MME 348 Level 3 Term 2 January 2020 Term

MME 348 Metal Joining Technology

Sessional
1.50 Credit One Laboratory Work per Week
Level 3 Term 2 January 2020 Term
Department of Materials and Bangladesh University of Engineering
Metallurgical Engineering and Technology, Dhaka 1000

Experiment Number 08
Experiment Name Micro and Macro Examination of a Welded Joint

Introduction

Up until the end of the 19th century, sections of metal were joined together by a heating and hammering process
called forge welding. Today, a variety of different welding processes are available, such that welding is extensively
used as a fabrication process for joining materials in a wide range of compositions, part shapes and sizes.

Difficulties during metallographic preparation

The introduction of any thermal damage during the cutting process must be avoided as it can alter the
microstructure and properties in the welded joint. A thorough understanding of the preparation process is
necessary to deal with the difficulties presented by the variations in the material properties in and across the
welded joint, if flatness between microstructural features with different hardness values is to be achieved.

Taking Test Sections from Welds

Metallographic principles and practices can be applied to the examination of welded sections to satisfy a number
of objectives; the more common of which are listed below:

Welder Approval Testing

In this type of test, an individual welder welds an appropriate test piece, under specified conditions. This test
piece is then examined by measurement, visual inspection, and examination of a prepared section through the
weld. If the weld reaches the agreed standard, that welder is approved to weld the same type as the test weld.

Procedure Approval Testing

In this type of test, it is a welding procedure in a particular material with a particular joint configuration which is
being approved. The completed weld is examined by a variety of means, one of which includes a prepared section
through the welded joint. A hardness traverse across parent material, heat affected zone and weld metal is
normally carried out.

Production Quality Control

In this type of test, a representative number of welds are sectioned and examined as part of a production process.

Failure Analysis

Research and Development

Page 1 of 3 Dr. Mamun Al Rashed, DMME, BUET Updated: 13 December 2020
 MME 348 Level 3 Term 2 January 2020 Term

Two Levels of Metallographic Inspection

The examination of metallographic sections through welded joints is commonly carried out at two levels of
inspection:

Macro: Where magnifications up to x50 are employed with stereomicroscopes.

Micro: Where examination is at higher magnifications (up to x1000) using optical microscopes.

Macro examination is commonly carried out on unmounted cross sections through welded joints and simply
involves cutting and coarse/fine grinding techniques. The resultant finish is adequate for etching, followed by an
examination of the macro features of the weld joint.

For micro examination techniques and hardness traverse, the provision of a polished, optically flat surface will be
required. This involves cutting, mounting and grinding and polishing. One has to be aware from the outset, that
artefacts can be introduced at any stage of the preparation process. This is particularly true of welded sections
because not only do microstructural variations occur over relatively short distances but welds can also involve
joints between dissimilar metals having widely different properties.

Drawing showing the various regions of the HAZ in a single-pass weld and the possible defects.

Macroetch Test. The weld test specimens shall be prepared with a finish suitable for macroetch examination. A suitable
solution shall be used for etching to give a clear definition of the weld.

Acceptance Criteria for Macroetch Test. For acceptable qualification, the test specimen, when inspected visually, shall
conform to the following requirements:

(1) Partial joint penetration groove welds; the actual weld size shall be equal to or greater than the specified weld size.

(2) Fillet welds shall have fusion to the root of the joint, but not necessarily beyond.

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 MME 348 Level 3 Term 2 January 2020 Term

(3) Minimum leg size shall meet the specified fillet weld size.

(4) The partial joint penetration groove welds and fillet welds shall have the following:

(a) no cracks

(b) thorough fusion between adjacent layers of weld metals and between weld metal and base metal

(c) weld profiles conforming to specified detail, but with none of the variations prohibited in 5.24 of AWS D1.1 2000

(d) no undercut exceeding 1/32 in. (1 mm)

Experimental Procedure

1. Determine the type of joining.

2. Conduct macro-study and micro-study of any two samples.
3. Make comments on the images acquired.
4. Submit report with images acquired with proper labelling and comment.
5. Include different weld test standard for testing weld materials.

Page 3 of 3 Dr. Mamun Al Rashed, DMME, BUET Updated: 13 December 2020