower energy 47 Joules
input used.

Transition range Ductile/Brittle

transition point

28 Joules

Brittle fracture Energy absorbed

- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees Centigrade
Three specimens are normally tested at each temperature
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Comparison Charpy Impact Test Results
Impact Energy Joules

Room Temperature -20oC Temperature

1. 197 Joules 1. 49 Joules

2. 191 Joules 2. 53 Joules
3. 186 Joules 3. 51 Joules

Average = 191 Joules Average = 51 Joules

The test results show the specimens carried out at room

temperature absorb more energy than the specimens carried out
at -20oC.
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 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.

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Mechanical Testing

Tensile Testing

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Tensile Testing

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UTS Tensile test

Rm

ReH
ReL

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Tensile Tests

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 Tensile Test
Rp 0.2% - Proof stress. Refers to materials which
do not have a defined yielding such as aluminium
and some steels.

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 Tensile Tests

Different tensile tests:

• Transverse tensile.
• All-weld metal tensile test.
• Cruciform tensile test.
• Short tensile test (through thickness test).

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 Tensile Test

All-Weld Metal Tensile

Specimen

Transverse Tensile
Specimen

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 Transverse Joint Tensile Test

Objective:
Measuring the overall strength of the weld joint.
Information to be supplied on the test report:
• Material type.
• Specimen type
• Specimen size (see QW-462.1).
• UTS.
• Location of final rupture.
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 Transverse Joint Tensile Test

Weld on plate

Multiple cross joint specimens

Weld on pipe
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 Transverse Tensile Test

Maximum load applied = 220 kN

Cross sectional area = 25 mm X 12 mm

Maximum load applied

UTS = csa

UTS = 220 000

25mm X 12mm

UTS = 733.33 N/mm2

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 Transverse Tensile Test

Reporting results:

• Type of specimen eg reduced section.

• Whether weld reinforcement is removed.
• Dimensions of test specimen.
• The ultimate tensile strength in N/mm2, psi or Mpa.
• Location of fracture.
• Location and type of any flaws present if any.

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 All Weld Metal Tensile Test

BS 709 / BS EN 10002
All Weld Metal Tensile Testing
Direction of the test *

Tensile test piece cut along weld specimen.

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 All-Weld Metal Tensile Test

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%

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 All-Weld Metal Tensile Test

Gauge length

Object of test:
• Ultimate tensile strength.

• Yield strength.

• Elongation %(ductility).

Increased gauge length

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 All-Weld Metal Tensile Test
2 marks are made
Gauge length 50mm

During the test, yield and tensile strength are recorded

The specimen is joined and the marks are re-measured

Force Applied

Increased gauge length 75mm

A measurement of 75mm will give Elongation of 50%.

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 All-Weld Metal Tensile Test

2 marks are made

Gauge length 50mm

During the test, Yield & Tensile strength are recorded

The specimen is joined and the marks are re-measured

Increased gauge length 75mm

A measurement of 75mm will give Elongation of 50%.
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 All Weld Metal Tensile Test

Reporting results:
• Type of specimen eg reduced section.
• Dimensions of test specimen.
• The uts, yield strength in N/mm2, psi or Mpa.
• Elongation %.
• Location and type of any flaws present if any.

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STRA (Short Transverse Reduction Area)

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STRA Test

Original CSA

Reduced CSA

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 UTS Calculation
A welded sample has undergone a transverse tensile test. The
specimen before testing 120mm long, and after testing had a length
150 mm the maximum load applied was 140 Kn. The cross
sectional area before testing was10 mm in depth and 40 mm in
width.

Please calculate the elongation % and UTS.

Change in length (150 – 120) = 30

Original length
= 0.25 x 100 = 25%
120

Load 140 Kn 14,000 n

= 350 n/mm²
CSA 10 x 40 400
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 STRA Test

Probable freedom from

tearing in any joint type

Some risk in highly restrained

20 joints eg node joint, joints
between sub-fabs
STRA %
Some risk in moderately
Reduction 15 restrained joints eg box
of CSA columns

Some risk in lightly restrained

10
joints T-joints eg I-beams

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 Mechanical Testing

Macro/Micro Examination

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 Macro Preparation

Purpose
To examine the weld cross-section to give assurance that:
• The weld has been made in accordance with the WPS.
• The weld is free from defects.

Specimen Preparation
• Full thickness slice taken from the weld (typically ~10mm thick).
• Width of slice sufficient to show all the weld and HAZ on both
sides plus some unaffected base material.
• One face ground to a progressively fine finish (grit sizes 120 to ~
400).
• Prepared face heavily etched to show all weld runs & all HAZ.
• Prepared face examined at up to x10 (& usually photographed for
records).
• Prepared face may also be used for a hardness survey.
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 Micro Preparation
Purpose
To examine a particular region of the weld or HAZ in order to:
• To examine the microstructure.
• Identify the nature of a crack or other imperfection.

