All 24.05.16

MECHANICAL LAB
TESTING
PROCEDURES
CONTENTS
TENSILE TESTING PROCEDURES 1 - 23

IS 1608:2005  Metallic Materials – Tensile Test At Ambient Temperature
ASTM A 370-15  Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM E8/E8M-15  Standard Test Methods for Tension Testing of Metallic Materials
BS EN 10002-1-2012  Metallic materials - Tensile testing - Part 1: Method of testing at ambient
temperature
IS 210-2009  Grey Iron Castings
IS 1865-1991  Iron Castings with Spheroidal or Nodular Graphite-Specification
ASTM B 557-10  Standard Test Methods for Tension Testing Wrought and Cast Aluminum- and
Magnesium-Alloy Products
BEND TESTING PROCEDURES 24 - 27

IS 1599:2012  Method for Bend Test
ASTM E 290-14  Standard Test Methods for Bend Testing of Material for Ductility
IS 2329:2005  Metallic Materials — Tube ( In Full Section ) — Bend Test
HARDNESS TESTING PROCEDURES 28 - 40

IS 1500-PART 1:2013  Metallic Materials - Brinell hardness Test
IS 1586-PART 1:2012  Metallic Materials - Rockwell Hardness Test - Part 1: Test Method (Scales
A, B, C, D, E, F, G, H, K, N, T)
ASTM E10-15  Standard Test Method for Brinell -Hardness of Metallic Materials
ASTM E18-15  Standard Test Methods for Rockwell Hardness of Metallic Materials
IMPACT TESTING PROCEDURES 41 - 54

IS 1757-1988  METHOD FOR CHARPY IMPACT TEST (V-NOTCH) ON METALLIC MATERIAL
IS 1499-1977  METHOD FOR CHARPY IMPACT TEST (U-NOTCH) FOR METALS
IS 1598- 1977  METHOD FOR IZOD IMPACT TEST OF METALS
ASTM E23-12C  Standard Test Methods for Notched Bar Impact Testing of Metallic Materials
FLATTENING TESTING PROCEDURES 55 - 62

IS 2328:2005  Metallic Materials-Tube-Flattening Test
ASTM A 530-12  Standard Specification for General Requirements for Specialized Carbon and
Alloy Steel Pipe
ERICHSEN CUPPING TESTING PROCEDURE 63 - 67
IS 10175-1-1993  Mechanical Testing of Metals-Modified Cupping test – Sheet and Strip (up to 2
mm thickness)
SPRING LOCK WASHER TESTING PROCEDURE 68 - 74

IS 3063-1994 Single coil Rectangular section Spring Lock Washers-Specification
WELD TEST PROCEDURES FOR WELD COUPON 75 - 131

IBR 1950-2011 Indian Boiler Regulations, 1950 and Indian Boiler Act 1923
ASME SEC-IX-2015 Qualification standard for welding, brazing, and fusing procedures; welders;
brazers; and welding, brazing and fusing operators.
AWS D 1.1/1.1 M-2015 Structural welding code- steel
BS EN ISO 15614-1-2004+A2:2012 Specification and qualification of welding procedures for
metallic materials-welding-procedure test
API 1104-2014 21ST EDITION welding of pipelines and Related Facilities
TMT BARS TEST PROCEDURE 132 - 136
IS 1786:2008High Strength deformed steel bars and wires for concrete reinforcement
specification
DIAGRAMS FOR TESTING FIXTURES
Proof load fixture Fig-1

Shear test for cladding materials  Fig-2
Washers Fig-3
Screw Fixtures  Fig-4
TENSILE TESTING PROCEDURES
IS 1608:2005  Metallic Materials – Tensile Test At
Ambient Temperature
ASTM A 370-15  Standard Test Methods and

Definitions for Mechanical Testing of Steel Products
ASTM E8/E8M-15  Standard Test Methods for

Tension Testing of Metallic Materials
BS EN 10002-1-2012  Metallic materials - Tensile

testing - Part 1: Method of testing at ambient
temperature
IS 210-2009  Grey Iron Castings
IS 1865-1991  Iron Castings with Spheroidal or

Nodular Graphite-Specification
ASTM B 557-10  Standard Test Methods for

Tension Testing Wrought and Cast Aluminum- and
Magnesium-Alloy Products
1
IMECH LABS ISSUE NO.: 01 REV. NO.: 00
WORK INSTRUCTION FOR TENSILE PAGE: 1 OF 4 DATE: 01.12.2015
TESTING
1.0 REFERENCE: IS: 1608/ 05, ASTM – A 370/ 15, ASTM E8/E8M, BS EN 10002-1-01
IS 1865-1991, IS 210-09, ASTM B 557-15
1.1 Tensile Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
1.1.1 PRINCIPLE: THE TEST CONSISTS OF STRAINING A TEST PIECE BY

TENSILE FORCE GENERALLY TO FRACTURE, FOR THE
PURPOSE OF DETERMINING THE FOLLOWING MECHANICAL
PROPERTIES.
a) YIELD STERSS
b) PROOF STRESS
c) TENSILE STRENGTH
d) PERCENTAGE ELONGATION
e) PERCENTAGE REDUCTION AREA
1.1.2 TEST PROCEDURE AFTER RECEIVING OF TEST SPECIMEN IN
MECHANICAL LAB.
 CHECK IDENTITY OF SPECIMEN AND TALLY WITH TEST

REQUEST.
 CHECK SURFACE FINISH, RADIUS ZONES, EDGES OF THE
TEST PIECES VISUALLY.
 CHECK DIMENSION OF THE TEST PIECE WHETHER IT HAS
BEEN PREPARED ACCORDING TO THE DIAGRAM AS
SPECIFIED IN RELEVANT ANNEXURE OF SAMPLE
PREPARATION.
 TAKE DIMENSION OF GAUGE DIA. / GAUGE WIDTH &
THICKNESS AT TWO OR THREE PLACES IN EACH SAMPLE.
 CALCULATE GAUGE LENGTH FROM RELEVANT STANDARD &
MARK GUAGE LENGTH BY MEANS OF A FINE MARK OR
SCRIBED LINES.
DO NOT MAKE NOTCHES WHICH COULD RESULT IN
FRACTURE.
 CHECK ZERO SETTING OF THE MACHINE & PLACE THE

SAMPLE IN THE MACHINE GRIPS.
 ENSURE PROPER GRIPPING OF SAMPLE TO AVOID SLIPPAGE.
IML/TP/01 PROCEDURE MANUAL PREPARED BY:

WORK INSTRUCTION APPROVED BY:
2
TESTING
1.1.2.1 DETERMINATION OF YIELD STRESS:
 NOTE YIELD POINT VERY CAREFULLY BY DROP BEAM

METHOD OR FROM GRAPH ATTACHED WITH THE MACHINE OR
BY USING EXTENSOMETER AS SPECIFIED.
 TO DETERMINE LOWER YIELD POINT, DO NOT CONTROL THE
MACHINE SPEED JUST BEFORE YIELD BEGINS & UNTIL THE
COMPLETION OF YIELD. IN NO CASE DO NOT EXCEED THE
RATE OF STRESSING IN THE ELASTIC RANGE AS GIVE IN
TABLE –1.
 CALCULATE YIELD STRESS USING THE FORMULA: -
LOAD AT YIELD POINT

YIELD STRESS = ---------------------------------------.
CROSS SECTIONAL AREA
MAINTAIN UNIT AS DESIRED BY THE SPECIFICATION.

TABLE – 1
MODULUS OF ELASTICITY OF THE RATE OF STRESSING
MATERIAL N/mm/S
N/mm MIN MAX
< 150000 (ALUMINIUM, GREY CAST 2 10
IRON, COPER)
> 150000 ( IRON, STEEL, STAINLESS 6 30

STEEL, MALLEABLE CAST IRON)
1.1.2.2 DETERMINATION OF PROOF STRESS:
 FOR DETERMINATION OF PROOF STRESS THE RATE OF

STRESSING SHOULD BE WITHIN THE LIMITS GIVEN IN THE
TABLE-1 AND THE STRAINING RATE SHOULD NOT EXCEED
0.0025/ S. USE AN EXTENSOMETER FOR THIS PURPOSE.
 TAKE SEVERAL READINGS OF FORCE APPLIED AND
CORRESPONDING EXTENSION VALUE CROSSING THE ELASTIC
LIMIT TILL RAPID CHANGES OF EXTENSION NOT COME.
IML/TP//01 PROCEDURE MANUAL PREPARED BY:

3
TESTING
 PLOT THIS VALUES OF FORCE / EXTENSION IN A GRAPH PAPER
AND DRAW A LINE PARALLEL TO THE STRAIGHT PORTION OF
THE CURVE AT A DISTANCE EQUIVALENT TO THE PRESCRIBED
NON-PROPORTIONAL PERCENTAGE, FOR EXAMPLE 0.2 %.
 CONSIDER THE FORCE AT WHICH THE LINE CUTS THE
CURVE.
 THEN CALCULATE THE PROOF STRESS VALUE BY DIVIDING
THE FORCE BY ORIGINAL CROSS-SECTIONAL AREA OF THE
TEST PIECE.
 MAINTAIN UNIT AS DESIRED BY THE SPECIFICATION.
1.1.2.3 DETERMINATION OF ULTIMATE TENSILE STRESS (U.T.S.):
 FOR DETERMINATION OF ULTIMATE TENSILE STRESS NOTE

THE FORCE AT WHICH THE SAMPLE BREAKS.
 THEN CALCULATE THE ULTIMATE TENSILE STRESS BY
DIVIDING THE BREAKING FORCE BY ORIGINAL CROSS-
SECTIONAL AREA OF THE TEST PIECE.
 MAINTAIN UNIT AS DESIRED BY THE SPECIFICATION.
1.1.2.4 DETERMINATION OF PERCENTAGE ELONGATION:
 TAKE OUT THE BROKEN TEST PIECE FROM THE MACHINE.

