10.

Testing of Welded Joints

10. Testing of Welded Joints 126

Ls
The basic test for determination of material
in test area

S S behaviour is the tensile test.

S S

a
in test area
Generally, it is carried out using a round

S
S

b1
b
specimen. When determining the strength of

S
S

r L0
Lc a welded joint, also standardised flat speci-
Lt

total length Lt depends on test unit

mens are used. Figure 10.1 shows both stan-
head width b1 b + 12

width of parallel length plates b

12 with a 2 dard specimen shapes for that test. A
25 with a > 2
6 with D 50
tubes b 12 with 50 < D specimen is ruptured by a test machine while
168,3
1 2
L S + 60
the actual force and the elongation of the
parallel length ) ) Lc
radius of throat r 25
1
) for pressure welding and beam welding, L S = 0.
specimen is measured. With these measure-
2
) for some other metallic materials (e.g.aluminium, copper and their alloys)
__ L c L S +100 may be required

ment values, tension and strain are calcu-

S
S

d1
d

lated. If is plotted over , the drawn diagram

r

LO
LC

d = specimen diameter
Lt
L0 = measurement length
is typical for this test, Figure 10.2.
d1 = head diameter depending (L0 = k S0 with k = 5,65)
on clamping device
LC = test length = L0 + d/2
Lt = total length
S0 = initial cross-section within
Normally, if a steel with a bcc lattice structure
r = 2 mm test length
br-er10-01.cdr ISF 2002
is tested, a curve with a clear yield point is
Flat and Round Tensile Test Specimen obtained (upper picture). Steels with a fcc
to EN 895, EN 876, and EN 10 002
lattice structure show a curve without yield
Figure 10.1
point.
The most important characteristic values
s
which are determined by this test are: yield
Rm stress ReL, tensile strength Rm, and elongation
ReH
Rel A.
sf

To determine the deformability of a weld, a

ALud e
Ag bending test to DIN EN 910 is used, Figure
A
s 10.3. In this test, the specimen is put onto two
Rm supporting rollers and a former is pressed
RP0,2
RP0,01 through between the rollers. The distance of
sf
the supporting rollers is Lf = d + 3a (former
diameter + three times specimen thickness).

0,2 % e The backside of the specimen (tension side)

0,01 %
Ag
A
is observed. If a surface crack develops, the
br-er10-02.cdr ISF 2002

test will be stopped and the angle to which

Stress-Strain Diagram With
and Without Distinct Yield Point the specimen could be bent is measured. The

Figure 10.2
10. Testing of Welded Joints 127

test result is the bending angle and the diameter of the used former. A bending angle of 180
is reached, if the specimen is pressed through the supporting rollers without development of
a crack. In Figure 10.3 specimen shapes of this test are shown. Depending on the direction
the weld is bent, one distinguishes (from top to bottom) transverse, side, and longitudinal
bending specimen. The tension side of all three specimen types is machined to eliminate any
influences on the test
through notch effects.
Specimen thickness of
transverse and longitudinal
specimens is the plate
thickness. Side bending
specimens are normally only
used with very thick plates,
here the specimen thickness
is fixed at 10 mm.

A determination of the
toughness of a material or Figure 10.3

welded joint is carried out

with the notched bar impact test. A cuboid specimen with a V-notch is placed on a support
and then hit by a pendulum ram of the impact testing machine (with very tough materials, the
specimen will be bent and
drawn through the sup-
ports). The used energy is
measured. Figure 10.4
represents sample shape,
notch shape (Iso-V-
specimen), and a sche-
matic presentation of test
results.

