CSWIP 3.

1 Welding Inspection

Destructive Testing
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Course Reference WIS 5
Course notes section reference 4.0
 Destructive Testing Definitions

What is Destructive Testing ?

The destruction of a welded
unit or by cutting out selected
specimens from the weld is
carried out to check the
mechanical properties of the
joint materials. They can be
produced to:

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• Approve welding procedures (BS EN 15614)
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• Approve welders (BS EN 287)

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• Production quality control
 Destructive Tests

Destructive tests include:

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•bend test •hardness test ©

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•impact test •metallographic examination
•tensile test
 Quantitative and Qualitative Tests

Quantitative Tests:
For measuring a ‘quantity’ ( a mechanical property )
• Mechanical tests - tensile test
- hardness test
- Charpy V-notch test (& CTOD)

Qualitative Tests:

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For assessing joint ‘quality’ (good fusion & free from defects)
• Qualitative tests - bend tests
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- macro examination
- fillet fracture & nick-break tests
 Qualitative and Quantitative Tests
The following mechanical tests have units and are termed
quantitative tests to measure Mechanical Properties
• Tensile tests (Transverse Welded Joint, All Weld Metal)
• Toughness testing (Charpy, Izod, CTOD)
• Hardness tests (Brinell, Rockwell, Vickers)

The following mechanical tests have no units and are termed

qualitative tests for assessing joint quality

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• Macro testing
• Bend testing ©

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• Fillet weld fracture testing
• Butt weld nick-break testing
 Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to withstand

deformation under static
• Ductility compressive loading without
• Toughness rupture
(Khả năng của vật liệu chịu
• Hardness

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được biến dạng dưới tĩnh Đang
• Tensile Strength nén mà không vỡ) ©

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 Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material undergo

plastic deformation under static
• Ductility tensile loading without rupture.
• Toughness Measurable elongation and
reduction in cross section area
• Hardness

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Khả năng của một loại vật liệu
• Tensile Strength chịu biến dạng dẻo dưới tĩnh ©

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Đang kéo mà không đứt gãy.
Độ giãn dài có thể đo lường và
giảm diện tích mặt cắt ngang
 Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Ability of a material to withstand

bending or the application of
• Ductility shear stresses by impact
• Toughness loading without fracture.
Khả năng chịu uốn của vật liệu
• Hardness

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hoặc các ứng dụng của ứng
• Tensile Strength suất cắt Đang tác động mà ©

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không gãy.
 Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of a materials

surface resistance to
• Ductility indentation from another
• Toughness material by static load
• Hardness Đo một sức đề kháng bề mặt

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vật liệu cho lõm vào từ các vật
• Tensile Strength liệu khác bởi sức chịu đựng ©

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tĩnh.(Đo độ cứng)
 Definitions

Mechanical Properties of metals are related to the amount of

deformation which metals can withstand under different
circumstances of force application.

• Malleability Measurement of the maximum

force required to fracture a
• Ductility materials bar of unit cross-
• Toughness sectional area in tension
• Hardness Đo lực tối đa cần thiết để đứt

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gãy một thanh vật liệu của đơn
• Tensile Strength vị diện tích mặt cắt ngang trong ©

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sức căng.(Tính chịu kéo)
 Mechanical Test Samples
Tensile Specimens
CTOD Specimen

Bend Test

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Specimen
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Charpy Specimen
Fracture Fillet
Specimen
 Destructive Testing
WELDING PROCEDURE QUALIFICATION TESTING

top of fixed pipe

2 Typical Positions for Test
Pieces
Specimen Type Position
•Macro + Hardness 5
3
•Transverse Tensile 2, 4

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•Bend Tests 2, 4 ©

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•Charpy Impact Tests 3

4 •Additional Tests 3
5
Mechanical Testing

Hardness Testing

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 Hardness Testing

Definition
• Measurement of resistance of a material against penetration of
an indenter under a constant load(Đo sức đề kháng của một vật
liệu chống lại sự xâm nhập của một lực tác động lạp xuống
không đổi)
• There is a direct correlation between UTS and hardness(Có một
mối tương quan trực tiếp giữa UTS và độ cứng)

Hardness tests:

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• Brinell ©

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• Vickers
• Rockwell
 Hardness Testing

Objectives:
• measuring hardness in different areas of a welded joint
• assessing resistance toward brittle fracture, cold cracking
and corrosion sensitivity.

