Destructive Testing

Section 4

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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 ISO 9606).
 Production quality control.

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 Destructive Tests

Destructive tests include:

3x
 Bend test. Toughness
(Charpy V
 Impact test. notch)
 Tensile test.
2 x Ductile
 Hardness test. (Bend 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.
 Malleability.
 Ductility. Ability of a material to
 Toughness. withstand deformation
under static compressive
 Hardness. loading without rupture.
 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 and 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 or
HAZ
fusion
boundary

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 (136° 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

Mn < 1.6 % Temperature range

Ductile fracture
increases toughness
in steels, and lower
energy input used. 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

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 Comparison Charpy
Impact Test Results
Impact energy joules

Room Temperature -20°C 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 -20°C.

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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

All-Weld metalTensile
tensile
specimen
Specimen

Transverse
TransverseTensile
tensile
Specimen
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

UTS = Maximum load applied

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/mm 2, 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

Two 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

Two 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

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 150mm, the maximum load applied was
140Kn. The cross sectional area before testing was 10mm
in depth and 40mm in width.

Please calculate the elongation % and UTS.

Change in
length (150 – 120) = 30
= 0.25 x 100 = 25%
Original 120
length

Load 140 Kn 14,000 n

= 350 n/mm²
CSA 10 x 40 400

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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.

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 Macro Preparation

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 and all
HAZ.
 Prepared face examined at up to x10 (and usually
photographed for records).
 Prepared face may also be used for a hardness survey.

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 Macro 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.

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 Macro Preparation

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 Macro/Micro Examination

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

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 Metallographic Examination

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 ISO 5173+A1):

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 generally this

specimen would be unacceptable.
Acceptance for minor ruptures
on tension surface 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 (90°, 120°, 180°).
 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 occurred

lack of fusion 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 Qualitative: (Have no

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

?
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