 ENSURE PROPER CONTACT BETWEEN THE BROKEN PARTS
OF THE TEST PIECE AND MEASURE PROPERLY THE FINAL
LENGTH BETWEEN THE GAUGE MARKS.
 NOW CALCULATE THE PERCENTAGE ELONGATION USING
THE FORMULA
AS BELOW-
FINAL LENGTH – ORIGINAL LENGTH

% ELONGATION = ---------------------------------------------------- X 100.
ORIGINAL LENGTH

4
TESTING
1.1.2.5 DETERMINATION OF PERCENTAGE REDUCTION AREA :
 TAKE OUT THE BROKEN TEST PIECE FROM THE MACHINE.

 ENSURE PROPER CONTACT BETWEEN THE BROKEN PARTS
OF THE TEST PIECE AND MEASURE PROPERLY THE
REDUCED DIAMETER AT THE FRACTURED JONE.
 NOW CALCULATE THE PERCENTAGE REDUCTION AREA
USING THE
FORMULA AS BELOW-
ORIGINAL DIAMETER – REDUCED DIAMETER

% REDUCTION AREA = ----------------------------------------------------------------- X 100.
ORIGINAL DIAMETER
AFTER CALCULATION OF FINAL VALUES OF YIELD STRESS/ PROOF

STRESS, ULTIMATE TENSILE STRESS, PERCENTAGE ELONGATION &
PERCENTAGE REDUCTION AREA RECORD THE DATA IN THE MASTER TEST
REGISTER.

5
Diagrams As Per IS 1608:1608:2005
Initial Gauge Length is 50 mm for 12.5 mm reduced section and 80 mm for 20 mm reduced
section for these type
6
Initial gauge length calculation for plates above 3 mm thick is = 5.65 x Sqrt of
Area
7
Initial gauge length calculation for Rods above 4 mm is = 5 x diameter
8
1) You can test any sample directly without any dumble shape
2) If the thickness above 25 mm then you will machined the sample
to round specimen
9
Diagrams As Per ASTM A 370-15
For Sheet Type
Plate Type Sheet Type

( If the specimen takes 37.9 mm (If the specimen takes 25.4 mm
References wide) wide)
inches mm inches mm
G-Gage Length: 8.0+/-0.01 200+/-0.25 2.00+/-0.005 50.0+/-0.10
W-Width:
1 ½+(1/8-1/4) 40+(3-6) 0.500+/-0.010 12.5+/-0.25
T-Thickness
Thickness of Thickness of Thickness of Thickness of
material material material material
R-Radius of
Fillet(min) ½ 13 ½ 13
L-Over-all
Length(min) 18 450 8 200
A-Length of
reduced
Section(min): 9 225 2¼ 60
B-Length of grip
section(min): 3 75 2 50
C-Width of grip
Section(min) 2 50 ¾ 20
In ASTM A370 THE INITIAL GUAGE LENGTH FOR SHEETS IS

50 MM
10
Diagrams As Per ASTM A 370-15
For Rod Type
References Standard(mm) Sub Size Specimens(mm)
G-Gage Length: 50 ± 0.10 35 ± 0.10 25 ± 0.10 1 6 ± 0.10 10 ± 0.10

R-Radius of Fillet(min) 10 6 5 4 2
A-Length of reduced
Section(min): 60 45 32 20 16
D-Diameter 12.5 ± 0.25 8.75 ± 0.18 6.25 ± 0.12 4 ± 0.08 2.5 ± 0.05
In ASTM A370 THE INITIAL GUAGE LENGTH FOR RODS IS 4

TIMES THE DIAMETER (12.5X4=50 MM)
If the length of the specimen is less than as per standard specimen,

you have to do threading at Grip section of the sample.
The threaded Section Length is depend on the specimen Length
Example:- The Overall length of the sample is 100 mm

Then go for any sub size specimen as mentioned above.
1) I choose Reduced diameter is 6.25 mm

2) The gauge length must be 25 mm
3) Length of reduced section is 32mm
4) The remaining length is 100-32=68 mm
5) Then add radius both sides 68-10 mm=58 mm
6) Then half into the remaining length 58/2=29 mm
7) Each threaded portion is 29 mm
11
Threaded tensile samples shown in below figure
Standard Tension Test Specimen for Cast Iron
Specimen 1 Specimen 2 Specimen 3
mm mm mm
G-Length of parallel Shall be equal to or greater than diameter D
D-Diameter 12.5± 0.25 0.750 ± 0.015 20.0 ± 0.40 30.0 ± 0.60
R-Radius of Þllet, min 25 25 50
A-Length of reduced section, min 32 38 60
L-Over-all length, min
95 100 160
B-Grip section, approximate
25 25 45
C-Diameter of end section,
approximate 20 30 48
E-Length of shoulder, min 6 6 8
F-Diameter of shoulder 16.0 ± 0.40 24.0 ± 0.40 36.5 ± 0.40
12
Tensile Test Specimen for Tubular Products As per ASTM A370
Location of the sample for pipe section is longitudinal direction
For tubular Products the standard dimension of the sample is specimen

No 1 in above table
13
Diagram as Per ASTM E8/E8M for Sheet Type
14
Diagram as Per ASTM E8/E8M for Rod Type
In ASTM E8 THE INITIAL GUAGE LENGTH FOR RODS IS 4 TIMES THE

DIAMETER (12.5X4=50 MM)
In ASTM E8M THE INITIAL GUAGE LENGTH FOR RODS IS 4 TIMES THE
DIAMETER (12.5X5=62.5 MM)
If the length of the specimen is less than as per standard specimen,

you have to do threading at Grip section of the sample.
15
Threaded tensile samples shown in below figure
The below specimens are under ASTM E8
The above specimens are under ASTM E 8M
16
Tensile Test Specimen for Tubular Products as per ASTM E8/E8M
Location of the sample for pipe section is longitudinal direction
For tubular Products the standard dimension of the sample is specimen

No 1 in above table
17
Standard Tension test specimen for CAST IRON As Per ASTM E8/E8M
18
BS EN 10002-
1-2001 IS
SAME AS IS
1608:2005
19
Diagrams as Per IS 1865-1991
Tensile Test
1) The Tensile Test carried out on accordance with IS 1608:2005
2) Otherwise unless agreed to between the manufacturer and

purchaser. The test piece shall have a gauge diameter of 14mm
and Initial gauge length is five times the diameter i.e. I.G.L=5d
3) In case the test piece of thickness is 12 mm then the gauge

diameter shall be 8 mm and gauge length is 40 mm.
20
Diagram as Per IS 1865-1991
Impact Test Piece
1) The Impact Test carried out in accordance with IS 1757
21
Diagram as per IS 210-2009
Tensile Test Specimen
Reduced Diameter= 20 mm ± 0.5 mm

Minimum Parallel Length = 55 mm
Minimum Radius= 25 mm
Gripping Dia for plain rods= 23 mm
Gripping Length for plain rods= 65 mm
Gripping Dia for screwed rods= 25 mm
Gripping Length for screwed rods= 30 mm
22
ASTM B 557-
15 IS SAME
AS ASTM
A 370-15
23
BEND TESTING PROCEDURES
IS 1599:2012  Method for Bend Test

ASTM E 290-14  Standard Test Methods for Bend

Testing of Material for Ductility
IS 2329:2005  Metallic Materials — Tube ( In Full

Section ) — Bend Test
24
WORK INSTRUCTION FOR BEND TEST PAGE: 1 OF 1 DATE: 01.12.2015
1.0 REFERENCE: IS: 1599/ 85, ASTM A 370-15.
1.1 Bend Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
1.1.1 PRINCIPLE: THE TEST CONSISTS OF SUBMITTING A TEST PIECE OF ROUND, SQUARE,
RECTANGULAR CROSS SECTION TO PLASTIC DEFORMATION BY BENDING
AND WITHOUT CHANGING THE DIRECTION OF LOADING UNTIL A SPECIFIED
ANGLE OF BEND IS REACHED.
1.1.2 TEST PROCEDURE AFTER RECEIVING OF TEST SPECIMEN IN MECHANICAL LAB.
 CHECK IDENTITY OF SPECIMEN AND TALLY WITH TEST REQUEST.

