DESTRUCTIVE TESTING

MECHANICAL

METALLOGRAPHIC

CHEMICAL

TESTING

EXAMINATION

ANALYSIS

1. TENSILE

1. MACRO

1. WET ANALYSIS

2. BEND

2. MICRO

2. DRY ANALYSIS

3. IMPACT
4. HARDNESS
5. DROP WEIGHT
6. DROP WEIGHT TEAR
7. NICK BREAK
8. FATIGUE
9. CREEP

3. X-RAY FLORESCENCE
4. ATOMICABSORPTION

PURPOSE OF TESTING
1.
2.

To determine the fundamental properties.

To

determine

Mechanical,

Chemical

and

Metallurgical properties in order to find out the

suitability for a specific purpose.
3.

To record the data for a group of metals and alloys

for the purpose of design.

4.

To check weather heat treatment imparted has

been carried out satisfactorily.

5.

To investigate into defects and flaws of the material

so as to improve manufacturing techniques.

PURPOSE OF TESTING
II.

As for as welding is concerned

1.

Qualification of welding procedure.

2.

Qualification of welding and welding operation.

3.

Qualification of welding consumables.

4.

Quality control

STANDARD TEST METODS

(For Mechanical Testing)
TYPE

ASTM

BS

IS

Tensile

E8

EN10002-1

1608,1521

Bend

E190

EN287-1

1599

Impact

E23

EN 10045-2

1757

Hardness

E10(Brinell)

BS 240-1

1500

E18(Rockwell) BS 891-1

1586

E 92(Vickers) BS 427

1501

STANDARD CODES FOR DESTRUCTIVE

TESTING
ASTM-A370

: Mechanical Testing of Steels

AWS-B4

: Standard methods for Mechanical testing of welds

BS-709

: Destructive testing for fusion welded Boiler

drums.

IBR Ch.-V

: Fusion Welded Boiler Drums.

IBR Ch.-Viii

: Qualification test for Welders.

IBR Ch.-XII

: Shell type Boiler construction

AWS 5.1,5.4,5.5

: Electrode Qualification Tests

IS 814,5206,1395 : Electrode Qualification Tests

ASME Sec.IX

: Procedure & performance Qualification of welding

API-5L

: For seamless and welded steel tubes & pipes.

TEST PLATE FOR PERFORMANCE

QUALIFICATION (as per IBR)

B1

T1

B2

B1

T2

B2

weld

M
B

250 mm

406 mm

16
mm

TEST PIPE & TUBE FOR PERFORMANCE

QUALIFICATION (as per IBR
Macro
Root
Face

weld

Root

Macro

Face

250mm

PIPE 127x12.5mm, CS Tube 63.5x5.2mm, AS Tube 54x5mm

PROCEDURE QUALIFICATION
(ASME SEC. IX)

Discard
Reduced Sec.

Discard
Tensile Specimen

Root
Face
Root

Bend
Bend

Face
Reduced Sec.

Bend
Tensile Specimen

Discard

Discard

Bend

250mm
QW-463.1(a) : Less than 3/4 PLATES

300mm

PROCEDURE QUALIFICATION
(ASME SEC. IX)

Discard

Discard

Side

Bend
Tensile Specimen
Bend

Reduced Sec.
Side

300

Side

Bend

Reduced Sec.
Side

Tensile Specimen
Bend

Discard

Discard
250

QW-463 1(b) :Over 3/4 PLATES

TENSILE SPECIMENS

TRANSEVERSE
TENSILE

ALL WELD
TENSILE

ELECTRODE QUALIFICATION TEST(AS PER AWS)

15

IMPACT SPECIMEN
(5Nos.)

WELD

ALL WELD TENSILE

170mm min. (1No.)

25

DISCARD

25

DISCARD

ALL WELD TENSILE SPECIMEN (as per IS)

R5
100.09

12 min

G L 50

PL 60
70mm min
FOR SIZE 4mm AND ABOVE

6.4 0.075
9.5
GL 32
38.9
44.8
FOR SIZE 3.15 mm and BELOW
THE SURFACE FINISH WIT THE PL SHALL BE 1.6

ALL WELD TENSILE SPECIMEN (AWS)

R 9.5

12.70.25

19.1

GL 50.8 0.13
PL 57.1

SL

SL

SIZE OF ELCTRODE 4 mm and ABOVE

R 4.6

6.40.13

SL

GL 25.4 0.13
GL 31.8

9.5
SL

SIZE OF ELECTRODE 3.15 mm and BELOW

THE SURFACE FINISH WITH THE PL SHALL BE 1.6

UNIVERSAL TESTING MACHINE

CALIBRATION:

ASTM-E4,
BIS: 1828,
EN: 10002-2

CALIBRATION : EN 10045-2, BIS 3766

0.