Figure 10.4
10. Testing of Welded Joints 128

Three specimens are tested at each test tem-

Designation Weld centre Designation Fusion line/bonding zone

VWS a/b
perature, and the average values as well as

b
Dicke (fusion
the range of scatter are entered on the impact
VWS a/b weld)
RL a RL a

energy-temperature diagram (AV-T curve).

b
b VHT 0/b
This graph is divided into an area of high im-
VWT 0/b Dicke

pact energy values, a transition range, and an

b

b
VWT a/b VHT a/b
a a
area of low values. A transition temperature is
assigned to the transition range, i.e. the rapid
b

b
VWT 0/b VHT a/b
RL a
RL
drop of toughness values. When the tempera-
ture falls below this transition temperature, a
b

VWT a/b VHT a/b

a
RL a
RL
transition of tough to brittle fracture behaviour
takes place.
V = Charpy-V notch
W = notch in weld metal; reference line is centre line of weld
H = notch in heat affected zone; reference line is fusion line or bonding zone
(notch should be in heat affected zone)
S = notched area parallel to surface
T = notch through thickness
a = distance of notch centre from reference line (if a is on centre line of weld, a = 0 and
As this steep drop mostly extends across a
should be marked)
b = distance between top side of welded joint and nearest surface of the specimen
(if b is on the weld surface, then b = 0 and should be marked) certain area, a precise assignment of transi-
br-er10-05.cdr ISF 2002
tion temperature cannot be carried out. Fol-
Position of Charpy-V Impact Test
Specimen in Welded Joints to EN 875 lowing DIN 50 115, three definitions of the
transition temperature are useful, i.e. to fix T
Figure 10.5
to:
1.) a temperature where the level of impact values is half of the level of the high range,
2.) a temperature, where the fracture area of the specimen shows still 50% of tough fracture
behaviour
3.) a temperature with an impact energy value of 27 J.

Figure 10.5 illustrates a specimen position and notch position related to the weld according to
DIN EN 875. By modifying the notch position, the impact energy of the individual areas like
HAZ, fusion line, weld metal, and base metal can be determined in a relatively accurate way.

Figure 10.6 presents the influence of various alloy elements on the AV-T - curve. Three basi-
cally different influences can be seen. Increasing manganese contents increase the impact
values in the area of the high level and move the transition temperature to lower values. The
values of the low levels remain unchanged, thus the steepness of the drop becomes clearer
with increasing Mn-content. Carbon acts exactly in the opposite way. An increasing carbon
content increases the transition temperature and lowers the values of the high level, the steel
becomes more brittle. Nickel decreases slightly the values of the high level, but increases the
10. Testing of Welded Joints 129

values of the low level with increasing con-

specimen position: specimen shape: tent. Starting with a certain Nickel content
J core longitudinal ISO V

300 (depends also from other alloy elements), a

2% Mn

1% Mn steep drop does not happen, even at lowest

200
0,5% Mn
temperature the steel shows a tough fracture
100
behaviour.
0% Mn
Charpy impact energy AV

27
200

J In Figure 10.7, the AV-T curves of some

commonly used steels are collected. These
100 13% Ni
8,5% 0% Ni
5% 3,5% 2% Ni
27
curves are marked with points for impact en-
ergy values of AV = 27 J as well as with points
200
0,1% C
J

100 where the level of impact energy has fallen to

0,4% C

27
0,8% C half of the high level. It can clearly be seen
-150 -100 -50
Temperature
0 50 C 100 that mild steels have the lowest impact en-
br-er10-06.cdr ISF 2002
ergy values together with the highest transi-
Influence of Mn, Ni, and C
on the Av-T-Curve
tion temperature. The development of fine-
grain structural steels resulted in a clear im-
Figure 10.6
provement of impact energy values and in
addition, the application of such steels could be extended to a considerably lower tempera-
ture range.
With the example of the
steels St E 355 and St E
690 it is clearly visible that
an increase of strength goes
mostly hand in hand with a
decrease of the impact en-
ergy level. Another im-
provement showed the
application of a thermome-
chanical treatment (con-
trolled rolling during heat
treatment). The application
of this treatment resulted in Figure 10.7
an increase of strength and
10. Testing of Welded Joints 130

impact energy values together with a parallel saving of alloy elements. To make a compari-
son, the AV-T - curve of the cryogenic and high alloyed steel X8Ni9 was plotted onto the dia-
gram. The material is tested under very high
P
test speed in the impact energy test, thus C