 CHECK SURFACE FINISH, RADIUS ZONES, EDGES OF THE TEST PIECES
VISUALLY.
 CHECK DIMENSION OF THE TEST PIECE WHETHER IT HAS BEEN PREPARED
ACCORDING TO THE DIAGRAM AS SPECIFIED IN RELEVANT ANNEXURE OF
SAMPLE PREPARATION.
 SET APPROPRIATE GAP BETWEEN ROLLERS AND CHOOSE CORRECT
MANDREL AS PER SPECIFICATION.
 KEEP THE SAMPLE ON THE ROLLERS AND VERY SLOWLY APPLY LOAD
THROUGH MANDREL ON THE CENTER OF THE SAMPLE UPTO THE DESIRED
ANGLE AS SPECIFICATION SAYS.
 AFTER BENDING OBSERVE VISUALLY VERY CAREFULLY THAT ANY CRACK
OR FAILURE OCCURS OR NOT.

25
Diagram for Bend Test (Approximate)
26
Points to be remember for Bend Testing
1) Bend the sample 180°
2) Distance between the supports is equal to Dia of the mandrel + 3 x Thickness of

the plate (l=D+3a)
3) Mandrel size is depending on Material Specification.
4) The Length of the sample shall be minimum 210 mm and also it depending on
thickness of the sample
5) <3 mm thickness of the plate, the width of the plate shall be 20 mm ± 5 mm
≥3 mm thickness of the plate, the width of the plate shall be 20 to 50 mm
6) Bend angle measured by Bevel Protractor.
IS 2329:2005
Tubes Full Section for bend test
Cold Bend Test (Up to and Including 50 mm NB)

When tested in accordance with IS 2329 an unfilled length of tube shall be capable of
being bent cold by tube bending machine around a grooved former (with radius at
bottom of the groove equal to 6 x 0. D. of the tube) through 180” (with weld at 90” to
the plane of bending) without showing any crack at the weld or the metal.
27
HARDNESS TESTING PROCEDURES
IS 1500-PART 1:2013  Metallic Materials - Brinell

hardness Test
IS 1586-PART 1:2012  Metallic Materials -

Rockwell Hardness Test - Part 1: Test Method (Scales
A, B, C, D, E, F, G, H, K, N, T)

ASTM E10-15  Standard Test Method for Brinell -

Hardness of Metallic Materials
ASTM E18-15  Standard Test Methods for Rockwell

Hardness of Metallic Materials
28
WORK INSTRUCTION FOR ROCKWELL PAGE: 1 OF 1 DATE: 01.12.2015
AND BRINELL HARDNESS
1.0 REFERENCE: IS: 1586/ 12, ASTM A 370-15, IS 1500-85
2.0 Rockwell Hardness Test: (PERFORMED IN ROCKWELL

HARDNESS TESTING MACHINE).
1.1.1 PRINCIPLE: FORCING AN INDENTOR (DIAMOND CONE OR STEEL
BALL) INTO THE SURFACE OF A TEST PIECE IN TWO STEPS UNDER
SPECIFIED CONDITIONS AND MEASURING THE PERMANENT INCREASE OF
DEPTH OF INDENTATION.
1.1.2 TEST PROCEDURE AFTER RECEIVING OF TEST SPECIMEN IN

MECHANICAL LAB.
 CHECK IDENTITY OF SPECIMEN AND TALLY WITH TEST

REQUEST.
 CHECK SURFACE FINISH OF THE TEST PIECES VISUALLY.
 PLACE THE TEST PIECE ON A RIGID SUPPORT, WHICH IS IN A
PLANE NORMAL TO THE AXIS OF THE IDENTER AND THE LINE
OF THE INDENTING FORCE.
 USE V-BLOCKS FOR CYLINDRICAL TEST PIECES AND FLAT
ANVIL FOR FLAT TEST PIECES HAVING AT LEAST 60 HRC
HARDNESS.
 SET THE MEASURING DEVICE TO ITS DATUM POSITION AND,
WITHOUT SHOCK OR VIBRATION, INCREASE THE REQUIRED
FORCE WITHIN 2 TO 8 SECOND. THEN AFTER REMOVAL OF THE
FORCE READ THE HARDNESS READING FROM THE DIAL
DIRECTLY.
 FOR CYLINDRICAL TEST PIECE ADD THE HARDNESS VALUE AS
PER TABLE 3, 4 & 5 OF IS: 1586.AND IS :1500
 NOTE DOWN THE ACTUAL HARDNESS VALUE IN THE ‘MASTER
TEST REGISTER (MECHANICAL)’.

29
These Tables are as per IS 1586
30
31
In ASTM A370 CONVERSION TABLES FROM ONE HARDNESS TO OTHER
HARDNESS BASED ON NONAUSTENIC MATERIALS
32
33
34
In ASTM A370 CONVERSION TABLES FROM ONE HARDNESS TO OTHER
HARDNESS BASED ON AUSTENIC MATERIALS
35
36
For Brinell hardness Conversion Tables
37
.
38
39
For HRC Testing
Load Applied is 150 Kgs
Indenter Used is DIAMOND
Reading Scale is BLACK- C SCALE
For HRB Testing

Indenter Used is 1/16” BALL
Reading Scale is RED – B- SCALE
For HRA Testing

Indenter Used is DIAMOND
Reading Scale is BLACK- C SCALE
For HBW(Brinell Hardness) Testing

Load Applied is 187.5 Kgs
Indenter Used is 2.5 mm Tungsten
Measured Depth of Indenter in terms of mm, based on depth take
the values as mentioned above Brinell hardness chart

Indenter Used is 5 mm Tungsten
Load Applied is 500, 1500, 3000 Kgs

Indenter Used is 10 mm Tungsten
After applying the load, the load holding time is 10 to 15 sec

Then remove the load and take the values.
40
IMPACT TESTING PROCEDURES
IS 1757-1988  METHOD FOR CHARPY IMPACT

TEST (V-NOTCH) ON METALLIC MATERIAL
IS 1499-1977  METHOD FOR CHARPY IMPACT

TEST (U-NOTCH) FOR METALS
IS 1598- 1977  METHOD FOR IZOD IMPACT TEST

OF METALS

ASTM E23-12C  Standard Test Methods for

Notched Bar Impact Testing of Metallic Materials
41
WORK INSTRUCTION FOR IMPACT TESTING PAGE: 1 OF 2 DATE: 01.12.2015
REFERENCE: IS: IS 1757-1988, IS 1499-1977, IS 1598-1977,

ASTM – A 370/ 15, ASTM E 23-12C
Impact Test: (PERFORMED IN IMPACT TESTING MACHINE).
Safety Precaution for this equipment must be handled with extra SAFETY, as the
Hammer Force when released from the latch is very powerful.
The Heavy Hammer Range: Low position (168 Joules) or high position (300 Joules)
Indicating dial is graduated in increments of 2.0 Joules for capacities of 168 and 300
Joules.
OPERATION OF MACHINE
1. Checking Zero – Latch pendulum, set pointer to full scale of scale, release latch and let
pendulum fall freely till stop. Adjust pointer to zero (no energy generated).
2. A single lever located on top of the frame operates 3 positions: latched (right), release
(center) and brake (left).
3. Latch the lever to the right, raise the pendulum carefully with both hands till the latch
automatically engaged and hold the pendulum in place. A safety catch prevented low latch
position while pendulum is swinging.
4. Then put in the safety pin to prevent accidental release of pendulum while
loading specimen.
5. Load the Charpy specimen in the charpy anvil with the tong provided.
6. Stay clear of the swing of the pendulum at all time!!!
7. Ensure that the pusher arm and pointer is at the maximum value.
8. Shift the lever to release (center) position, the hammer will swing and break the
specimen.
9. Remove the safety pin, shift the lever to brake (left) position.
Gradually, the hammer will come to a stop.
10. Repeat Step 3 till all specimens completed.
12. Lift hammer slightly away from the charpy anvil and place a wooden block provided in
between and let the hammer rest on the wood on the charpy anvil.
13. Clear all tested materials from the work area and latch the safety door of the cage.
14. Report any damage to Technician before you leave.