Information to be supplied on the test report:

• material type

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• location of indentation
• type of hardness test and load applied on the indenter
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• hardness value
 Hardness Testing

usually the hardest region

1.5 to 3mm
fusion line
or
fusion HAZ
boundary

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Hardness Test Methods Typical Designations
Vickers 240 HV10 ©

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Rockwell Rc 22
Brinell 200 BHN-W
 Vickers Hardness Test

Typical location of the indentations

Butt weld from one side only

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Butt weld from both side
 Vickers Hardness Test
Vickers hardness tests:
• indentation body is a square based diamond pyramid (136º
included angle)
• the average diagonal (d) of the impression is converted to a
hardness number from a table
• it is measured in HV5, HV10 or HV025 Adjustable
Diamond Indentation shutters
indentor

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Vickers Hardness Test Machine

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 Brinell Hardness Test

• Hardened steel ball of given diameter is subjected for a given

time to a given load
• Load divided by area of indentation gives Brinell hardness in
kg/mm2
• More suitable for on site hardness testing

30KN

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Ø=10mm
steel ball
 Rockwell Hardness Test

Rockwell B Rockwell C
1KN
1.5KN

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Ø=1.6mm 120°Diamond

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steel ball Cone
 Portable Hardness Test

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• dynamic and very portable hardness test
• accuracy depends on the the condition of the test/support
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surfaces and the support of the test piece during the test
• for more details, see ASTM E448
 Portable Hardness Test
Typical Impact Device
Impact Body

Coil

Magnet

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Tungsten
Carbide Ball ©

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 Portable Hardness Test
Typical Impact Device
The impact body is
projected down into the
materials surface by
spring force at a defined
speed.
The impact creates plastic
deformation at the surface,
the impact body loses part of
its original speed (energy)
the larger the indentation the
more speed it will lose.
The speeds are measured
before and after impact by
means of a magnet passing
through a coil which generates
an inductive voltage which is
proportional to speed a signal
can be then shown before and
after impact and converted to
an hardness value
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Mechanical Testing

Impact Testing

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 Charpy V-Notch Impact Test

Objectives:
• measuring impact strength in different weld joint areas
• assessing resistance toward brittle fracture
Information to be supplied on the test report:
• Material type

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• Notch type
• Specimen size
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• Test temperature
• Notch location
• Impact Strength Value
Charpy V-Notch Impact Test

Pendulum
Specimen (striker)

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Anvil (support)
Charpy V-notch impact test specimen

Specimen dimensions according ASTM E23

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ASTM: American Society of Testing Materials
 Charpy Impact Test
22.5o 100% Brittle
10 mm
2 mm Giòn
Machined
notch

Fracture surface
8 mm

100% bright
crystalline brittle
fracture

100% Ductile
Mềm
Machined

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notch

Large reduction ©

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in area, shear
lips
Randomly torn,
dull gray fracture
surface(bị rách Ngẫu
nhiên, xỉn bề mặt đứt
gãy màu xám)
xám)
 Ductile / Brittle Transition Curve
Ductile fracture
Temperature range

47 Joules

Transition range Ductile/Brittle

transition
point

28 Joules

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Brittle fracture Energy absorbed ©

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- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees
ThreeCentigrade
specimens are normally tested at each temperature
 Ductile / Brittle Transition Curve
Temperature range Ductile fracture

Mn < 1.6 % increases

toughness in steels* 47 Joules

Transition range Ductile/Brittle

transition
point

28 Joules

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Energy absorbed
Brittle fracture
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- 50 - 40 - 30 - 20 - 10 0
Testing temperature - Degrees
ThreeCentigrade
specimens are normally tested at each temperature
 Comparison Charpy Impact Test Results

Impact Energy Joules

Room Temperature -20oC Temperature

1. 197 Joules 1. 49 Joules

2. 191 Joules 2. 53 Joules
3. 186 Joules 3. 51 Joules

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Average = 191 Joules Average = 51 Joules ©

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The test results show the specimens carried out at room
temperature absorb more energy than the specimens carried
out at -20oC
 Charpy Impact Test

Reporting results
• Location and orientation of notch
• Testing temperature
• Energy absorbed in joules
• Description of fracture (brittle or ductile)
• Location of any defects present

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• Dimensions of specimen
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Charpy Impact Testing

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Mechanical Testing

Tensile Testing

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 Tensile Testing

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 UTS Tensile test

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 Tensile Tests

Different tensile tests:

• Transverse tensile.
• All-weld metal tensile test
• Cruciform tensile test

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• Short tensile test (through thickness test) ©

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 Tensile Test

All-Weld Metal Tensile

Specimen

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Transverse Tensile
Specimen ©

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 Transverse Joint Tensile Test

Objective:
Measuring the overall strength of the weld joint

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Information to be supplied on the test report:
• material type
• specimen type
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• specimen size (see QW-462.1)
• UTS
• location of final rupture
Transverse Joint Tensile Test

Weld on plate

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Multiple cross joint
Weld on pipe specimens
 Transverse Tensile Test

Maximum load applied = 220 kN.