TRANSEVERSE TENSILE SPECIMEN

SL

W
PL

SL

RECTANGULAR TENSILE TEST SPECIMEN

(FOR PLATE as per ASTM E8M )

13 min

40

50

200
75

225

5min.

75

GAUGE LENGTH AS PER VARIOUS STDS.& CODES.

STANDARD

ROUND TENSILE (GL)

FLAT TENSILE (GL)

ASTM

5d

50 mm

BS

5d

5.65A

IBR

4d

4A

IS

5d

5.65 A

BEND TEST METHODS

1. Guided bend

2. Free Bend

ROOT BEND TEST

ROOT BEND TEST

3t

t
1.5t
5.2t

FACE BEND TEST

3t

t
1.5t
5.2t

SIDE BEND TEST

3t

W
5.2t

CALIBRATION : EN 10045-2, BIS 3766

STRICKER

Specimen
Specimen Supporter

CALIBRATION : EN 10045-2, BIS 3766

TENIUS OLSON IMPACT TESTER

CAL : ASTM - E23

IMPACT TEST SPECIMEN

100.025
20.1
450.1

27.5

10 0.025

550.1
CHARPY VNOTCH TEST SPECIMEN

100.025

50.1

27.5

10 0.025

550.1
CHARPY UNOTCH TEST SPECIMEN

IZOD IMPACT TEST SPECIMEN

10

2
75

27.5

10

HARDNESS TEST
1.BRINELL HARDNESS 2. ROCKWELL HARDNESS
3.VICKERS HARDNESS 4. MICRO HARDNESS

BRINELL HARDNESS TEST

HARDENED STEEL BALL IS USED FOR
MEASURING UPTO 500 BHN
FOR 500 BHN TUNGSTON STEEL BALL IS USED F
FOR IRON AND STEEL 3000Kg OF LOAD IS APPLIED
FOR INTERMEDIATE HARD MATERIALS 1500Kg, 500Kg
OF LOADS ARE USED.
FOR SOFT MATERIALS 100 Kg OF WEIGHT IS USED.
RATE OF LOADING IS AN IMPORTANT CRITERIA,
RAPID RATE OF LOADING AFECTS THE INDENTATION.

POLISHED SURFACE

BHN=APPLIED LOAD/AREA OF INDENTATION

BHN=P/[( D/2) X (D-D2 - d2)]

WHERE P=LOAD IN Kg,
D=DIAMETER OF STEEL BALL IN mm, d= DIAMETER OF THE INDENTATION IN mm.
APPLICATION
FOR C.STEEL, CAST IRON,COPPERALLOYS, ALUMINIUM ALLOYS, LEAD AND TIN ETC.

UNIVERSAL HARDNESS TESTER

TEST IS CARRIED OUT BY IN ACCORDENCE

ASTM E92 TEST IS CARRID OUT BY IN
ACCORDENCE ASTM E92

ROCKWELL HARDNESS TEST

Minor Load

Major Load

TEST IS CARRIED OUT BY IN ACCORDENCE

ASTM E92 TEST IS CARRID OUT BY IN
ACCORDENCE ASTM E92

VICKERS HARDNESS TEST

VICKERS HARDNESS TEST

Angle between faces of the

pyramid is 136
VHN=1.854 P/ D2
P=Load in Kgf
D= Average of measured
diagonals of impression in mm

TEST IS CARRIED OUT BY IN ACCORDENCE WITH ASTM E92

DROP WEIGHT TEST

STANDARD DROP WEIGHT TEST SPECIMEN

P1=25X90X360
P2=19X50X130
P3=16X50X130

DROP WEIGHT TEST

SPECIMEN

SPECIMEN
SUPPORTER

DROP WEIGHT TEST IS CONDUCTED IN ACCORDANCE WITH ASTM E208

MACRO EXAMINATION
It involves the visual observation of the gross structural
details of materials after preparation of the surface,
either by unaided or with the aid of low power
microscope . Usually under 10X.
When macroscopic examinations appropriately carried
out, some important metallic characteristics are
determined by such studies.
Example : As for as welding is concerned macro will
reveal
Undercut, Excess penetration, Incomplete penetration,
Dilution lack of fusion pores and cracks etc.

MICRO EXAMINATION

The most important part of metallography deals with the

microscopic examinations of a prepared metal
specimen,employing magnification with the optical
microscope from 100X to as high as 2000X.
Such microscopic studies are of much broader scope than
macro examinations.

It will reveal clear picture of structural characteristics as

grain size, shape, distribution secondary phases, non
metallic inclusions, segregation and other heterogeneous
conditions.
Microstructure reflects almost complete history of the
mechanical and thermal treatment that a metal has
received.

THANK YOU