Destructive

Testing
Project Team Members

Anurag (2020UMP4359)

Devashish(2020UMP4333)

Monish (2020UMP4359)

Ritik (2020UMP4360)

Udhay (2020UMP4311)
 Destructive Testing
• Destructive testing is undertaken in order to make the specimen fail
under various circumstances.

• The main objective is to identify mechanical properties of the

specimen such as tensile strength, yield strength, elongation,
hardness, toughness resilience, ductility etc. through failure
investigation.

• Its other common applications include materials characterization,

fabrication validation, determining quality of welds and
engineering critical assessments
• Destructive testing methods are necessary since it allows us to
analyze a material from a molecular level so as to determine its
exact chemical composition
• It is used to test the stability and tolerance of a material or product
in harsh conditions before it is mass produced. This reduces the
level of ignorance and also the factor of safety that needs to be
considered.
• Some destructive tests are cheap while many our expensive and are
equipment intensive.
• The main negative is made evident by the name itself. Destructive
testing techniques tests a material to failure and they cannot be
reused further.
Destructive v/s Non Destructive Testing
Parameter Destructive testing Non destructive testing

To deduce the mechanical properties To detect the position, orientation and size
Objective
of a material of defects present in a specimen

No load is applied. Instead other techniques

A load is applied onto the specimen
Method of Application like X-Rays, magnetic fields etch are
until it fails
utilized

Specimen may or may not need
surface preparation. However, since
Material condition
the material is tested to failure, it
cannot be reused
The specimen must be prepared prior to the
test for accurate results. The test can be
performed at any stage of manufacturing
without causing damage

Examples Bend test, Tensile test Liquid penetration test, Eddy Current test
Bend Test
 Introduction
 Bend tests are used to determine internal weld quality. As shown in Figure 1,
there are three different types of bend tests:
 Face bend (face of the specimen is tested)
 Root bend (root of the specimen is tested)
 Side bend (sides of the specimen are tested)

 In bend tests, a material is sliced into test strips, called coupons. The specimen
is then bent around a die of a specific size, creating a horseshoe of the coupon.
This process stretches the weld to test the weld’s integrity.
 The three types of bend tests are shown
here.

The root bend test places the greatest

amount of stress on the weld root. The face
bend test places the greatest amount of
stress on the weld face. The side bend
places the greatest amount of stress along
the weld axis.

Figure 1
Figure 2 shows a radius bend testing machine. This machine bends the prepared test coupon into a U form
over a specified radius, which is dependent on the thickness and strength of the material. After bending, the
outer surface and the inner surface of the U are checked for cracks and other indications as required by the
weld inspection criteria. The outer face of the bend may be examined by a visual, penetrant, or magnetic
particle test to detect defects such as cracks, lack of fusion, and lack of penetration.

Figure 2. This adjustable fillet and crown gauge is being used

to check the height of the weld bead.
TENSILE TEST
Introduction
◈ Tensile test is a test in which the material is pilled apart or compressed to
failure
◈ Tensile testing provides data on strength and ductility of metals under
uniaxial tensile forces.
◈ In addition, tensile test is commonly used to select a material for an
application, for quality control, and to predict how a material will react under
different types of forces.
◈ The material is sliced into coupons, and then each end of the coupon is
pulled in opposite directions until the coupon fails (breaks). A tensile test
machine is shown in
Uses of Tensile test
◈ Ultimate strength of the weld.-This is the point at which the specimen fails
under tension.
◈ Yield strength of the weld- This is the point at which the specimen yields
or stretches under tension and will not return to its original dimensions.
◈ Elongation-This is the amount of stretch that occurs during the tensile test.
It is measured by placing gauge marks on the sample or coupon before
testing and comparing the after- break distance with the original gauge
marks.
 Tensile Test

Figure 3. Tensile test machine with extensometer to perform

tensile testing
Introduction
◈ Notch-toughness tests are used to define the ability of a material to resist
cracking or crack propagation at low temperatures under loads.
◈ It is the ability of a material to absorb energy until failure
◈ These tests are used on specimens that are intended for use in low
temperature environments with pulsating or vibrating loading.
◈ The specimen is cut into test coupons, which are then notched, cooled to a
low temperature, and put under pressure until they fail.
Method of Testing
◈ The test coupons are cut from the test weld. They are prepared for either a Charpy or
an Izod impact test, Figure 4.
◈ The test bars are cooled to the test temperature and then placed into the test machine
and broken, Figure 5. The results are measured in the energy required to make the
coupon break and are expressed in foot-pounds.
◈ Comparisons are then made with the original material and specification requirements.