42
Diagrams for Charpy V-Notch Impact Test Specimen as per IS 1757

43
Diagrams for Charpy U-Notch Impact Test Specimen as per IS 1499

44
Sample Placement Diagram for both Charpy V-Notch & U-Notch

45
Diagrams for Izod V-Notch Impact Test Specimen as per IS 1598

46
Sample Placement Diagram for Izod V-Notch

47
Sample Tolerances as Per IS 1757 Charpy V-Notch
Sample Tolerances as Per IS 1499 Charpy U-Notch

48
Sample Tolerances as Per IS 1598 IZOD V-Notch
Note: No sub sizes in Izod V-Notch specimen
Sample Tolerances as Per ASTM A370 CHARPY V-Notch
Notch length to edge 90 ±2°

Adjacent sides shall be at 90° ± 10 min
Cross-section dimensions ±0.075 mm
Length of specimen (L) + 0, − 2.5
Centering of notch (L/2) ±1 mm
Angle of notch ±1°
Radius of notch ±0.025 mm
Notch depth ±0.025 mm
Finish requirements 2 μm on notched surface and opposite
face 4 μm on other two surfaces

49
In this standard sub size specimen are there
Notch length to edge 90 ±2°

Adjacent sides shall be at 90° ± 10 min
Cross-section dimensions ±0.075 mm
Length of specimen (L) + 0, − 2.5
Centering of notch (L/2) ±1 mm
Angle of notch ±1°
Radius of notch ±0.025 mm
Notch depth ±0.025 mm
Finish requirements 2 μm on notched surface and opposite
face 4 μm on other two surfaces

50
Sample Tolerances as Per ASTM E23 CHARPY V,U-Notch

51
Sample Tolerances as Per ASTM E23 IZOD V-Notch
Note: No sub sizes in Izod V-Notch specimen

52
Lateral Expansion

53
Impact Strength Calculations
1) Impact Strength measured in terms of Joules
2) Impact Strength can also be converted into j/sq cm and kgfm/sq cm
Calculations
1) J to J/sq cm
For Example: 27 J
1) Dimension of the specimen is 10x10x55
2) Notch Cutting dimension is 2 mm
3) Un-notched dimension is 8 mm
4) Notched area is 10x2=20 sq mm= 0.2 sq cm
5) Un-notched area is 10x8=80 sq mm= 0.8 sq cm
Formula = Observed Joules/Un-notched area = 27/0.8 = 33.75 J/sq cm
2) J to kgfm/sq cm
For Example: 27 J
1) Conversion Factor for J to Kgfm is = 1 J x 0.1016
2) First convert from J to J/sq cm.
3) Same as above calculation the value is 33.75 J/sq cm
4) Then convert from J/sq cm to Kgfm/sq cm is = 33.75 x 0.1016 = 3.43 Kgfm/sq cm

54
FLATTENING TESTING PROCEDURES
IS 2328:2005  Metallic Materials-Tube-Flattening

Test
ASTM A 530-12  Standard Specification for General

Requirements for Specialized Carbon and Alloy Steel
Pipe
55
WORK INSTRUCTION FOR FLATTENING PAGE: 1 OF 1 DATE: 01.12.2015
TEST
1.0 REFERENCE: IS: 2328-2005,ASTM A530/530M-12
1.1 Flattening Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
1.1.1 PRINCIPLE: FLATTENING THE END OF A TUBE OR A TEST PIECE OF SPECIFIED

LENGTH, CUT FROM A TUBE IN ADIRECTION PERPENDICULAR TO THE LONGITUDINAL AXIS
OF THE TUBE, UNTIL THE DISTANCE BETWEEN PLATENS MEASURED UNDER LOAD IN THE
DIRECTION OF FLATTENING REACHES A SPECIFIED VALUE

VISUALLY.
SAMPLE PREPARATION.
 THE TEST SHALL BE CARRIED OUT AT ROOM TEMPERATURE WITH IN THE
LIMITS 10°C TO 35°C.
 PLACE THE TEST PIECE BETWEEN TWO PLATENS
 ENSURE THAT THE WELD OF THE WELDED TUBES IS IN POSITION AS
REQURIED BY THE RELAVENT PRODUCT
 FLATTEN THE TEST PIECE BY MOVING THE PLATENS IN DIRECTION
PERPENDICULAR TO LONGITUDINAL AXIS OF THE TUBE.
 THE RATE OF MOVEMENT OF THE PLATENS SHALL NOT EXCEED 25mm/min.
 AFTER FLATTENING OBSERVE VISUALLY VERY CAREFULLY THAT ANY
CRACK OR FAILURE OCCURS OR NOT.

56
Diagram for Flattening Test (As per IS 2328)
Upper platen
Below platen
Points to be remember for Flattening Testing
1) The length of the test piece no less than 10 mm or not more than 100 mm i.e. the
sample length is obtained by relevant product standard.
2) The edges of the test piece may be rounded by filing or chamfered by other
methods
3) Slight cracking at the edges shall not be considered cause for rejection.
57
Samples Taken as per IS 1161:2008
Load Apply this direction
Upper Cross head
Sample
Below Bed
58
Samples Taken as per ASTM A530/530M
59
For Seamless and Centrifugally Cast
1) Sample Length not less than 63 mm
For Weld pipe
1) Sample not less than 100 mm
2) The weld shall be placed 90° to the direction of applying force
The above Flattening test we calculate distance between the two platens
height i.e. H
H= (1+e) t / (e+t/D)
The Standard ASTM A106 Shows Height between the two platens in
the below table
60
Dimensions are inches in above table
Dimensions are mm in below table
61
62
ERICHSON CUPPING TEST PROCEDURE
IS 10175-1-1993  Mechanical Testing of Metals-

Modified Cupping test – Sheet and Strip (up to 2 mm
thickness)
63
WORK INSTRUCTION FOR ERICHSEN PAGE: 1 OF 1 DATE: 01.12.2015
CUPPING TEST
1.0 REFERENCE: IS: 10175 PART-1 :1993
1.1 Erichsen Cupping Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
1.1.1 PRINCIPLE: Forming a cup shape by pressing a punch with a spherical end
Against a clamped test piece between a blank holder and a die until
a through crack appears. The measured depth of the cup is the result
of the test based on the movement of the-punch.

VISUALLY.
SAMPLE PREPARATION.
 THE TEST SHALL BE CARRIED OUT AT ROOM TEMPERATURE WITH IN THE
LIMITS 10°C TO 35°C.
 DETERMINE THE THICKNESS OF THE TEST PIECE TO THE NERAEST 0.01 mm
 BEFORE OPERATING THE MECHINE,LIGHTLY GREASE THE TWO FACES OF
THE TEST PIECE AND THE PUNCH WITH GRAPHITE GREASE
 CLAMP THE TEST PIECE BETWEEN THE BLANK HOLDER AND DIE
 PLACE THE PUNCH WITHOUT CONTACT WITH THE TEST PIECE
 PROCEED WITH FOMING THE CUP SMOOTHLY AT THE RATE 5 AND 20
MM/MIN TOWARDS THE END OF OPERATION
 TEMINATE THE MOVEMENT OF THE PUNCH AT THE INSTANT WHEN CRACK
APPERS THROUGH THE FULL THICKNESS OF THE TEST PIECE.
 MEASURE THE DEPTH OF PENETRATION TO THE NEAREST 0.1 MM. THIS
DEPTH IS EXPRESSED IN MM AND IS THE VALUE OF ERICHSON CUPPING
INDEX(IE)

64
Erichsen Cupping Test (As per IS 10175)
Test Piece Size
Thickness = Plate thickness (Max 2 mm)
90 mm
45 mm
Diagram for Ericshen Cupping Test Fixture (As per IS 10175)
65
Points to be remember for Erichsen Cupping Test
1) The length of the test piece 45X90 mm
2) The edges of the test piece may be rounded by filing or chamfered by other
methods
3) Before testing, the test piece shall not be submitted to any hammering or cold or
hot working.
66
Cupping Test as on IS 513-2008
67
SPRING LOCK WASHER TEST PROCEDURE
IS 3063-1994 Single coil Rectangular section Spring

Lock Washers-Specification
68
WORK INSTRUCTION FOR SPRING LOCK PAGE: 1 OF 1 DATE: 01.12.2015
WASHERS TEST
1.0 REFERENCE: IS: 3063-1994
1.1 Spring Lock Washers Test: (PERFORMED IN UNIVERSAL TESTING MACHINE).
Tests conduct on spring Lock Washers i.e.
1) Dimension test
2) Hardness test
3) Permanent set test
4) Permanent Load test
5) Twist test
Dimension Test: - Spring lock washer looks like this below figure

69
70
71
Hardness Test: -
=>The spring lock washers after coiling shall be suitably heat treated to
hardness HV (430-530).
Permanent Set Test:-
The above test as follows

First take one bolt and one spring lock washer and that washer moves freely in to the
bolt
Take two flattened and hardened washers and the hardness is not less than 60 HRC
The washer placed between the two hardened, flattened washers
The above three washers engaged with bolt
The bolt with washers placed on lower bed of the UTM Machine
And take one pipe placed into that bolt, contact with the three washers
72
After apply the compressive load on that pipe up to specified load as on table 2A, 2B
Maintain the holding time after compression load is 2 minutes.
Then release the load
Measure the free height of the washer after release the load
Compare the free height of washer as mentioned in below tables.
Permanent Load Test: -
73
Same as the above procedure but take 10 spring washers and placed in between the
flattened washers one by one
And apply the compressive load as above tables 2A, 2B
And maintain holding time is 48 hrs after compressive load
Release the load and measure free height of the ten spring lock washers
Twist Test: -
As shown in below Diagram
74
WELD TEST PROCEDURES FOR WELD COUPON
IBR 1950-2011 Indian Boiler Regulations, 1950
and Indian Boiler Act 1923
ASME SEC-IX-2015 Qualification standard for

welding, brazing, and fusing procedures; welders;
brazers; and welding, brazing and fusing operators.
AWS D 1.1/1.1 M-2015 Structural welding code-
steel
BS EN ISO 15614-1-2004+A2:2012 Specification
and qualification of welding procedures for metallic
materials-welding-procedure test
API 1104-2014 21ST EDITION Welding of pipelines

and Related Facilities
IS 7310-PART1-1974(2006) Approval test for

welders working to approved welding procedures
75
IBR TEST PROCEDURE FOR WELD COUPON
IBR 1950-2011 Indian Boiler Regulations, 1950
and Indian Boiler Act 1923
76
WORK INSTRUCTION FOR IBR TEST PAGE: 1 OF 4 DATE: 01.12.2015
FOR WELD
REFERENCE: IBR 1950-2011
Selection of Test Pieces
The above figure shows how to mark the samples on weld plate
The below tests are conduct on weld plate as per IBR 1950-2011
1) Transverse Tensile Test - 1 No