0,55h 0,25
1,2h 0,25
there are no reliable findings about crack
C

growth and fracture mechanisms. P

a b CT - specimen
L
h
1,25h 0,13
Figure 10.8 shows two commonly used specimen width b specimen height h = 2b 0,25
total crack length a = (0,50 0,05)h
test load P
specimen shapes for a fracture mechanics
test to determine crack initiation and crack

h
a
growth. The lower figure to the right shows a SENB -specimen
2,1h 2,1h b
3PB
possibility how to observe a crack propaga-
S
specimen width b bearing distance S = 4h
sample height h = 2b 0,05 total crack length a = (0,50 0,05)h
tion in a compact tensile specimen. During F,U crack initiation U
F
the test, a current I flows through the speci- UE,aE

U
men, and the tension drop above the notch is UO

measured.
V

br-er10-08.cdr V ISF 2002

Fracture Mechanics Test

As soon as a crack propagates through the Sample Shape and Evaluation
material, the current conveying cross section
Figure 10.8
decreases, resulting in an increased voltage
drop. Below to the left a measurement graph of such a test is shown. If the force F is plotted
across the widening V, the drawn curve does not indicate precisely the crack initiation.
Analogous to the stress-
F F

strain diagram, a decrease

of force is caused by a re-
duction of the stressed
cross-section. If the voltage
h

drop is plotted over the

d
force, then the start of
crack initiation can be de-
termined with suitable ac-
d1

2
d

curacy, and the crack

br-er-10-09.cdr

propagation can be ob-

Hardness Testing to Brinell and Vickers
served.
Figure 10.9
10. Testing of Welded Joints 131

Another typical characteristic of material behaviour is the hardness of the workpiece. Figure
10.9 shows hardness test methods to Brinell (standardised to DIN 50 351) and Vickers (DIN
50 133). When testing to Brinell, a steel ball is pressed with a known load to the surface of
the tested workpiece. The diameter of the resulting impression is measured and is a magni-
tude of hardness. The hardness value is calculated from test load, ball diameter, and diame-
ter of rim of the impression (you find the formulas in the standards). The hardness
information contains in addition to the hardness magnitude the ball diameter in mm, applied
load in kp and time of influence of the test load in s. This information is not required for a ball
diameter of 10 mm, a test load of 3000 kp (29420 N), and a time of influence of 10 to 15 s.
This hardness test method may be used only
on soft materials up to 450 BHN (Brinell 4 5 4
3 3 1 3 5
1 3 3
3
Hardness Number). 0,200 mm
6 7 8 10 6 7 8 10

0,200 mm
2
100 130
0 30
0

Hardness testing to Vickers is analogous. specimen surface specimen surface

6 reference 6 reference
100 level for 130 level for
This method is standardised to DIN 50133.
hardness
scale

0,200 mm
0,200 mm

measurement

hardness
scale
8,9 measurement 8,9
7 7
10
Instead of a ball, a diamond pyramid is 0 30
0
10

pressed into the workpiece. The lengths of

Abbreviation Terms
the two diagonals of the impression are 1 - cone angle = 120 ball diameter = 1,5875 mm ( 1/16 inch)
2 - radius of curvature of cone tip = 0,200 mm

measured and the hardness value is calcu- 3

4
F0
F1
test preload
test load
5 F total test load = F0 + F1

lated from their average and the test load. 6 t0

penetration depth in mm under test preload F0. This defines the reference level
for measurement of tb.

The impressions of the test body are always

7 t1 total penetrationn depth in mm under test load F1
8 tb resulting penetration depth in mm, measured after release of F1 to F0
resulting penetration depth, expressed in units of 0,002 mm: e =

geometrically similar, so that the hardness

9 e
tb / 0,002

HRC HRB
10 Rockwell hardness = 100 - e Rockwell hardness = 130 - e
HRA HRF
value is normally independent from the size
of the test load. In practice, there is a hard- br-er10-10.cdr ISF 2002

ness increase under a lower test load be- Hardness Test to

Rockwell
cause of an increase of the elastic part of the
Figure 10.10
deformation.

Hardness testing to Vickers is almost universally applicable. It covers the entire range of ma-
terials (from 3 VHN for lead up to 1500 VHN for hard metal). In addition, a hardness test can
be carried out in the micro-range or with thin layers.

