Senior Welding Inspection: Fracture Assessments Course Reference WIS 10

TECHNOLOGY
SWI 3.2
Senior Welding Inspection

Fracture Assessments
Course Reference WIS 10
Copyright 2003 TWI Ltd
M.S.Rogers
SWI 3.2
TECHNOLOGY
Fracture Surfaces
Introduction:
Fatigue and brittle fractures are the two most
important forms of service failure in welded
structures
Fatigue fractures account for more than 90% of all
service failures
Brittle fractures although rare in occurrence are usually

catastrophic in economic terms and may cause loss in
life
M.S.Rogers
TECHNOLOGY
Fatigue Fracture Surfaces
SWI 3.2
Features of Fatigue fractures:

Service failure
Occurs under cyclic/fluctuating stress
Smooth appearance
Initiates at some form of stress concentration. These
stress points may be weld defects, poor profiles,
notches etc
In certain cases evidence of beach markings
Fracture occurs perpendicular to the applied stress
M.S.Rogers
TECHNOLOGY
Fatigue Fractures
SWI 3.2
Fatigue cracking at the

weld toe
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TECHNOLOGY
SWI 3.2
Points of initiation
Smooth fracture surface
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SWI 3.2
Ductile fracture
Beach Marks
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Ductile Fracture
SWI 3.2
Features of ductile fractures:

Rough fibrous appearance
Dull grey in colour
In certain cases evidence of shear lips
In most cases a reduction in area
Occurs as a secondary mode of failure
M.S.Rogers
SWI 3.2
TECHNOLOGY
Brittle Fracture
Features of brittle fractures:
Usually occurs without visible or audible warning
In certain cases bright crystalline appearance
In certain cases a chevron pattern appearance, the
chevron pattern points back to the point of
initiation
Little if no reduction in area
Little if no evidence off shear lips
May be a straight brittle fracture or secondary
mode of failure
M.S.Rogers
TECHNOLOGY
Brittle Fracture
SWI 3.2
M.S.Rogers
TECHNOLOGY
Brittle Fracture
SWI 3.2
M.S.Rogers
TECHNOLOGY
Brittle Fracture
SWI 3.2
M.S.Rogers
SWI 3.2
TECHNOLOGY
Remember in the CSWIP 3.2 Senior Welding Inspectors

examination your are required to conduct a practical
examination of two fracture samples and complete a
sketch and a final report on your findings
Time allowed 1 hour for both fracture samples

30 minutes for each fracture sample
M.S.Rogers
SWI 3.2
TECHNOLOGY
You are required
Sketch the fracture surface.
Indicate the fracture initiation points (if known)
Show any defects present
Identify the primary mode of failure
Identify the secondary mode of failure
State whether failure occurred in the weld, parent
material or both (if known)
Write a conclusion to summarize your findings,
providing reasons and evidence
Sign and date your report
M.S.Rogers
SWI 3.2
TECHNOLOGY
FractureSample 1
Ductile
Fracture
A. Initiation point
B. Initiation point
C. Initiation point
D. Initiation point
E. Initiation point
F. Initiation point
G. Initiation point
H. Weld crater/crater pipe

I. Cap undercut
J. Ductile fracture
K. Ductile fracture
L. Fatigue fracture
M. Shear lips
M.S.Rogers
Fracture Assessment Report specimen 1.
TECHNOLOGY
B
E
G
H
H
G
A
B
SWI 3.2
A. Shear lips
B. Initiation points/weld
toe undercut
C. Weld spatter
D. Fatigue fracture surface
E. Ductile fracture surface
F. Weld undercut
G. Poor weld craters
H. Possible beach marks
Primary mode of failure: Fatigue perpendicular to the applied stress

Secondary mode of failure: Ductile fracture
Conclusion: Fatigue failure occurred at the weld toes of a fillet weld on both sides of the
joint. The fatigue failure has initiated at a number of points along the weld toes (B), theses
separately initiated into fatigue cracks and joined up by a series of steps on each side of
the of the joint (D) this is evident by the smooth appearance of the fracture surface. The
fatigue crack stopped at he possible beach marks (H).
The secondary and final mode of failure is a ductile fracture (E) this is evident by the
rough fibrous appearance and areas of shear lips (A). Other points of interest are the poor
weld craters (G) and the weld undercut (F).
Name: Mark Rogers
Date: 13/06/03
Signature: M.S Rogers

M.S.Rogers
TECHNOLOGY
Fracture Sample 2
A-A. Initiation point

B. Stepping
C. Stepping
D. Ductile fracture
E. Inclusions
F. Inclusions
G. Fatigue fracture
SWI 3.2
Ductile Fracture
M.S.Rogers
SWI 3.2
TECHNOLOGY

E
D
H
B
A. Shear lips B. Reduction in area C. Fatigue fracture D. Ductile fracture