2) All Weld Test - 1 No
3) Bend Test(at weld)
a) Outer surface bend - 1 No
b) Inner surface bend - 1 No
4) Impact Test(at weld)
a) Izod impact test, outer surface of plate- 1 No
b) Izod impact test, inner surface of plate- 1 No
5) Micro and Macro Test - 1 No for each specimen
77
Transverse Tensile Test:-
When your cutting for gas cutting the tensile sample marking on the plate
shall be 45 mm why because after gas cutting will do milling of tensile
specimen total width, the width shall be 37 mm, reduced section shall be 25
mm and radius is R50
78
1) In Transverse tensile test specimen is like as a tensile test and find
out the tensile strength
2) The tensile strength meets the specified value of parent metal Tensile
strength
3) Some cases the transverse tensile test broken inside the weld, in
those cases also compares the specified value of parent metal tensile
strength. The tensile strength meets the specified value then the
tensile test sample is satisfactory and the transverse tensile test is
acceptable
All Weld Test
1) All Weld specimen cut only on hand saw machine why because will
do cut gas cutting some properties are changes due to heat.
2) The specimen cut longitudinally along the weld with the length of
180 mm and reduced section shall be not more than 20 mm as shown
in above figure.
3) In All weld specimen test like as a tensile test and to find out the
properties like as follows
a) Tensile strength
b) Yield Stress or 0.2% Proof Stress
c) % Elongation
d) % Reduction Area
4) The above properties are meets the specified values of parent metal
then the All weld test is Acceptable, if any one of the above properties
not meet the specified value then the test is not Acceptable.
79
Bend Test:
80
1) The Bend Test specimen width shall be at least 30 mm
2) The surface of the specimen shall be machined just to remove the
surface irregularities of the plate and weld.
3) Where plate thickness does not exceed 38.1 mm the thickness of the
specimen shall be equal to the full thickness of the plate.
4) Where the plate thickness exceed 38.1 mm the thickness of the
specimen is reduced to 38.1 mm
Or
5) The plate thickness exceeds or equal to 38.1 mm then the plate
thickness reduced to 31.75 mm from one surface of the plate.
6) Bend tests are
a) Outer surface bend: The plate thickness more than or equal to
38.1 mm will reduce the thickness to 31.75 mm from inner surface
of the plate
b) Inner surface bend: The plate thickness more than or equal to 38.1
mm will reduce the thickness to 31.75 mm from outer surface of
the plate
7) The Bend test carried out 3 point bending as shown above figure
8) Mandrel used i.e.3T and bend angle 180°
9) Distance between the rollers after completion of test is 5.2T
Acceptance
81
Impact Test:-
Izod Impact Test at 50°C ± 2°C
1) Samples are taken by sample marking

a) Outer surface Impact Izod test
b) Inner surface impact Izod test
2) If the plate thickness 8 and 10 mm will not to impact test why
because the standard Izod Impact test specimen size is 10x10x75 mm
Due to that reason will do impact test from 12 thick plate.
3) First cut impact specimen 15 mm and do milling, surface grinding
after that the sample size meets the standard size, then go for notch
cutting V-notch
4) V-notch cutting done by broaching machine. The V-notch dimensions
are
a) Notch angle 45°
b) Notch depth is 2mm
82
5) The above two parameters are measured with V-profile by Profile
Projector
6) The Notch cutting shall be
a) The center of the weld at outer surface
b) The center of the at Inner surface
7) Each plate have two Impact Izod test pieces
How to do the test at 50°C
1) First take one steel bath and poured into water up to a certain level
2) Insert the samples in water steel bath
3) Insert the temperature controller sensor into that water steel bath
4) Then put a heater in to the water steel bath after that boil the water
by using heater
5) Water slowly increase the temperature and it shows on temperature
controller
6) After reaches the desired temperature will maintain the temperature
at 15 min i.e. holding time
7) Also take temperature controller sensor and put on the sample will
show temperature
8) Switch of the heater
9) Once will check the machine accuracy
10) Take the sample and put on machine, release the lock note
down the reading and same thing will do another sample also
Micro and Macro Test
1) J to kgfm/sq cm
For Example: 27 J
1) Conversion Factor for J to Kgfm is = 1 J x 0.1016

2) First convert from J to J/sq cm
3) J/0.8 = the value is 33.75 J/sq cm
4) Then convert from J/sq cm to Kgfm/sq cm is = 33.75 x 0.1016 = 3.43
Kgfm/sq cm
83
WELD TEST PROCEDURE FOR WELD
COUPON AS PER ASME SEC-IX-2015
ASME SEC-IX-2015Qualification Standard for

Welding and Brazing Procedures,Welders, Brazers,
andWeldingand Brazing Operators
84
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER ASME SEC-IX-2015
REFERENCE: ASME SEC-IX-2015
Section IX of the ASME Boiler and Pressure Vessel Code relates to the qualification of welders, welding
operators,brazers, and brazing operators, and the proceduresemployed in welding or brazing in
accordance with theASME Boiler and Pressure Vessel Code
In ASME SEC-IX there are two procedures.
1) Welding procedure specification(WPS)

2) Welding performance qualification.(WPQ)
Now we are discussed with WPS and WPQ
Generally the WPS and WPQ test conduct on Butt Welds
Butt welds are different in shapes
1) Plate to Plate
2) Pipe to Pipe
WPS
WPS Tests to be conducted on Weld Plate or Pipe
1) Transverse tensile test - 2 No’s
2) Face Bend Tests - 2 No’s
3) Root Bend Tests - 2 No’s
4) Side Bend Tests - 4 No’s
Supplementary test
1) Impact Test
Plate to Plate and Pipe to Pipe WPS Test: The plates are like this
The Pipes are like this
85
Based on ASME SEC-IX the above test divided into two parts
a) Less than 10mm or equal to 10 mm plate thickness
b) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates
and pipes
The standard size of the WPS plate is 300 mm length X 250 mm Wide
Plate Thickness Less Than 10 mm

Or equal to 10 mm Greater Than 10 mm thickness
Figure-1 Figure-2
Figure-3 Figure-4
86
The above figures (1, 2) discard portion of the sample is 25 mm
In Figure-1 & 3 will take sample like as follows
1) Transverse Tensile Test - 2 No’s - Marking for this test is 35 mm for gas cut
2) Face bend Tests - 2 No’s - Marking for this test is 40 mm for gas cut
3) Root Bend Tests - 2 No’s - Marking for this test is 40 mm for gas cut
1) Transverse Tensile Test - 2 No’s -Marking for this test is 35 mm for gas cut
2) Side Bend Tests - 4 No’s -Marking for this test is 15 mm for gas cut
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per ASME SEC-IX
87
1) When you choose gas cutting the tensile sample marking on the plate or pipe shall be 35 mm
why because after gas cutting will do milling of tensile specimen total width, the width shall
be 31 mm, reduced section shall be 19 mm and radius is R25mm
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile strength
3) The tensile strength meets the specified value of parent metal Tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those cases also
compares the specified value of parent metal tensile strength. The tensile strength
meets the specified value then the tensile test sample is satisfactory and the
transverse tensile test is acceptable
5) In ASME SEC-IX if the specimen breaks in the base metal outside of the weld or
weld interface, the test shall be accepted as meeting the requirements, provided the
strength is not more than 5% below the minimum specified tensile strength of the
base metal.
6) In case of thickness is greater than 38 mm then it will take multiple Transverse
tensile specimens
7) Multiple tensile specimens are also follow same diagram as shown above QW
462.1(a) in ASME SEC-II
8) Transverse Tensile Test specimen dimensions (Diagram) are same at any Plate
thickness. As given above two figures for Plate QW 462.1(a) and for Pipe QW
462.1(b).
Face Bend and Root Bend tests:
As shown in below figures
88
1) The Plate or Pipe thickness less than or equal to 10 mm then only we take Face &
Root bend specimens
2) 2 No’s Root bends & 2 No’s Face bends samples are taken in WPS Test.
3) When you choose gas cutting the face bend and Root bend samples mark on the
plate or pipe shall be 40 mm why because after gas cutting will do milling of
bend specimen total width is 38 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend an angle of
180°
5) The length of the specimen is 150 mm (min) or as required for bend test.
For example Plate thickness is 10 mm = The Mandrel used is 4T = 4x10=40 mm Dia

