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Tapany Udomphol
Sep-Dec 2007
Objectives
This chapter aims to:
This chapter provides information on weld mechanical assessments: Destructive testing and non destructive testing (NDT). Students are required to analyse mechanical properties and corrosion of weldments, such that information can be used for the selection of the weldments in service.
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Sep-Dec 2007
Weld assessments
Weldments normally contain defects. However we need to keep weld defects at a minimum level to maintain reliable products.
Swing arm
Longitudinal crack
Crater cracking
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Sep-Dec 2007
Weld assessments
Appropriate welding method Reliable products Specifications Quality control method
Destructive testing
Mechanical testing, i.e., tensile, fracture toughness, impact, fatigue tests. Expensive, require specimen preparation under standard specifications.
Tapany Udomphol
Sep-Dec 2007
Destructive testing
Mechanical tests are destructive testing, which are expensive since it requires specimen preparation and then destroying it. The orientation of the weld in the testpiece must be recorded. Requires standard specimen dimension for each specification used.
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Sep-Dec 2007
Destructive testing
Mechanical tests are destructive testing, which are expensive since it requires specimen preparation and destroying it. The orientation of the weld in the testpiece must be recorded. Requires standard specimen dimensions for each specification used.
Sep-Dec 2007
Destructive testing
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Sep-Dec 2007
Destructive testing
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Destructive testing
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Destructive testing
Sep-Dec 2007
Destructive testing
PN
PQ
NQ
NP
N = Normal to the weld direction P = Parallel to the weld direction Q = Weld thickness direction First letter : the direction normal to the crack plane Second letter: the expected direction of crack propagation Specimen orientations NP and PN are referred to as through-thickness notched Specimen orientations NQ and PQ are referred to as surface notched
(c) EB and TIG welds
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Sep-Dec 2007
Non-destructive testing
We must remember that NDT result itself cannot guarantee whether the weld is acceptable, but can only report what types of defects we discover. There are a range of NDT techniques available;
Visual inspection Liquid penetrant inspection Magnetic-particle inspection Radiography Ultrasonic inspection
Note: At least one of the NDT methods should be taken for weld inspections.
Suranaree University of Technology Sep-Dec 2007
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Visual inspection
Weld defects can often be discovered by naked eyes and can be repaired at this stage: Check on defects Surface cracks Crater cracks Incomplete root penetration Undercut Underfill on face, groove, or fillet (concave) Underfill of root (suck back) Excessive face reinforcement, groove, or fillet (convex) Excessive root reinforcement Overlap Misalignment Arc strikes Excessive spatter Warpage (distortion) Base metal defects
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Sep-Dec 2007
Sep-Dec 2007
Liquid-penetrant inspection
Used to detect minute discontinuities such as cracks, pores, which are open to the surface. Can be applied to ferrous & non ferrous metals, glass and plastics. The surface must be clean.
Properties
Liquid panetrant
Liquid penetrant inspection is portable and very easy to use on site. Required appropriate protections because the liquid used might be toxic. Limited on surface inspection and should be used in combination of other NDT techniques.
Principle of penetrant examination
Suranaree University of Technology
Tapany Udomphol
Sep-Dec 2007
Note: Ultraviolet or black light source are used for the inspection of fluorescence liquid penetrant. Sound areas appear deep violet while the defects will glow a brilliant yellowish green.
Suranaree University of Technology
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www.instytutgamma.com
Sep-Dec 2007
www.bbrail.com
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Cracks
Iron particles can be applied dry or wet. Detecting fluid is normally particles of magnetic iron oxide suspended in kerosene and may be coated with fluorescence compound for viewing under ultraviolet light.
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Sep-Dec 2007
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Sep-Dec 2007
Radiographic examination
Interior defects (porosity, cracks, voids) can be examined by using X-ray or gamma ray, which can penetrate through materials and its intensity depends on materials thickness and density. Provide a permanent film record which is easy to interpret. Slow and expensive, however this method is positive to determine defect size. X-ray is generated by electron bombardment on tungsten. Gamma ray is emitted by radioactive elements. X-ray or gamma ray is absorbed during transmission through the materials. Pores or defects absorb less energy than uniform areas giving a variation of intensity of the beam generated on the film placed underneath the materials.
