CSWIP 3.

1 Welding Inspection

Destructive Testing
TWI Training & Examination
Services

Course Reference WIS 5

Course notes section reference 4.0
 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
Destructive Tests

Destructive tests include:

•bend test •hardness test
•impact test •metallographic examination
•tensile test
Quantitative and Qualitative Tests
Quantitative Tests:
For measuring a ‘quantity’ ( a mechanical property )
• Mechanical tests - tensile test
- hardness test
- Charpy V-notch test (& CTOD)

Qualitative Tests:
For assessing joint ‘quality’ (good fusion & free from defects)
• Qualitative tests - bend tests
- macro examination
- fillet fracture & nick-break tests
Qualitative and Quantitative Tests
The following mechanical tests have units and are termed
quantitative tests to measure Mechanical Properties
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 joint quality
Macro testing
Bend testing
Fillet weld fracture testing
Butt weld nick-break testing
Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to withstand

deformation under static
• Ductility compressive loading without
• Toughness rupture
• Hardness
• Tensile Strength
Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material undergo

plastic deformation under static
• Ductility tensile loading without rupture.
• Toughness Measurable elongation and
reduction in cross section area
• Hardness
• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to withstand

bending or the application of
• Ductility shear stresses by impact
• Toughness loading without fracture.
• Hardness
• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of a materials

surface resistance to
• Ductility indentation from another
• Toughness material by static load
• Hardness
• Tensile Strength
 Definitions
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of the maximum

force required to fracture a
• Ductility materials bar of unit cross-
• Toughness sectional area in tension
• Hardness
• Tensile Strength
 Mechanical Test Samples
Tensile Specimens
CTOD Specimen

Bend Test
Specimen

Charpy Specimen
Fracture Fillet
Specimen
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

4 •Additional Tests 3
5
Mechanical Testing

Hardness Testing
 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
 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
 Hardness Testing
usually the hardest region
1.5 to 3mm
fusion line
or
fusion HAZ
boundary

Hardness Test Methods Typical Designations

Vickers 240 HV10
Rockwell Rc 22
Brinell 200 BHN-W
Vickers Hardness Test
Typical location of the indentations

Butt weld from one side only

Butt weld from both side

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
Vickers Hardness Test Machine
 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
Rockwell Hardness Test
Rockwell B Rockwell C
1KN
1.5KN

Ø=1.6mm 120°Diamond
steel ball Cone
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
 Portable Hardness Test
Typical Impact Device
Impact Body

Coil

Magnet

Tungsten
Carbide Ball
 Portable Hardness Test
Typical Impact Device
The speeds are measured
before and after impact by
The impact body is means of a magnet passing
projected down into the through a coil which generates
materials surface by an inductive voltage which is
spring force at a defined proportional to speed a signal
speed. can be then shown before and
after impact and converted to
The impact creates plastic an hardness value
deformation at the surface,
the impact body loses part of
its original speed (energy)
the larger the indentation the
more speed it will lose.
Mechanical Testing

Impact Testing
Charpy V-Notch Impact Test

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
Charpy V-Notch Impact Test

Pendulum
Specimen (striker)

Anvil (support)
Charpy V-notch impact test specimen

Specimen dimensions according ASTM E23

ASTM: American Society of Testing Materials

Charpy Impact Test
22.5o
10 mm 100% Brittle
2 mm

Machined
notch

Fracture surface
8 mm

100% bright
crystalline brittle
fracture

100% Ductile
Machined
notch

Large reduction
in area, shear
lips
Randomly torn,
dull gray fracture
surface
Ductile / Brittle Transition
Curve Temperature range
Ductile fracture

47 Joules

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
 Ductile / Brittle Transition
Curve Temperature range Ductile fracture

Mn < 1.6 % increases

toughness in steels* 47 Joules

Transition range Ductile/Brittle

transition
point

28 Joules
Energy absorbed
Brittle fracture
- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees Centigrade
Three specimens are normally tested at each temperature
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
 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
Charpy Impact Testing
Mechanical Testing

Tensile Testing
Tensile Testing
UTS Tensile test
Tensile Tests
Different tensile tests:
Transverse tensile.
All-weld metal tensile test
Cruciform tensile test
Short tensile test (through thickness test)
 Tensile Test

All-Weld Metal Tensile

Specimen

Transverse Tensile
Specimen
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
Transverse Joint Tensile Test

Weld on plate

Multiple cross joint

Weld on pipe specimens
Transverse Tensile Test

Maximum load applied = 220 kN.

Least cross sectional area = 25 mm X 12 mm

UTS = Maximum load applied

Least c.s.a.

UTS = 220 000

25mm X 12mm

UTS = 733.33 N/mm2

Transverse Tensile Test
Reporting results:
• Type of specimen e.g. reduced section

• Whether weld reinforcement is removed

• Dimensions of test specimen

• The ultimate tensile strength in N/mm2, p.s.i or Mpa

• Location of fracture.

• Location and type of any flaws present if any

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.

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%
All-Weld Metal Tensile Test
Gauge length

Object of test:
Ultimate tensile strength.

Yield strength.

Elongation %(ductility).

Increased gauge length

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 %
All-Weld Metal Tensile Test
Reporting results:

Type of specimen e.g. reduced section

Dimensions of test specimen
The u.t.s, yield strength in N/mm2, p.s.i or Mpa
Elongation %
Location and type of any flaws present if any
STRA (Short Transverse Reduction Area)
STRA test

Original CSA

Reduced CSA
STRA test

20
STRA %
Reductio
n of CSA 15

10
Mechanical Testing

Macro / Micro Examination

 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
 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 & then lightly
etched
• Prepared face examined under the microscope at up to ~ 100 – 1000X
 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
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
 Macro Micro
• Visual examination for • Visual examination for
defects defects & grain structure
• Cut transverse from the • Cut transverse from a
weld weld
• Ground & polished P400 • Ground & polished P1200
grit paper grit paper, 1µm paste
• Acid etch using 5-10% • Acid etch using 1-5%
nitric acid solution nitric acid solution
• Wash and dry • Wash and dry
• Visual evaluation under 5x • Visual evaluation under
magnification 100-1000x magnification
• Report on results • Report on results
Metallographic Examination

Macro examination Micro examination

 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)
Mechanical Testing

Bend Testing
 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:

Face bend
Root bend Side bend
Side bend tests are normally carried out on welds over 12mm
in thickness
 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
 Bending test methods

Guided bend test

Wrap around bend test
Bend Testing
Face bend Side bend Root bend

Defect
indication Acceptance for
Generally this minor ruptures on
specimen tension surface
would be depends upon code
unacceptable requirements
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.
Bend Testing
Mechanical Testing

Fillet Weld Fracture Testing

 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
Fillet Weld Fracture Tests
Hammer

2mm
Notch

Fracture should break weld saw cut to root

Fillet Weld Fracture Tests

This fracture indicates This fracture has

lack of fusion occurred saw cut to root

Lack of Penetration
 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
Mechanical Testing

Nick-Break Testing
 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
Nick-Break Test
Notch cut by hacksaw
3 mm
19 mm

3 mm
Approximately 230 mm

Weld reinforcement
may or may not be
removed
Nick Break Test

Alternative nick-break test

specimen, notch applied all
way around the specimen

Lack of root penetration Inclusions on fracture

or fusion line
 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
 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 & 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
 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 (e.g. flexible
pipes, diaphragms) must be removed
• the ambient temperature MUST be above 0°C (preferably 15-
20°C)
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
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
Mechanical Testing

Any Questions