6) You are doing Face bend test the mandrel is put on the root side of the weld then
only face side of the weld comes outer surface as well as Root bend also the
mandrel put on the face side of the weld then only Root side of the weld comes
outer surface
7) Distance between the rollers = mandrel +2xT
8) After test will have to observer any cracks on the weld and corners also.
9) The Acceptance of cracks is not over the 3mm on the weld curved surface.
In Pipe Face bend and Root bend test specimen width is vary at lower diameters in that
cases will take the width of the bend specimens is like as follows
Note:
1) If the pipe being tested has a diameter of NPS 4 (DN 100) or less, the width of the bend specimen
may be 3/4 in. (19 mm)
2) For pipe diameters NPS 2 (DN 50) to and including NPS 4 (DN 100). The bend specimen width may be
3/8 in. (10 mm)
3) for pipe diameters less than NPS 2 (DN 50) down to and including NPS 3/8 (DN 10) and as an
alternative, if the pipe being tested is equal to or less than NPS 1 (DN 25) pipe size, the width of the
bend specimens may be that obtained by cutting the pipe into quarter sections, less an allowance for
saw cuts or machine cutting. These specimens cut into quarter sections are not required to have one
surface machined flat as shown in QW-462.3(a). Bend specimens taken from tubing of comparable
sizes may be handled in a similar manner.
89
Side bend Tests:
As shown in below figure
1) The Plate or Pipe thickness greater than 10 mm then only we take Side bend
specimens
2) 4 No’s Side bends samples are taken in WPS Test.
3) When you choose gas cutting the Side bend samples mark on the plate or pipe
shall be 15 mm why because after gas cutting will do milling of bend specimen
total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is 4T or Ø40 ,and bend an angle of
180°

6) Why the mandrel is 40 mm Dia for all thickness is the side bend specimen width
taken as 10 mm as per standard and will apply the load on the sample is side of
the weld in that cases the width is converted into thickness and the thickness is
converted into width. So width =10 mm converted into thickness that’s why will
choose a mandrel size is 40 Dia for thickness greater than 10 mm plates or pipes.
7) You are doing side bend test the mandrel is put on the side of the weld then only
total surface of the weld comes outer surface
9) If the plate or Pipe thickness above 38 mm will do multiple Side bend Specimens.
10)After test will have to observer any cracks on the weld and corners also.
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface.
90
WPQ
1) Face Bend Test - 1 No
2) Root Bend Test - 1 No
Based on ASME SEC-IX the above test divided into two parts
c) Less than 10mm or equal to 10 mm plate thickness
d) Greater than 10 mm plate thickness
and pipes

Figure-5 Figure-6
Figure-7 Figure-8
91
1) Face bend Test - 1 No - Marking for this test is 40 mm for gas cut
2) Root Bend Test - 1 No - Marking for this test is 40 mm for gas cut
Face bend & Root bend test:

1) The Plate or Pipe thickness less than or equal to 10 mm then only we take Face &
Root bend specimen
2) 1 No’s Root bend & 1 No’s Face bend samples are taken in WPQ Test.
plate or pipe shall be 40 mm why because after gas cutting will do milling of
bend specimen total width is 38 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend an angle of
180°

92
outer surface
9) The Acceptance of cracks is not over the 3mm on the weld curved surface.
In Pipe Face bend and Root bend test specimen width is vary at lower diameters in that
cases will take the width of the bend specimens is like as follows
Note:
1) If the pipe being tested has a diameter of NPS 4 (DN 100) or less, the width of the bend specimen
may be 3/4 in. (19 mm)
2) For pipe diameters NPS 2 (DN 50) to and including NPS 4 (DN 100). The bend specimen width may be
3/8 in. (10 mm)
3) for pipe diameters less than NPS 2 (DN 50) down to and including NPS 3/8 (DN 10) and as
an alternative, if the pipe being tested is equal to or less than NPS 1 (DN 25) pipe size, the
width of the bend specimens may be that obtained by cutting the pipe into quarter sections,
less an allowance for saw cuts or machine cutting. These specimens cut into quarter
sections are not required to have one surface machined flat as shown in QW-462.3(a). Bend
specimens taken from tubing of comparable sizes may be handled in a similar manner.
Side bend Tests:
1) The Plate or Pipe thickness greater than 10 mm then only we take Side bend
specimens
2) 2 No’s Side bends samples are taken in WPQ Test.
180°

93
10)After test will have to observer any cracks on the weld and corners also.
94
COUPON AS PER AWS D1.1/1.1M-2015
AWS D1.1/1.1M-2015Structural welding code-Steel
95
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER AWS D1.1/1.1M-2015
REFERENCE: AWS D 1.1/1.1 M-2015
In AWS D 1.1/1.1 M there are two procedures.

1) Plate to Plate
2) Pipe to Pipe
WPS
1) Transverse tensile test - 2 No’s
2) Face Bend Tests - 2 No’s
3) Root Bend Tests - 2 No’s
Supplementary test
5) Charpy Impact tests - 2 Sets(one set is WELD other one is HAZ)
Plate to Plate and Pipe to Pipe WPS Test: The plates are like this
The Pipes are like this
96
Based on AWS D1.1/1.1 M the above test divided into two parts ON PLATES,
PIPES, and TUBES
a) Less than 10mm or equal to 10 mm plate thickness
b) Greater than 10 mm plate thickness
The standard size of the WPS plate is 380 mm length X 360 mm Wide

Figure-1 Figure-2
The below diagrams shown how to mark the samples on BUTT WELD coupon for Pipes
Figure-3 Figure-4
97
Figure-5
The above figures (1, 2) discard portion of the sample is 25
mm In Figure-1 & 3 will take sample like as follows
1) Transverse Tensile Test - 2 No’s - Marking for this test is 35 mm for gas cut
3) Root Bend Tests - 2 No’s -Marking for this test is 30 mm for gas cut
4) Charpy Impact Test(if Reqd) - 2 sets - Marking for this test is 100x100 mm for gas cut
Note: If Pipe O.D is >100 mm & the pipe wall thickness is <10 mm the face bend and Root
bend specimens width is 42 mm for gas cut why because the width of the specimen is 40
mm as per standard
3) Charpy Impact Test(if Reqd) - 2 sets - Marking for this test is 100x100 mm for gas cut
In Figure- 5 will take sample like as follows
Or
4) Root Bend Tests - 2 No’s - Marking for this test is 42 mm for gas cut
5) Charpy Impact Test(if Reqd) - 2 sets -Marking for this test is 100x100 mm for gas cut
Note: If TUBE or PIPE thickness <10 mm the face bend and Root bend specimens width is
42 mm for gas cut why because the width of the specimen is 40 mm as per standard
Note: If TUBE or PIPE thickness >10 mm the side bend specimens width is 15 mm for gas
cut why because the width of the specimen is 10 mm as per standard
98
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per AWS D 1.1/1.1M
1) When you choose gas cutting the tensile sample marking on the plate or pipe shall
be 35 mm why because after gas cutting will do milling of tensile specimen total
width, the width shall be 32 mm, reduced section shall be 20 mm and radius is
R25mm & Smaller diameters like 50 mm & 75 mm diameter the reduced section
shall be 12 mm and width of grip section shall be 24 mm but radius is same.
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile
strength
4) Some cases the transverse tensile test broken inside the weld, in those
cases also compares the specified value of parent metal tensile strength.
The tensile strength meets the specified value then the tensile test sample
is satisfactory and the transverse tensile test is acceptable
5) In case of thickness is greater than 38 mm then it will take multiple
Transverse tensile specimens
6) Multiple tensile specimens are also follow same diagram as shown above
Figure
7) Transverse Tensile Test specimen dimensions (Diagram) are same at
any Plate or Pipe or Tube any thickness except for smaller diameter
of Pipe
99
Face Bend and Root end tests:
1) The Plate or Pipe or Tube thickness less than or equal to 10 mm then

only we take Face & Root bend specimens
3) When you choose gas cutting the face bend and Root bend samples
mark on the plate or pipe shall be 42 mm why because after gas
cutting will do milling of bend specimen total width is 40 mm as per
standard. Where as in pipe or Tube <100 mm diameter will take 30
mm for gas cutting and reduced to 25 mm width.
4) In face & Root bend specimens use the mandrel size is depend upon
the yield stress of the parent metal please see below and bend an
angle of 180°
Yield stress Dia of the mandrel
Under 345 Mpa 38.1 mm
345 MPa to 620 MPa 50.8 mm
Over 620 MPa 63.5 mm
6) You are doing Face bend test the mandrel is put on the root side of the
weld then only face side of the weld comes outer surface as well as Root
bend also the mandrel put on the face side of the weld then only Root
side of the weld comes outer surface
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and not
over 6 mm for corner cracks.
100
Side bend Tests:
1) The Plate or Pipe or Tube thickness greater than 10 mm then only we take
Side bend specimens
4) In Side bend specimens use the mandrel size is depend upon the
yield stress of the parent metal please see below and bend an angle
of 180°
345 MPa to 620 MPa 50.8 mm
Observation: The Acceptance of cracks is not over the 3mm on the weld curved surface
and not more than 6 mm on corner cracks.
101
WPQ
1) Face Bend Test - 1 No
2) Root Bend Test - 1 No
Based on AWS D 1.1/1.1 M the above test divided into two parts
c) Less than 10mm or equal to 10 mm plate thickness
d) Greater than 10 mm plate thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon for plates,
pipes, Tubes