E. Stepping F. Beach markings G. Inclusions H-H. Initiation point
Conclusion: Fracture occurred at the weld toe (H-H) of a butt weld along its entire
length.
A fatigue crack has initiated at the weld toe (H-H) along the welds entire length, this is
evident by the smooth fracture surface (C). The fatigue crack stopped at point (F).
The secondary mode of failure is a ductile fracture this is evident by the rough fibrous
fracture surface (D), the evidence of shear lips (A) and a reduction in area (B). Other
points to notice are the opening up of the plate inclusions (G) in the rolled direction.
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
SWI 3.2
TECHNOLOGY
Fracture Sample 3
Ductile
Fracture
A. Slag inclusion
B. Slag inclusion
C. Slag inclusion
D. Shear lip
E.
Slag inclusion
F.
Shear lip
G. Fatigue fracture
H. Ductile fracture
Note: Reduction in area
M.S.Rogers
TECHNOLOGY
F
D
C
SWI 3.2
A. Fatigue fracture
surface
B. Shear lips
C. Reduced area
D. Ductile fracture surface
E. Weld defects (slag
inclusions)
F. Beach markings

Conclusion: The butt weld failed due to fatigue cracks which initiated from weld metal
defects (E). The cracks have a smooth appearance this is evidence of fatigue fracture (A).
The secondary mode of failure which is the final mode is a ductile fracture this is evident
by the dull fibrous appearance of the fracture surface (D), shear lips (B) and a slight
reduction in area (C).
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
SWI 3.2
TECHNOLOGY
Fracture Sample 4
Ductile
Fracture
A.
Gas pore/initiation
point
B.
Beach mark
C.
Ductile fracture
D.
Fatigue fracture
E.
Shear lip
F.
Shear lip
G.
Shear lip
M.S.Rogers
TECHNOLOGY
SWI 3.2
A. Gas pore
B. Beach mark
C. Fatigue fracture surface

D
D. Shear lips/slight reduction in area

E. Ductile fracture surface

Conclusion: The metal shaft failed due to a fatigue crack, which initiated from a small
gas pore (A)
The primary mode of failure is from a fatigue crack (C) this is evident by the smooth
appearance of the fracture surface.
The secondary and final mode of failure is a ductile fracture (E) this is evident by the dull
gray fibrous appearance of the fracture surface, evident of shear lips (D) and a reduction
in area (D).
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
SWI 3.2
TECHNOLOGY
Fracture Sample 5
Brittle
Fracture
A. Weld defect possible toe crack initiation point point

B. Small shear lip
C. Shear lip
D. Shear lip
Note: Patterned fracture surface - Brittle fracture.
M.S.Rogers
TECHNOLOGY
SWI 3.2
A. Weld defect, possible toe

crack
B. Shear lips
C. Patterned brittle fracture
C
Primary and final mode of failure: Brittle fracture

Conclusion: The brittle fracture initiated from a welding defect, possible toe crack.
A straight brittle fracture occurred in a butt weld, initiated from a welding defect, possible
toe crack (A).
The brittle fracture surface (C) has a distinctive pattern of markings which radiate from
the surface of the weld toe defect, possible toe crack (A). It should be noted that the
pattern points back towards the initiation point (A). Other features of interest are the
slight shear lips (B).
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
TECHNOLOGY
Fracture Sample 6
SWI 3.2
Brittle Fracture
Note: Patterned/chevron fracture surface - Brittle
fracture.
Note: Small shear lips along both plate surfaces.
M.S.Rogers
SWI 3.2
TECHNOLOGY
A. Slight shear lips

C
B. Brittle fracture
surface/chevron pattern
C. Initiation point
A
DIRECTION OF PROPERGATION
Primary and final mode of failure: Brittle fracture

Conclusion: This service failure has no visible initiation point, the fracture is a brittle
fracture this is evident by the uniform chevron pattern (B), which points back towards the
origin of the fracture initiation point.
Other interesting points are the slight shear lips (A) and no reduction in area evident.
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
TECHNOLOGY
Fracture Sample 7
SWI 3.2
CTOD Brittle Fracture

A
A.
Machined notch initiation point
B.
Fatigue fracture surface
C. Brittle fracture
Note: Very little reduction in area
and no evidence of shear lips
M.S.Rogers
SWI 3.2
TECHNOLOGY

A. Machined notch,
initiation point
A
B
B. Fatigue fracture surface

C. brittle fracture surface
Primary and final mode of failure: Fatigue
fracture
Secondary mode of failure: Brittle fracture.
Conclusion: The CTOD sample failed from a purposely initiated fatigue crack
The primary mode of failure is a fatigue fracture (B) this is evident by the smooth fracture
surface, which initiated from a machined notch (A). The secondary mode of failure is a
brittle fracture (C) this is evident by the crystalline fracture surface with very little
evidence of plastic deformation (very little reduction in area) and no evidence of shear lips
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
TECHNOLOGY
Fracture Sample 8
SWI 3.2
CTOD Ductile Fracture