Figure 10.10 illustrates a hardness test to Rockwell. In DIN 50103 are various methods stan-
dardised which are based on the same principle.
10. Testing of Welded Joints 132

With this method, the penetration depth of a penetrator is measured.

At first, the penetrator is put on the workpiece by application of a pre-test load. The purpose
is to get a firm contact between workpiece and penetrator and to compensate for possible
play of the device.

Then the test load is applied in a shock-free way (at least four times the pre-force) and held
for a certain time. Afterwards it is released to reach minor load. The remaining penetration
depth is characteristic for the hardness. If the display instrument is suitably scaled, the hard-
ness value can be read-out directly.

All hardness test methods to Rockwell use a ball (diameter 1.5875 mm, equiv. to 1/16 Inch)
or a diamond sphero-conical penetrator (cone angle 120) as the penetrating body. There are
differences in size of pre- and test load, so different test methods are scaled for different
hardness ranges. The most commonly used scale methods are Rockwell B and C. The most
considerable advantage of these test methods compared with Vickers and Brinell are the low
time duration and a possible fully-automatic measurement value recognition. The disadvan-
tage is the reduced accuracy in contrast to the other methods. Measured hardness numbers
are only comparable under identical conditions and with the same test method. A comparison
of hardness values which were determined
with different methods can only be carried out
for similar materials. A conversion of hardness
values of different methods can be carried out
piston

for steel and cast steel according to a table in

DIN 50150. A relation of hardness and tensile
strength is also given in that table.

All the hardness test methods described above

require a coupon which must be taken from the reference bar

workpiece and whose hardness is then deter-

mined in a test machine. If a workpiece on-site
is to be tested, a dynamical hardness test specimen

method will be applied. The advantage of these

methods is that measurements can be taken br-er10-11.cdr ISF 2002

on completed constructions with handheld

Poldi - Hammer

Figure 10.11
10. Testing of Welded Joints 133

units in any position. Figure 10.11 illustrates a hardness test using a Poldi-Hammer. With this
(out of date) method, the measurement is carried out by a comparison of the workpiece
hardness with a calibration piece. For this purpose a calibration bar of exactly determined
hardness is inserted into the unit, which is held by a spring force play-free between a piston
and a penetrator (steel ball, 10 mm diameter). The unit is put on the workpiece to be tested.
By a hammerblow to the piston, the penetrator penetrates the workpiece and the calibration
pin simultaneously. The size of both impressions is measured and with the known hardness
of the calibration bar the hardness of the workpiece can be determined. However, there are
many sources of errors with this method which may influence the test result, e.g. an inclined
resting of the unit on the surface or a hammerblow which is not in line with the device axis.
The major source of errors is the measurement of the ball impression on the workpiece. On
one hand, the edge of the impression is often unsharp because of the great ball diameter, on
the other hand the measurement of the impression using magnifying glasses is subjected to
serious errors.

Figure 10.12 shows a modern measurement method which works with ultrasound and com-
bines a high flexibility with easy handling and high accuracy. Here a test tip is pressed manu-
ally against a workpiece. If a defined test load is passed, a spring mechanism inside the test
tip is triggered and the measurement starts.
Test force
The measurement principle is based on a
measurement of damping characteristics in
5 kp
5.0
the steel. The measurement tip is excited to
kp

4.0 emit ultrasonic oscillations by a piezoelectric

crystal. The test tip (diamond pyramid) pene-
3.0

trates the workpiece under the test pressure

2.0
caused by the spring force. With increasing
Federweg
penetration depth the damping of the ultra-
sonic oscillation changes and consequently
the frequency. This change is measured by
the device. The damping of the ultrasonic os-
- little work on surface preparation of specimens (test force 5 kp)
cillation depends directly on penetration depth
- Data Logger for storage of several thousands of measurement points
- interfaces for connection of computers or printers
- for hardness testing on site in confined locations thus being a measure for material hardness.
br-er10-12.cdr ISF 2002 The display can be calibrated for all com-
monly used measurement methods, a meas-

Figure 10.12
10. Testing of Welded Joints 134

urement is carried out quickly and easily. Measurements can also be carried out in confined
spaces. This measurement method is not yet standardised.