Figure-5 Figure-6
Figure-7 Figure-8
102
Figure-9
In Figure- 5 & 7 will take sample like as follows
In Figure- 6 & 8 will take sample like as follows
In Figure- 9 will take sample like as follows
Or
Face bend & Root bend test:

1) The Plate or Pipe or Tube thickness less than or equal to 10 mm then

only we take Face & Root bend specimens
103
2) 1 No Root bends & 1 No Face bends samples are taken in WPQ Test.
standard. Where as in pipe or Tube <100 mm diameter will take 30
mm for gas cutting and reduced to 25 mm width.
4) In face & Root bend specimens use the mandrel size is depend upon
the yield stress of the parent metal please see below and bend an
angle of 180°
345 MPa to 620 MPa 50.8 mm
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and not
over 6 mm for corner cracks.
Side bend Tests:
1) The Plate or Pipe or Tube thickness greater than 10 mm then only

we take Side bend specimens
2) 2 No’s Side bends samples are taken in WPQ Test.
3) When you choose gas cutting the Side bend samples mark on the
plate or pipe shall be 15 mm why because after gas cutting will do
milling of bend specimen total width is 10 mm as per standard.
4) In Side bend specimens use the mandrel size is depend upon the
yield stress of the parent metal please see below and bend an angle
of 180°
104
345 MPa to 620 MPa 50.8 mm
and not more than 6 mm corner cracks.
Charpy Impact Test(If Required):
In WPS will do Impact Test as per customer requirement
Based on that AWS D 1.1 says take the samples into three positions there are
1) Center weld V-Notch( 3 specimens)
2) Fusion line +1 mm V-Notch (3 specimens)
3) Fusion line +5 mm V-Notch (3 specimens)
The V-Notch Profile is same as ASTM A370-2015

1) Notch Angle is 45° ± 1°
2) Notch Depth is 2mm ± 0.02 mm
The above three types of Impact sets as shown given below
105
As per weld joint will take the samples.
Samples Test Location and its Energy
106
107
COUPON AS PER BS EN ISO 15614-
1-2004+A2-2012
BS EN ISO 15614-1-2004+A2:2012Specification
and Qualification of welding procedures for Metallic
Materials-Welding Procedure Test-Part: 1-Arc and
Gas welding of steels and Arc welding of Nickel and
Nickel alloys
108
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER BS EN ISO 15614
REFERENCE: BS EN ISO 15614
Now we are discussed with BS EN ISO 15614

Butt Joint Test piece
1) Transverse Tensile Test - 2 No’s
2) Transverse Root Bend Tests - 2 No’s
3) Transverse Face Bend Tests - 2 No’s
4) Transverse Side Bend Tests - 4 No’s
5) Charpy Impact Test - 2 sets
6) Hardness Test (Vickers) - Required
7) Macroscopic Examination - 1 No
Based on BS EN ISO 15614 the above test divided into two parts
a) Less than 12mm
b) Greater than and equal to 12 mm plate thickness
and pipes
Figure-1
109
Figure-2
The above figures (1) discard portion of the sample is 25 mm
If the thickness of plate or pipe < 12 mm

2) Transverse Root Bends - 2 No’s
3) Transverse Face Bends - 2 No’s
4) Charpy Impact tests - 2 sets(Customer Requirement)
5) Hardness Test (VICKERS) - Required
If the thickness of plate or pipe ≥ 12 mm

2) Transverse Side Bends - 4 No’s
3) Charpy Impact tests - 2 sets
4) Hardness Test (VICKERS) - Required
In BS EN ISO 15614 shows each test has its own standard
1) Transverse Tensile Test - EN 895

2) Transverse Side, Root & face Bends - EN 910 -
3) Charpy Impact tests - EN 875
4) Hardness Test (VICKERS) - EN 1043-1
5) Macroscopic Examination - EN 1321
110
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per EN 895
Test Specimen for Plates
Test specimen for Pipes
111
1) When you choose gas cutting the tensile sample marking on the plate or pipe shall
be 40,30,20 mm why because after gas cutting will do milling of tensile specimen
total width, the width shall be 37, 24,12 mm, reduced section shall be 25,12,6 mm
respectively and radius is R25mm
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile
strength
4) Some cases the transverse tensile test broken inside the weld, in those
cases also compares the specified value of parent metal tensile strength.
The tensile strength meets the specified value then the tensile test sample
is satisfactory and the transverse tensile test is acceptable
5) In case of thickness is greater than 30 mm then it will take multiple
Transverse tensile specimens
6) Multiple tensile specimens are also follow same diagram as shown
above figures
7) Transverse Tensile Test specimen dimensions (figure 1 & 2) are
same at anyPlate thickness. As given above two figures for Plate and
for Pipe.
8) In Case for dissimilar metal joints the Tensile Strength shall not be
less than the minimum value specified for the parent metal having
the lowest Tensile Strength.
Face Bend and Root Bend tests: As Per EN 910

1) The Plate or Pipe thickness less than 12 mm then only we take Face &
Root bend specimens
standard.
4) In face & Root bend specimens use the mandrel size is 4T,and bend
an angle of 180°
For example Plate thickness is 10 mm = The Mandrel used is 4T =4x10=40 mm Dia
112
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and the
corner cracks are ignored.
Side bend Tests: As per EN 910

1) The Plate or Pipe thickness greater than and equal to 12 mm then only we
take Side bend specimens
180°
113
Charpy Impact Tests: As Per EN 875
Charpy V-Notch angle 45° and Notch Depth 2 mm
Different types of weld shapes and samples taken as shown in above figure
Important:
Specification
114
Hardness Test (Vickers) : As Per EN 1043-1
The above figure shows the indentation of Harness (Vickers)
115
Macroscopic Examination Test: As Per EN 1321
The examination of the test piece by naked eye, under low magnification, with or without
etching.
Abbreviations.
Purpose of Test
116
Removal of Test Piece
Test Specimen Preparation:
Etching Methods
Report
117
COUPON AS PER API 1104 - 2014
API 1104-2014 Welding of Pipelines and Related

Facilities
118
WORK INSTRUCTION FOR WELD TEST FOR WELD COUPON AS PER API 1104
REFERENCE: API 1104
This standard covers the gas and arc welding of butt, fillet, and socket welds in carbon
and low-alloy steel piping used in the compression, pumping, and transmission of crude
petroleum, petroleum products, fuel gases, carbon dioxide, nitrogen, and where applicable,
covers welding on distribution systems. It applies to both new construction and in service
welding. The welding may be done by a shielded metal arc welding, submerged arc welding, gas
tungsten arc welding, gas metal arc welding, flux-cored arc welding, plasma arc welding,
oxyacetylene welding, or flash butt welding process or by a combination of these processes
using a manual, semiautomatic, mechanized, or automatic welding technique or a combination
of these techniques. The welds may be produced by position or roll welding or by a
combination of position and roll welding.
This standard also covers the procedures for radiographic, magnetic particle, liquid
penetrant, and ultrasonic testing, as well as the acceptance standards to be applied to
production welds tested to destruction or inspected by radiographic, magnetic particle, liquid
penetrant, ultrasonic, and visual testing methods.
In API 1104 there are two procedures.