Figure 5. The impact test

machine arm swings
downward to break the
coupon at impact. The
results are shown on the
scale.
Nick-Break Test
• Nick-break tests are destructive tests that are very simple to
make. They are used to determine the internal quality of a weld
with regard to porosity, lack of fusion, and slag.
• Notches are cut in the sides of a weld coupon in the weld area.
The coupons are then laid across a support on each end and
force is applied with a hammer to try to break the weld
sideways for a simple internal inspection. A nick or groove cut
into the weld helps the specimen break when force is applied.
• A section of the weld to be tested is removed from the weld and
prepared as shown in Figure 6.

Figure 6. Nick-break test dimensions.

Pressure Test
• Pressure tests subject a vessel, tank, piping, or tubing to internal
pressure. Pressure tests can use either air or fluid. If a fluid is used, the
test is called a hydrostatic test.
• The test program may require a number of cycles to be performed,
simulating the use of the part in actual service.
• During the test, the part will expand. This expansion should not be
restricted with tools, or undue stresses will build within the part.
☞ When conducting a pressure test, be alert to the possible failure of the
unit. Before beginning the test, make sure the test procedure ensures
the safety of everyone in the testing area.
Hardness Test - Introduction
Hardness is defined as the ability of a material to resist plastic deformation. However,
hardness is not a fundamental property of a material. Therefore, when drawing
conclusions of a hardness test, you should always evaluate the quantitative value in
relation to:
• The given load on the indenter
• A specific loading time profile and a specific load duration
• A specific indenter geometry
The application of hardness testing enables you to evaluate a material’s properties, such
as strength, ductility and wear resistance, and so helps you determine whether a material
or material treatment is suitable for the purpose you require.
A hardness test is typically performed by pressing a specifically dimensioned and
loaded object (indenter) into the surface of the material you are testing. The indenter is
always harder in comparison to the specimen. The hardness is determined by measuring
the depth of indenter penetration or by measuring the size of the impression left by an
indenter
o Hardness tests that measure the depth of indenter penetration include: Rockwell,
Instrumented Indentation Testing, and Ball Indentation Hardness
o Hardness tests that measure the size of the impression left by the indenter
include: Vickers, Knoop, and Brinell

Micro hardness testing apparatus Macro hardness testing apparatus

Types of Hardness tests
The four most common indentation hardness tests are
 The Rockwell hardness test
 The Vickers hardness test
 The Knoop hardness test
 The Brinell hardness test
The hardness test we choose should be determined by the microstructure – e.g. the homogeneity of
the material we are testing, as well as the type of material, the size of the part and its condition.
Furthermore, the test changes based on the standards we have to comply with.
Hardness testing is divided into two ranges: macro hardness and micro hardness. Macrohardness
covers testing with an applied load over 1 kg or about 10 N. Microhardness testing, with applied
loads under 10 N, is typically used for smaller samples, thin specimens, plated surfaces or thin films.
 The Rockwell hardness test
Rockwell is a fast hardness test method developed for production control, with a direct readout,
mainly used for metallic materials. The Rockwell hardness (HR) is calculated by measuring the
depth of an indent after an indenter has been forced into the specimen material at a given load. It is
only used for macro hardness
Indenters :The Rockwell hardness test utilizes 1 of 5 different indenters:
 Diamond cone
 Tungsten ball in sizes 1/16", 1/8", 1/4", or 1/2“

Diamond cone
TYPE A,C,D indenter

Spherical
Rockwell Tests TYPE B,G,F indenter of 1/16”
diameter

Spherical
TYPE E indenter of 1/8”
diameter
 BRINELL HARDNESS TESTING
 Used for materials with a coarse or inhomogeneous grain structure
 Used for larger samples
 Suitable for forgings and castings where the structural elements are large
Indenter sizes: 1, 2.5, 5 and 10 mm diameter sphere of tungsten carbide

 VICKERS HARDNESS TESTING

 Used for hardness testing of all solid materials, including metallic materials
 Suitable for a wide range of applications like micro and macro hardness testing
 Includes a sub-group of hardness testing of welds
Indenter: Diamond pyramid, used for all specimens
  KNOOP HARDNESS TESTING
 It is an alternative to the Vickers hardness test in the micro hardness testing range
 Used to facilitate the hardness testing of thin layers.
 Suitable for small elongated areas, such as coatings
 Used for hard and brittle materials, such as ceramics
Indenter: Elongated pyramidal diamond

Diagrammatic representation of indenters

used in different hardness tests