Least cross sectional area = 25 mm X 12 mm

UTS = Maximum load applied

Least c.s.a.

UTS = 220 000

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25mm X 12mm ©

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UTS = 733.33 N/mm2
 Transverse Tensile Test

Reporting results:
• Type of specimen e.g. reduced section

• Whether weld reinforcement is removed

• Dimensions of test specimen

• The ultimate tensile strength in N/mm2, p.s.i or Mpa

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• Location of fracture. ©

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• Location and type of any flaws present if any
 All Weld Metal Tensile Test

BS 709 / BS EN 10002
All Weld Metal Tensile Testing
Direction of the test *

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Tensile test piece cut along weld specimen.
 All-Weld Metal Tensile Test

Original gauge length = 50mm

Increased gauge length = 64

Elongation % = Increase of gauge length X 100

Original gauge length

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Elongation % = 14 X 100
50 ©

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Elongation = 28%
 All-Weld Metal Tensile Test

Gauge length

Object of test:
Ultimate tensile strength.

Yield strength.

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Elongation %(ductility). ©

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Increased gauge length
 All-Weld Metal Tensile Test
2 marks are made
Gauge length 50mm

During the test, Yield & Tensile strength are recorded

The specimen is joined and the marks are re-measured

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Increased gauge length 75mm
A measurement of 75mm will give Elongation of 50 %
 All-Weld Metal Tensile Test

Reporting results:
• Type of specimen e.g. reduced section
• Dimensions of test specimen
• The u.t.s, yield strength in N/mm2, p.s.i or Mpa
• Elongation %

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• Location and type of any flaws present if any ©

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STRA (Short Transverse Reduction Area)

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STRA test

Original CSA

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Reduced CSA
 STRA test

20
STRA %
Reductio

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n of CSA 15 ©

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10
 Mechanical Testing

Macro / Micro Examination

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 Macro Preparation
Purpose
To examine the weld cross-section to give assurance that: -
• The weld has been made in accordance with the WPS
• The weld is free from defects
Specimen Preparation
• Full thickness slice taken from the weld (typically ~10mm thick)
• Width of slice sufficient to show all the weld and HAZ on both sides
plus some unaffected base material

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• One face ground to a progressively fine finish (grit sizes 120 to ~ 400)
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• Prepared face heavily etched to show all weld runs & all HAZ

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• Prepared face examined at up to x10 (& usually photographed for records)
• Prepared face may also be used for a hardness survey
 Micro Preparation
Purpose
To examine a particular region of the weld or HAZ in order to:-
• To examine the microstructure
• Identify the nature of a crack or other imperfection
Specimen Preparation
• A small piece is cut from the region of interest
(typically up to ~ 20mm x 20mm)
• The piece is mounted in plastic mould and the surface of interest

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prepared by progressive grinding (to grit size 600 or 800)
• Surface polished on diamond impregnated cloths to a mirror finish ©

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• Prepared face may be examined in as-polished condition & then lightly
etched
• Prepared face examined under the microscope at up to ~ 100 – 1000X
 Macro / Micro Examination

Object:
• Macro / microscopic examinations are used to give a visual
evaluation of a cross-section of a welded joint
• Carried out on full thickness specimens
• The width of the specimen should include HAZ, weld and parent
plate
• They maybe cut from a stop/start area on a welders approval

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test
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 Macro / Micro Examination

Will Reveal:
• Weld soundness
• Distribution of inclusions
• Number of weld passes
• Metallurgical structure of weld, fusion zone and HAZ

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• Location and depth of penetration of weld
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• Fillet weld leg and throat dimensions
 Macro Micro
• Visual examination for • Visual examination for
defects defects & grain structure
• Cut transverse from the • Cut transverse from a
weld weld
• Ground & polished P400 • Ground & polished P1200
grit paper grit paper, 1µm paste
• Acid etch using 5-10% • Acid etch using 1-5%
nitric acid solution nitric acid solution

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• Wash and dry • Wash and dry ©

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• Visual evaluation under 5x • Visual evaluation under
magnification 100-1000x magnification
• Report on results • Report on results
 Metallographic Examination