+ tension
Description Application
m > a

m < a
m = a

m = 0
Dye penetrant method

crack is free, surface all materials with

is clean surface cracks
compression -

m < a

m > a
m = a
time crack and surface
with penetrant
liquid

cleaned surface,
dye penetrant
liquid in crack
pulsation range pulsation range
(compression) alternating range (tension) surface with
developer shows
the crack by coloring
Whler line

Magnetic particle testing

I A workpiece is placed
II between the poles of
a magnet or solenoid.
failure line Defective parts disturb
the power flux. Iron
Stress

particles are collected.

III
D

Surface cracks and

0 cracks up to 4 mm
1 10 102 103 104 105 106 107 below surface.
Fatigue strength (endurance) number lg N However:
Only magnetizable
I area of overload with material damage materials and only
II area of overload without material damage for cracks perpendicular
III area of load below fatigue strength limit to power lines

br-er10-14.cdr ISF 2002

br-er10-13.cdr ISF 2002

Fatigue Strength Testing

Figure 10.13 Figure 10.14

To test a workpiece under oscillating stress, the fatigue test is standardised in DIN 50100.
Mostly a fatigue strength is determined by the Whler procedure. Here some specimens
(normally 6 to 10) are exposed to an oscillating stress and the number of endured oscillations
until rupture is determined (endurance number, number of cycles to failure). Depending on
where the specimen is to be stressed in the range of pulsating tensile stresses, alternating
stresses, or pulsating compressive stresses, the mean stress (or sub stress) of a specimen
group is kept constant and the stress amplitude (or upper stress) is varied from specimen to
specimen, Figure 10.13. In this way, the stress amplitude can be determined with a given
medium stress (prestress) which can persist for infinite time without damage (in the test: 107
times). Test results are presented in fatigue strength diagrams (see also DIN 50 100). As an
example the extended Whler diagram is shown in Figure 10.13. The upper line, the Whler
line, indicates after how many cycles the specimen ruptures under tension amplitude a. The
10. Testing of Welded Joints 135

Description Application
W ire diameter
X-ray or isotope radiation penetrate Mainly for defects with orientation Tolerated
a workpiece. The thicker the work- in radiation direction. deviation W ire number
piece, the weaker the radiation mm mm
reaching the underside.
3,2 1
2,5 0,03 2
2 3
1,6 4
1,25 5
1 0,02 6
0,8 7
0,63 8
0,5 9
0,4 10
0,32 11
0,01
0,25 12
- 0,2 13
0,16 14
0,125 15
0,005
0,1 16

W ire number to W ire length Material groups

Abbreviation W ire material
Table 1 mm to be tested

FE 1/7 1 to 7 50
mild
FE 6/12 6 to 12 50 or 25 iron materials
steel
FE 10/16 10 to 16 50 or 25
CU 1/7 1 to 7 50
copper, zink, tin
CU 6/12 6 to 12 50 copper
and its alloys
CU 10/16 10 to 16 50 or 25
radiation source AL 1/7 1 to 7 50
aluminium
- workpiece AL 6/12 6 to 12 50 aluminium
and its alloys
film (displayed in distance from workpiece) AL 10/16 10 to 16 50 or 25

defect in radiation direction; difficult to identify (flank lack of fusion)

defect in radiation direction; easy to identify
br-er10-15.cdr ISF 2002 br-er10-16.cdr ISF 2002

Non-Destructive Test Methods Determination of Picture Quality

Radiographic Testing Number to DIN 54105

Figure 10.15 Figure 10.16

damage line indicates analogously, when a

Description
US-head generates high-frequency sound
waves, which are transferred via oil coupling
to the workpiece. Sound waves are reflected
on interfaces (echo).
Application
Mainly for defects with an orientation
damage to the material starts in form of
transverse to sound input direction.
cracks. Below this line, a material damage
does not occur.