Suranaree University of Technology
Principal of radiography
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Sep-Dec 2007
Radiogram
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Sep-Dec 2007
Light Dark
Radiography detection also depends on orientation of the flaw with respect to the beam. Used to detect defects in all types of weldments and materials such as aluminium, steel, magnesium. Used in pipeline industry.
Orientation of flaw with respect to X-rays
Suranaree University of Technology
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Sep-Dec 2007
Precautions
www.arrowheadproducts.net
Require concrete, steel, leadlined bricks to house the X-ray to protect the operator from exposure. On site operation is carried out in distance. X-ray is more manageable than gamma ray. The area is safe when switching off the X-ray source while a radioactive isotope emits radiation continuously and must be kept in a shield container.
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Sep-Dec 2007
Ultrasonic inspection
A beam of ultrasonic vibration produced by quartz crystal is directed into the specimen to detect defects or discontinuities. Sound area gives small loss of signal, except when the ultrasonic is intercepted and reflected by defects.
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Sep-Dec 2007
Ultrasonic inspection
There are two ways of using ultrasonic waves for welded joint inspection.
Transmission
Reflection
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Sep-Dec 2007
www.olympusndt.com
Moving the probe to scan the thickness of the weld with an angle probe.
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Sep-Dec 2007
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Weld properties
Weldments normally possess a degradation of weld properties due to changes in microstructures and defects. Weld properties should be assessed in order to correctly select the weldment, which can satisfy the condition in service.
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Sep-Dec 2007
Hardness test orientation in the weld joint of AISI 1040 friction weld
Hardness profile
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Sep-Dec 2007
Fractography of weldments tested at (a) Room temperature (b) 700oC Fractography of base metal at (a) Room temperature (b) 700oC
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140
120
100
80
As Deposited Reheated
60
40
20
0 -200
-150
-100
50
100
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Sep-Dec 2007
800
Lower fatigue limit was observed in autogenous TIG weld of titanium alloys in comparison to the base metal.
max, MPa
600
400
Number of cycle
TIMET bar III, AR Autogenous BuRTi TIG weld, HT Ti679-BuRTi-Ti679 TIG weld, AR
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Sep-Dec 2007
da/dN, mm/cycle
Fatigue crack growth is faster in the weld joint than in the base metal. Factors affecting the FCG results are coarsening microstructure, embrittlement, precipitation hardening, etc.
R = Pmin/Pmax = 0.1 Frequency = 0.25 Hz 1e-2 TIMET bar III m = 2.02 BuRTi EBW01 m = 9.05 BuRTi EBW02 m = 2.35 Ti679-BuRTi-TI679 TIG01 m = 6.84 Ti679-BuRTi-Ti679 TIG02 m = 10.18
1e-3
1e-4
1e-5
1e-6 1 10
1/2 K, MPa.m
100
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Sep-Dec 2007
Corrosion of weldments
www.forensicmetallurgy.com
PLUMBING - PIPING
Corrosion failure of underground propane pipe Broken stainless steel air injection pipes in a sewage treatment plant Cracking of brass inserts in fire sprinkler head adaptors Freeze failure of copper plumbing and air conditioner fittings Dry solder joints in copper plumbing fittings Pitting corrosion of copper pipes using well water Pitting of air conditioner copper heat exchanger chillier water tubing Corrosion of steam boilers Rust clogging of high rise building steam heating systems Leakage of propane from a connector fitting with a worn rubber seal Corrosion failures of underground fuel tanks
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Sep-Dec 2007
References
Gourd, L.M., Principles of welding technology, 3rd edition, 1995, Edward Arnold, ISBN 0 340 61399 8. Cary, H.B., Modern welding technology, 4th edition, 1998, Prentice Hall, ISBN 0-13-241803-7. Sahin, M., Akata, H.E., Gulmez, T., Characterization of mechanical properties in AISI 1040 parts welded by friction welding. 2006. K.S. Guana, X.D. Xub, Y.Y. Zhangb and Z.W. Wang, Cracks and precipitate phases in 321 stainless steel weld of flue gas pipe, 2005, Vol.12, Issue 4, p 623-633.
Tapany Udomphol
Sep-Dec 2007