A
A.
Machined notch initiation point
B.
Fatigue fracture surface
C. Ductile fracture surface

Note: The reduction in area and the
large shear lips
M.S.Rogers
SWI 3.2
TECHNOLOGY

A. Machined notch,
initiation point
A

C. Shear lips
D. Ductile fracture surface
Primary and final mode of failure: Fatigue
fracture
Secondary mode of failure: Ductile fracture.
Conclusion: The CTOD sample failed from a purposely initiated fatigue crack
surface, which initiated from a machined notch (A). The secondary mode of failure is a
ductile fracture (D) this is evident by the fibrous appearance of the fracture surface with
evidence of plastic deformation, a large reduction in area and shear lips (C).
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
TECHNOLOGY
Fracture Sample 9
SWI 3.2
D
A
G
F
B
Ductile / Brittle
Fracture
A.
B.
C.
D.
E.
F. Ductile fracture
Cracks / forging bursts.
G. Brittle fracture
Cracks / forging bursts.
Cracks / forging bursts
Initiation point / threat tip
Fatigue fracture
M.S.Rogers
TECHNOLOGY

C
A
E
B
SWI 3.2
A. Cracks/forging bursts
C. Ductile fracture surface
D. Brittle fracture surface
E. Initiation point
A
A
Primary and final mode of failure: Fatigue fracture

Secondary mode of failure: Brittle fracture. Third mode of failure: Brittle fracture
Conclusion: The threaded bar failed from a fatigue crack, which initiated at the base
of the thread (E).
surface, which initiated from the base of the thread (E). The secondary mode of failure is
a ductile fracture (C) this is evident by the fibrous appearance of the fracture surface with
evidence of plastic deformation. The final mode of failure is brittle (D) this is evident by
the bright crystalline fracture surface.
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
TECHNOLOGY
Fracture Sample
10
F
C
Ductile Fracture
D
B
SWI 3.2
A. Fatigue fracture surface. D. Initiation point / weld toe

undercut
B. Ductile fracture surface.
C. Initiation point / weld toe E. Beach marks
F. Weld spatter
undercut
M.S.Rogers
TECHNOLOGY
A. Fatigue fracture surface
SWI 3.2
B. Ductile fracture surface
C. Initiation point, weld toe

undercut
A
D. Initiation point, weld toe

undercut
E. Beach markings
F. Weld spatter

Conclusion: The fabricated cruciform joint failed as a result of a fatigue fracture this is
evident by the smooth fracture surface (A), its point of initiation (C,D), possible undercut
at the weld toe. The fatigue cracks tip is evident by the beach markings (E), where the
crack stop and starts with each stress cycle.
The secondary and final mode of failure is a ductile fracture (B) this is evident by the
fibrous appearance of the fracture.
Name: Mark Rogers
Date: 13/06/03

M.S.Rogers
SWI 3.2
TECHNOLOGY
Any Questions
M.S.Rogers

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TECHNOLOGY

Senior Welding Inspection

Copyright 2003 TWI Ltd

Brittle fractures although rare in occurrence are usually

Copyright 2003 TWI Ltd

Fatigue Fracture Surfaces

Features of Fatigue fractures:

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Fatigue cracking at the

Fatigue Fracture Surfaces

Smooth fracture surface

Copyright 2003 TWI Ltd

Fatigue Fracture Surfaces

Copyright 2003 TWI Ltd

Features of ductile fractures:

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Remember in the CSWIP 3.2 Senior Welding Inspectors

Time allowed 1 hour for both fracture samples

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

Copyright 2003 TWI Ltd

H. Weld crater/crater pipe

Fracture Assessment Report specimen 1.

Primary mode of failure: Fatigue perpendicular to the applied stress

Copyright 2003 TWI Ltd

Signature: M.S Rogers

A-A. Initiation point

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Fracture Assessment Report specimen 2.

A. Shear lips B. Reduction in area C. Fatigue fracture D. Ductile fracture

Copyright 2003 TWI Ltd

Signature: M.S Rogers

Copyright 2003 TWI Ltd

Fracture Assessment Report specimen 3.

Primary mode of failure: Fatigue perpendicular to the applied stress

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Signature: M.S Rogers

Copyright 2003 TWI Ltd

Fracture Assessment Report specimen 4.

C. Fatigue fracture surface

D. Shear lips/slight reduction in area

Primary mode of failure: Fatigue perpendicular to the applied stress

Copyright 2003 TWI Ltd

Signature: M.S Rogers

A. Weld defect possible toe crack initiation point point

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Fracture Assessment Report specimen 5.

A. Weld defect, possible toe

Primary and final mode of failure: Brittle fracture

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Signature: M.S Rogers

Copyright 2003 TWI Ltd

Fracture Assessment Report specimen 6.