Test methods described above require
specimens taken out of the workpiece and a

partly very accurate sample preparation. A

testing of completed welded constructions is
impossible, because this would require a de-

sound head
struction of the workpiece. This is the reason
oil coupling
workpiece
defect
why various non-destructive test methods
ultrasonic test device
radiation pulse
defect echo
were developed, which are not used to de-
backwall echo

termine technological properties but test the
br-er10-17.cdr ISF 2002
workpiece for defects. Figure 10.14 shows
Non-Destructive Test Methods
Ultrasonic Testing II

Figure 10.17
10. Testing of Welded Joints 136

two methods to test a workpiece for surface defects.

Figure 10.15 illustrates the principle of radiographic testing which allows to identify also de-
fects in the middle of a weld. The size of the minimum detectable defects depends greatly on
the intensity of radiation, which must be
adapted to the thickness of the workpiece to
be radiated. As the film with documented de-
fects does not permit an estimation of the
plate thickness, a scale bar must be shown for
estimation of the defect size.

For that purpose, a plastic template is put on

the workpiece before radiation which contains
metal wires with different thickness and incor-
porated metallic marks, Figure 10.16. The size
of the thinnest recognisable wire indicates the

Figure 10.18 size of the smallest visible defect. Radiation

testing provides information about the defect
position in the plate plane, but not about the
position within the thickness depth. A clear
advantage is the good documentation ability
Figure 10.18 of defects.

An information about the

depth of the defect is pro-
vided by testing the work-
piece with ultrasound. The
principle is shown in Fig-
ures 10.17 and 10.18
(principle of a sonar).

The display of original br-er10-19.cdr

pulse, backwall and defect

Ultrasonic Testing of Fillet Welds
echo is carried out with an
oscilloscope. Figure 10.19
10. Testing of Welded Joints 137

This method provides not only a perpendicular sound test, but also inaccessible regions can
be tested with the use of so called angle testing heads, Figure 10.19.

Pores between 10 and 20 mm

depth provide an unbroken
echo sequence across the entire
display starting from 10mm. The
backwall echo sequence of 30
mm is not yet visible. Wall thickness is below 40 mm.
30
The roughness provides smaller
and wider echos.
Echo sequence of 20 mm depth.
The backwall is completely
screened.

40 The perpendicular crack

penetrating the material
does not provide a display
The oblique and rough defect
because the reflecting surface
from 20 to 30 mm provides a (tip of crack) is too small.
wide echo of 20 to 30 mm.
Starting with SKW 4, an un-
broken echo sequence follows.
The inclination of the reflector The oblique backwall reflects
is recornised by a change of the soundwaves against the
the 1st echo when shifting the crack. this is the reason why
test head. an impossible depth of
65 mm is displayed.
Echo sequence of 10 mm depth.
The reflector in 30 mm depth is
completely screened.

br-er10-20.cdr ISF 2002 br-er10-21.cdr ISF 2002

Defect Identification with Ultrasound Defect Identification With Ultrasound

Figure .10.20 Figure 10.21

Figures 10.20 and 10.21

show schematically the
macro section
display of various defects

50
on an oscilloscope. A cor-
base material ferrite
+ perlite coarse grain zone bainite
rect interpretation of all the
signals requires great ex-
2,5 mm
perience, because the
fine grain zone ferrite
+ perlite
fusion line bainite shape of the displayed sig-
Steel: S355N nals is often not so clear.
(T StE 355)
weld metal cast structure

br-er10-22.cdr

Figure 10.22 illustrates the

Metallographic Examination of a Weld
potential of metallographic
Figure 10.22 examination. Grinding and
10. Testing of Welded Joints 138

etching with an acid makes the microstructure

visible. The reason is that depending on
structure and orientation, the individual grains
react very differently to the acid attack thus
25 100
Fe % Fe reflecting the light in a different way. The
% Cr 80
Cr macrosection, i.e. without magnification, gives
20 60

a complete survey about the weld and fusion

40

15 line, size of the HAZ, and sequence of solidi-

20

10 0
fication. Under adequate magnification, these
% Ni
8
10
areas can still not be distinguished precisely,
Ni