1) Pipe to Pipe
WPS
WPS Tests to be conducted on Weld Pipe Only

1) Transverse tensile test
2) Face Bend Tests
3) Root Bend Tests
4) Side Bend Tests
5) Nick Break Tests
If Repair, tests to be conducted

1) Charpy Impact Test
2) Hardness Test
119
Based on API 1104 the above test divided into two parts
a) Less than 12.7 mm Wall thickness
b) Greater than 12.7 mm Wall thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon pipes
120
The below table shows how many samples and what types of tests to be conducted in WPS
Sample preparation
Transverse Tensile Test: - Standard Specimen as Per API 1104-2014
OR
121
1) When you choose gas cutting the tensile sample marking on the pipe shall be 30 mm why
because after gas cutting will do milling of tensile specimen total width, the width shall be
25 mm (Figure (a)). OR The Tensile specimen preparation as shown in above figure (b).
2) In Transverse tensile test specimen is like as a tensile test and find out the tensile strength
4) Some cases the transverse tensile test broken inside the weld, in those cases also
compares the specified value of parent metal tensile strength. The tensile strength
meets the specified value then the tensile test sample is satisfactory and the
transverse tensile test is acceptable
5) In API 1104 if the specimen breaks in the base metal outside of the weld or weld
interface, the test shall be accepted as meeting the requirements, provided the
strength is not more than 5% below the minimum specified tensile strength of the
base metal.
6) Thickness is as Material thickness.
Face Bend and Root Bend tests:

1) The Pipe Wall thickness less than 12.7 mm then only we take Face & Root bend
specimens
2) Root bends & Face bends samples are taken in WPS Test follow above table.
Pipe shall be 30 mm why because after gas cutting will do milling of bend
specimen total width is 25 mm as per standard.
4) In face & Root bend specimens use the mandrel size is 90 mm, Distance
between the rollers is 120 mm and bend an angle of 180°
outer surface
7) Distance between the rollers = 120 mm
9) The Acceptance of cracks is not over the 3mm on the weld curved surface and not more
than 6 mm at corner radius cracks.
122
Side bend Tests:
1) The Pipe wall thickness greater than 12.7 mm then only we take Side bend
specimens
2) Side bends samples are taken in WPS Test as shown above table.
4) In Side bend specimens use the mandrel size is 90 mm, Distance between the
rollers is 120 mm and bend an angle of 180°
7) Distance between the rollers = 120 mm
and not more than 6 mm on corner radius cracks.
123
Nick Break Test:
As Shown in below figure
1) When you choose gas cutting the Nick Break sample marking on the pipe shall be
30 mm why because after gas cutting will do milling of Nick Break specimen total
width, the width shall be 25 mm (Figure (5)).
2) The Nick Break test specimen is like as a tensile test Procedure and find out the
defects inside the weld.
3) The Nick Break sample preparation is shown in above figure, cut 3 mm groove one
side of the sample,3 mm groove cut another side of the sample in the pipe thickness
& 1.6 mm groove cut top and 1.6 mm groove cut on bottom of the sample along the
weld after will do Nick break test.
Acceptance
124
Bend Set up Diagram
125
REPAIR PROCEDURE FOR WPS TEST
Repair procedure Qualification (WPS)
Types of repair procedures
Qualification
Testing of Repair Welds

Tensile, Nick Break and Bend Tests
The above three test already discussed in WPS test. Dimensions are same in Repair
procedure also.
In repair procedure additional tests are added there are
126
1) Macro Test
2) Hardness Test
3) Charpy Impact Test
Now we discussed with above three tests
Macroscopic Examination
Hardness Test
127
128
Charpy Impact Test
Charpy Impact Testing shall be performed at locations in the weld as specified company
Acceptance
129
WPQ
WPS Tests to be conducted on Weld Pipe Only
1) Transverse tensile test
2) Face Bend Tests
3) Root Bend Tests
4) Side Bend Tests
5) Nick Break Tests
Based on API 1104 the above test divided into two parts
c) Less than 12.7 mm Wall thickness
d) Greater than 12.7 mm Wall thickness
The below diagrams shown how to mark the samples on BUTT WELD coupon pipes
130
1) The above tests are already discussed in WPS
2) All tests dimensions are same as WPS test
3) Based on above table will take the samples and tests to be conducted
Repair Welder Qualification Test
Based on above table -7 take the sample and conduct test on welded pipe
131
TMT BARS TEST PROCEDURE
IS 1786:2008High Strength deformed steel bars

and wires for concrete reinforcement
specification
132
WORK INSTRUCTION FOR TMT BARS AS PER IS 1786-2008
REFERENCE: IS 1786-2008
Tests to be conducted on TMT BARS

1) Unit Weight Test
2) Tensile test
3) Bend Test
4) Rebend Test
5) Ar Value of TMT Bar
Unit Weight Test
Procedure:
1) Take the sample 1 meter length of TMT bar
2) Put the sample on weighing machine and take the weight in terms of kgs
3) Note down the reading and compare the value to standard weight in specification.
4) Based on that confirm TMT bar is Acceptable or Not.
Standard weights of TMT bars as given in below table
Tolerances on NOMINAL MASS and DIMENSIONS as given below
in
133
Tensile Test:
1) The tensile test carried out In accordance with IS 1608:2005

2) In TMT bars will do testing directly without machining upto 28 mm size bars,above
28 mm bars can do directly or can do machining also.
3) Above 28 mm size bars do machining only at deformation of bars i.e transvers ribs
only do the machining.
4) After machining caluclate area of machined diameter.
5) Remaining testing is same as tensile test.
6) Find out tensile strength,yeild stress, 0.2 % proof stress, %Elongation.
7) Compare observed values to specified values of TMT bars and give the report that
material is ok or Not.
134
Bend Test:
Re-bend Test:
135
Ar value of TMT bar:
Ar means The mean projected rib area per unit length(sq mm/mm)
Calculation of Ar is
Ar=A x N x sin θ / S
A= Area of rib (sq mm)
N=Number of transverse ribs
First calculate A i.e.
A= Area of rib (sq mm) = 2/3 x L x D

L= Length of transverse rib (mm)
D=depth of transverse rib (mm)
And calculate Ar using formula

Ar=A x N x sin θ / S (sq mm/mm)
Standard Ar values of TMT bars
136

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MECHANICAL LAB

TENSILE TESTING PROCEDURES 1 - 23

BEND TESTING PROCEDURES 24 - 27

HARDNESS TESTING PROCEDURES 28 - 40

IMPACT TESTING PROCEDURES 41 - 54

FLATTENING TESTING PROCEDURES 55 - 62

SPRING LOCK WASHER TESTING PROCEDURE 68 - 74

WELD TEST PROCEDURES FOR WELD COUPON 75 - 131

TMT BARS TEST PROCEDURE 132 - 136

DIAGRAMS FOR TESTING FIXTURES

Proof load fixture Fig-1

ASTM A 370-15  Standard Test Methods and

ASTM E8/E8M-15  Standard Test Methods for

BS EN 10002-1-2012  Metallic materials - Tensile

IS 210-2009  Grey Iron Castings

IS 1865-1991  Iron Castings with Spheroidal or

ASTM B 557-10  Standard Test Methods for

1.1.1 PRINCIPLE: THE TEST CONSISTS OF STRAINING A TEST PIECE BY

 CHECK IDENTITY OF SPECIMEN AND TALLY WITH TEST

 CHECK ZERO SETTING OF THE MACHINE & PLACE THE

IML/TP/01 PROCEDURE MANUAL PREPARED BY:

1.1.2.1 DETERMINATION OF YIELD STRESS:

 NOTE YIELD POINT VERY CAREFULLY BY DROP BEAM

 CALCULATE YIELD STRESS USING THE FORMULA: -

LOAD AT YIELD POINT

MAINTAIN UNIT AS DESIRED BY THE SPECIFICATION.

> 150000 ( IRON, STEEL, STAINLESS 6 30

1.1.2.2 DETERMINATION OF PROOF STRESS:

 FOR DETERMINATION OF PROOF STRESS THE RATE OF

IML/TP//01 PROCEDURE MANUAL PREPARED BY:

1.1.2.3 DETERMINATION OF ULTIMATE TENSILE STRESS (U.T.S.):

 FOR DETERMINATION OF ULTIMATE TENSILE STRESS NOTE

1.1.2.4 DETERMINATION OF PERCENTAGE ELONGATION:

 TAKE OUT THE BROKEN TEST PIECE FROM THE MACHINE.

FINAL LENGTH – ORIGINAL LENGTH

IML/TP/01 PROCEDURE MANUAL PREPARED BY:

1.1.2.5 DETERMINATION OF PERCENTAGE REDUCTION AREA :

 TAKE OUT THE BROKEN TEST PIECE FROM THE MACHINE.

ORIGINAL DIAMETER – REDUCED DIAMETER

AFTER CALCULATION OF FINAL VALUES OF YIELD STRESS/ PROOF

IML/TP/01 PROCEDURE MANUAL PREPARED BY:

Plate Type Sheet Type

In ASTM A370 THE INITIAL GUAGE LENGTH FOR SHEETS IS

References Standard(mm) Sub Size Specimens(mm)

G-Gage Length: 50 ± 0.10 35 ± 0.10 25 ± 0.10 1 6 ± 0.10 10 ± 0.10

In ASTM A370 THE INITIAL GUAGE LENGTH FOR RODS IS 4

If the length of the specimen is less than as per standard specimen,

The threaded Section Length is depend on the specimen Length

Example:- The Overall length of the sample is 100 mm

1) I choose Reduced diameter is 6.25 mm

Standard Tension Test Specimen for Cast Iron

Specimen 1 Specimen 2 Specimen 3

Location of the sample for pipe section is longitudinal direction

For tubular Products the standard dimension of the sample is specimen

In ASTM E8 THE INITIAL GUAGE LENGTH FOR RODS IS 4 TIMES THE

If the length of the specimen is less than as per standard specimen,

The below specimens are under ASTM E8

The above specimens are under ASTM E 8M

Location of the sample for pipe section is longitudinal direction

For tubular Products the standard dimension of the sample is specimen

1) The Tensile Test carried out on accordance with IS 1608:2005

2) Otherwise unless agreed to between the manufacturer and