Specimen Preparation
• A small piece is cut from the region of interest (typically up to ~
20mm x 20mm).
• The piece is mounted in plastic mould and the surface of interest
prepared by progressive grinding (to grit size 600 or 800).
• Surface polished on diamond impregnated cloths to a mirror finish
• Prepared face may be examined in as-polished condition and then
lightly etched.
• Prepared face examined under the microscope at up to ~ 100 –
1000X.

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 Macro/Micro Examination

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 Examination

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.

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 Macro Micro

• Visual examination for • Visual examination for defects

defects. and grain structure.
• Cut transverse from the weld. • Cut transverse from a weld.
• Ground and polished P400 • Ground and polished P1200
grit paper. grit paper, 1µm paste.
• Acid etch using 5-10% nitric • Acid etch using 1-5% nitric
acid solution. acid solution.
• Wash and dry. • Wash and dry.
• Visual evaluation under 5x • Visual evaluation under 100-
magnification. 1000x magnification.
• Report on results. • Report on results.

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 Metallographic Examination

Macro examination Micro examination

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 Metallographic Examination

Objectives:
• Detecting weld defects (macro).
• Measuring grain size (micro).
• Detecting brittle structures, precipitates, etc.
• Assessing resistance toward brittle fracture, cold cracking and
corrosion sensitivity.
Information to be supplied on the test report:
• Material type.
• Etching solution.
• Magnification.
• Grain size.
• Location of examined area.
• Weld imperfections (macro).
• Phase, constituents, precipitates (micro).

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Mechanical Testing

Bend Testing

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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:

Root bend Face bend Side bend

Side bend tests are normally carried out on welds over 12mm in thickness.

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 Bending Test
Types of bend test for welds
(acc BS EN 910):

Root/face
t up to 12 mm
bend

Thickness of material - t

t over 12 mm Side bend

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 Bending Test Methods

Guided bend test Wrap around bend test

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 Bend Testing

Face bend Side bend Root bend

Defect indication Acceptance for

Generally this minor ruptures on
specimen would tension surface
be unacceptable. 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 eg type and
location of any flaws.

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Bend Testing

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 Mechanical Testing

Fillet Weld Fracture Testing

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 Fillet Weld Fracture Tests

Object of test:
• To break open the joint through the weld to permit
examination of the fracture surfaces.
• Specimens are cut to the required length.
• A saw cut approximately 2mm in depth is applied along
the fillet welds length.
• Fracture is usually made by striking the specimen with a
single hammer blow.
• Visual inspection for defects.

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 Fillet Weld Fracture Tests

Hammer

2mm
Notch

Fracture should break weld saw cut to root

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 Fillet Weld Fracture Tests

This fracture indicates This fracture has

lack of fusion occurred saw cut to root

Lack of penetration
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 Hammer

2mm
Notch

Fracture should break weld saw cut to root

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 Hammer

This fracture indicates

lack of fusion
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 Fillet Weld Fracture Tests

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.

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Mechanical Testing

Nick-Break Testing

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 Nick-Break Test

Object of test:
• To permit evaluation of any weld defects across the
fracture surface of a butt weld.
• Specimens are cut transverse to the weld.
• A saw cut approximately 2mm in depth is applied along
the welds root and cap.
• Fracture is usually made by striking the specimen with
a single hammer blow.
• Visual inspection for defects.

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 Nick-Break Test

Notch cut by hacksaw

3 mm
19 mm

3 mm
Approximately 230 mm

Weld reinforcement
may or may not be
removed

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 Nick Break Test

Alternative nick-break test

specimen, notch applied all
way around the specimen

Lack of root Inclusions on fracture

penetration or fusion line
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 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.

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 Summary of Mechanical Testing

We test welds to establish minimum levels of mechanical

properties, and soundness of the welded joint

We divide tests into qualitative and quantitative methods:

Quantitative: (Have units) Qualitative: (Have no units)

Hardness (VPN & BHN) Macro tests
Toughness (Joules & ft.lbs) Bend tests
Strength (N/mm2 & PSI, MPa) Fillet weld fracture tests
Ductility/Elongation (E%) Butt Nick break tests

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 Hydrostatic Test

Under pressure leakage proof test

Vessel configuration:
• The test should be done after any stress relief.
• Components that will not stand the pressure test (eg
flexible pipes, diaphragms) must be removed.
• The ambient temperature MUST be above 0°C
(preferably 15-20°C).

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 Hydrostatic Test

Test procedure:
• Blank off all openings with solid flanges.
• Use correct nuts and bolts, NOT G clamps.
• Two pressure gauges on independent tapping points
should be used.
• For safety purposes bleed all the air out.
• pumping should be done slowly (no dynamic pressure
stresses).
• Test pressure - see relevant standards (PD 5500, ASME
VIII). Usually 150% design pressure.
• Hold the pressure for minimum 30 minutes.

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 Hydrostatic Test

What to look for:

• Leaks (check particularly around seams and nozzle
welds)!
• Dry off any condensation.
• Watch the gauges for pressure drop.
• Check for distortion of flange faces, etc.

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 Mechanical Testing

Any Questions

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