6 however, an assessment of the developed

5
4
microstructure is possible.
2

0 0
200 mm 100 0 100 An assessment of the distribution of alloy
Distance from fusion line
br-er10-23.cdr ISF 2002
elements across the welded joint can be car-
Micro-Analysis of the Transition Zone
Base Material - Strip Cladding ried out by the electron beam micro-analysis.
An example of such an analysis is shown in
Figure 10.23
Figure 10.23. If a solid body is exposed to a
focused electron beam of high energy, its atoms are excited to radiate X-rays. There is a
simple relation between the wave length of this radiation and the atomic number of the
chemical elements. As the intensity of the radiation depends on the concentration of the ele-
ments, the chemical composition of the solid body can be concluded from a survey of the
emitted X-ray spectrum
qualitatively and quantita-
tively. A detection limit is 50 50
50
50
20 20 1. weld 20 20
about 0.01 mass % with this 2. weld
0
10

method. Microstructure ar-

eas of a minimum diameter axis of
weld
axis of
weld bending former bending former

of about 5 m can be ana- Agents:

- electrolytic copper in the form of chips (min. 50 g/l test solution)
- 100 ml H2SO4 diluted with 1 l water and then
lysed. If the electron beam is .
110 g CuSO 5 H2O are added

Test:
moved across the specimen The specimens remain for 15 h in the boiling test solution.
Then the specimens are bent across a former up to an angle
of 90 and finally examined for grain failure under a

(or the specimen under the 6 to 10 times magnification.

br-er-10-24.cdr

beam), the element distribu-

Strau - Test
tion along a line across the
Figure 10.24
10. Testing of Welded Joints 139

solid body can be determined. Figure 10.23 presents the distribution of Ni, Cr, and Fe in the
transition zone of an austenitic plating in a ferritic base metal. The upper part shows the re-
lated microsection which belongs to the analysed part. This microanalysis was carried out
along a straight line between two impressions of a Vickers hardness test. The impressions
are also used as a mark to identify precisely the area to be analysed.

The so called Strau test is

12
standardised in DIN 50
web 914. it serves to determine

tack welds measurement points

the resistance of a weld
80

base plate against intergranular corro-

weld2 weld1 20 40 40 20
sion. Figure 10.24 shows
the specimen shape which
12

a
aa
a

a a
is normally used for that
a

80 120
aa

test. In addition, some de-

br-er-10-25.cdr

Test of Crack Susceptibility of Welding tails of the test method are

Filler Materials to DIN 50129
explained.
Figure 10.25

Figure 10.25 presents a specimen shape for testing the crack susceptibility of welding con-
sumables. For this test, weld number 1 is welded first. The 2. weld is welded not later than 20
s in reversed direction after completion of the first weld. Throat thickness of weld 2 must be
20% below of weld 1. After
cooling down, the beads
are examined for cracks. If
tensioning bolt
hexagon nut
min. M12 DIN 934
guidance plates cracks are found in weld 1,
a

tensioning plate
the test is void. If weld 1 is
specimen free from cracks, weld 2 is
base body
examined for crack with
magnifying glasses. Then
weld 1 is machined off and
weld 2 is cracked by bend-
br-er-10-26.cdr

Tensioning Specimen for Crack

ing the weld from the root.
Susceptibility Test Test results record any
Figure 10.26
10. Testing of Welded Joints 140

surface and root cracks together with information about position, orientation, number, and
length. The welding consumable is regarded as 'non-crack-susceptible' if the welds of this
test are free from cracks.

Figure 10.26 presents two proposals for self-stressing specimens for plate tests regarding
their hot crack tendency. Such tests are not yet standardised to DIN.

thermo couple
cross-section electrode
groove shape
60 60 welding direction
weld
metal
support plate
Wd./2
Wd. H
Hc implant
Wd./2

2 2
load
specimen shape temperature in C
load in N
Tmax
start end crater crack coefficient

c
150 C= x 100 (in %)
800
500
1 2 3 4 5
sections 150
100
60 80 60
t8/5 time in s rupture time
anchor weld test weld anchor weld

br-er10-27.cdr ISF 2002 br-er10-28.cdr ISF 2002

Tekken Test Implant Test

Figure 10.27 Figure 10.28

There are various tests to examine a cold crack tendency of welded joints. The most impor-
tant ones are the self-stressing Tekken test and the Implant test where the stress comes from
an external source.