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Macro examination Micro examination
 Metallographic examination
Objectives:
• detecting weld defects (macro)
• measuring grain size (micro)
• detecting brittle structures, precipitates, etc
• assessing resistance toward brittle fracture, cold cracking and
corrosion sensitivity
Information to be supplied on the test report:
• material type
• etching solution

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• magnification
• grain size ©

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• location of examined area
• weld imperfections (macro)
• phase, constituents, precipitates (micro)
Mechanical Testing

Bend Testing

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 Bend Tests
Object of test:
• To determine the soundness of the weld zone. Bend testing can
also be used to give an assessment of weld zone ductility.
There are three ways to perform a bend test:

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Face bend ©

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Root bend Side bend
Side bend tests are normally carried out on welds over 12mm
in thickness
 Bending test

Types of bend test for welds (acc. BS EN 910):

Root / face
“t” up to 12 mm
bend

Thickness of material - “t”

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“t” over 12 mm

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Side bend
 Bending test methods

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Guided bend test Wrap around bend test
 Bend Testing
Face bend Side bend Root bend

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Defect
indication Acceptance for ©

Generally this minor ruptures on

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specimen tension surface
would be depends upon code
unacceptable requirements
 Bend Tests

Reporting results:
• Thickness and dimensions of specimen

• Direction of bend (root, face or side)

• Angle of bend (90o, 120o, 180o)

• Diameter of former. (typical 4T)

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• Appearance of joint after bending e.g. type and location of any
flaws. ©

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 Bend Testing

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 Mechanical Testing

Fillet Weld Fracture Testing

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 Fillet Weld Fracture Tests

Object of test:
• To break open the joint through the weld to permit examination
of the fracture surfaces
• Specimens are cut to the required length
• A saw cut approximately 2mm in depth is applied along the fillet
welds length
• Fracture is usually made by striking the specimen with a single
hammer blow

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• Visual inspection for defects ©

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 Fillet Weld Fracture Tests

Hammer

2mm
Notch

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Fracture should break weld saw cut to root
 Fillet Weld Fracture Tests

This fracture indicates This fracture has

lack of fusion occurred saw cut to root

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Lack of Penetration
 Fillet Weld Fracture Tests

Reporting results:
• Thickness of parent material
• Throat thickness and leg lengths
• Location of fracture
• Appearance of joint after fracture
• Depth of penetration
• Defects present on fracture surfaces

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Mechanical Testing

Nick-Break Testing

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 Nick-Break Test

Object of test:
• To permit evaluation of any weld defects across the fracture
surface of a butt weld.
• Specimens are cut transverse to the weld
• A saw cut approximately 2mm in depth is applied along the welds
root and cap
• Fracture is usually made by striking the specimen with a single

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hammer blow
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• Visual inspection for defects

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 Nick-Break Test

Notch cut by hacksaw

3 mm
19 mm

3 mm
Approximately 230 mm

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Weld reinforcement
may or may not be
removed
 Nick Break Test

Alternative nick-break test

specimen, notch applied all
way around the specimen

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Lack of root penetration Inclusions on fracture
or fusion line
 Nick-Break Test

Reporting results:
• Thickness of parent material
• Width of specimen
• Location of fracture
• Appearance of joint after fracture
• Depth of penetration
• Defects present on fracture surfaces

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 Summary of Mechanical Testing

We test welds to establish minimum levels of mechanical

properties, and soundness of the welded joint

We divide tests into Qualitative & Quantitative methods:

Quantitative: (Have units) Qualitative: (Have no units)

Hardness (VPN & BHN) Macro tests

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Toughness (Joules & ft.lbs) Bend tests
Strength (N/mm2 & PSI, MPa) Fillet weld fracture tests
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Ductility / Elongation (E%) Butt Nick break tests
 Hydrostatic test

under pressure leakage proof test

Vessel configuration:
• the test should be done after any stress relief
• components that will not stand the pressure test (e.g. flexible
pipes, diaphragms) must be removed
• the ambient temperature MUST be above 0°C (preferably 15-
20°C)

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 Hydrostatic Test
Test procedure:
• blank off all openings with solid flanges
• use correct nuts and bolts, NOT “G” clamps
• two pressure gauges on independent tapping points should be
used
• for safety purposes bleed all the air out
• pumping should be done slowly (no dynamic pressure stresses)
• test pressure - see relevant standards (PD 5500, ASME VIII).

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Usually 150% design pressure
• hold the pressure for minimum 30 minutes ©

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 Hydrostatic test

What to look for:

• leaks (check particularly around seams and nozzle welds!)
• dry off any condensation.
• watch the gauges for pressure drop

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• check for distortion of flange faces, etc
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 Mechanical Testing

Any Questions

?
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