In the Tekken test which is standardised in Japan, two plates are coupled with anchor joints
at the ends as a step in joint preparation see Figure 10.27. Then a test bead is welded along
the centre line. After storing the specimen for 48 hours, it is examined for surface cracks. For
a more precise examination, various transverse sections are planned. The value to be de-
termined is the minimum working temperature at which cracks no longer occur. The speci-
men shape simulates the conditions during welding of a root pass.
10. Testing of Welded Joints 141

The most commonly used cold crack test is the Implant test, Figure 10.28. A cylindrical body
(Implant) is inserted into the bore hole of a support plate and fixed by a surface bead. After
the bead has cooled down to 150C the implant is exposed to a constant load. The time is
measured until a rupture or a crack occurs (depending on test criterion 'rupture' or 'crack').
Varying the load provides the possibility to determine the stress which can be born for 16
hours without appearance of a crack or rupture. If a stress is specified to be of the size of the
yield point as a requirement, a preheat temperature can be determined by varying the work-
ing temperature to the point at which cracks no longer appear.

As explained in chapter 'cold cracks' the hydrogen content plays an important role for cold
crack development. Figure 10.29 shows results of trials where the cold crack behaviour was
examined using the Tekken and Implant test. Variables of these tests were hydrogen content
of the weld metal and preheat temperature. The variation of the hydrogen content of the weld
metal was carried out by different exposure to humidity (or rebaking) of the used stick elec-
trodes. Based on the hydrogen content, the preheat temperature was increased test by test.
Consequently, the curves of Figure 10.29 represent the limit curves for the related test.
Specimens above these
heat input: 12 kJ/cm
basic coated stick electrode
plate and support plate thickness: 38 mm curves remain free from

C C
cracks, below these curves
Implant-Test Tekken-Test
150 Rcr = Rp0,2 = 358 N/mm 150 cracks are present. Evi-
dent for both graphs is that
Preheat temperature

Preheat temperature

100 100
with increased preheat
temperature considerably
50 fractured 50
starting cracks
starting cracks
crack-free
higher hydrogen contents
crack-free
20
ml/
20
ml/
are tolerated without any
0 10 20 30 40 0 10 20 30 40
100 g 100 g

br-er-10-29.cdr
Diffusible hydrogen content crack development be-
Test Result Comparison of cause of the much better
Implant and Tekken Test
hydrogen effusion.
Figure 10.29

If both graphs are com-

pared it becomes obvious that the tests produce slightly different findings, i.e. with identical
hydrogen content, the determined preheat temperatures required for the avoidance of crack-
ing, differ by about 20C.
10. Testing of Welded Joints 142

Figure 10.30 illustrates a method to measure the diffusible hydrogen content in welds which
is standardised in DIN 8572. Figure a) shows the burette filled with mercury before a speci-
men is inserted. The coupons are inserted into the opened burette and drawn with a magnet
through the mercury to the capillary side (density of steel is lower than that of mercury, cou-
pons surface). Then the burette is closed and evacuated. The hydrogen, which effuses of the
coupons but does not diffuse through the mercury, collects in the capillary. The samples re-
main in the evacuated burette 72 hours for degassing. To determine the hydrogen volume
the burette is ventilated and the coupons are removed from the capillary side. The volume of
the effused hydrogen can be read out from the capillary; the height difference of the two mer-
cury menisci, the air pres-
sure, and the temperature
provide the data to calculate to pump
hydrogen
under redu- VT
the norm volume under ced pressure air pressure B

evacuated

standard conditions. This capillary side

volume and the coupons meniskus1

M
weight are used to calculate, meniskus2

mercury coupons
as measured value, the hy-
drogen volume in ml/100 g
weld metal. This is the most br-er-10-30.cdr
a) starting condition b) during degassing c) ventilated after degassing

commonly used method to Burettes for Determination of

Diffusible Hydrogen Content
determine the hydrogen
content in welded joints. Figure 10.30