Importance of Macro Etch Testing of

Welds
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M acro etch tests are commonly done as part of

qualification tests for welders and welding procedures. This

test is relatively easy to do and does not require complex or
expensive equipment.  However, very few fabricators ever
perform this test.
A macro etch test can serve as verification that a change on how
something is welded is still providing a sound weld.  How a weld looks from
the outside can be an indication of quality, but assuming the exterior
appearance tells all is a big mistake.  Plenty of beautiful welds have lack of
fusion.
Just recently we conducted a survey for a potential customer.  We noticed
that a print for a weldment called for an 1/8” fillet weld joining a 3-inch
diameter boss with 1/2-inch wall thickness to a 1/4-inch thick plate.  This was
being welded robotically.  However, the fillet weld being made by the robot
was not 1/8-inch; it was 1/4-inch.

This part was being overwelded by 300%!  This meant that if they stuck to
the size called for by the print they would reduce welding time by 75%.
When asked why they were not putting down 1/8-inch fillet welds they
mentioned being afraid of not getting fusion with such a small weld.  For the
past 3 years they had been overwelding because they weren’t sure if that
very small 1/8-inch fillet weld could fuse to the root.  A simple macro etch
test could verify that.  Since they were using a robot, it would be expected
that if they get the penetration they need once, they will always get it due to
the repeatability of the robot.

We took one of their parts and cut it open and this is what we saw…
 The green line shows the effective throat of the fillet weld.

As you can see they were getting not just fusion but very deep penetration. 
The image shows the effective throat (green line) having a dimension of
0.209 inches.  The engineering drawing required a 1/8-inch fillet weld with
fusion to the root, meaning that the necessary throat only had to be 0.088
inches.  The current weld is providing more than double the throat which
means more than double the load carrying capacity.  So this is not bad. 
Except for using four times the amount of weld metal necessary and taking
four times as long to weld.

We then mocked up this joint.  Slightly different configuration but close

enough to give us a good idea of whether or not we could achieve root fusion
with a much smaller weld.   This was the result…
 The green line shows the effective throat of the fillet weld.

Much to the surprise of our customer this weld achieved a significant amount
of root penetration.  The penetration was so deep that the dimension of the
throat ended up being 0.246 inches.  The weld size was not quite 1/8-inch; it
was roughly 3/16-inch.  Still, this would represent a 25% reduction of weld
metal.  The wonderful thing was that no strength was lost.  This weld, due to
a larger effective throat, had 18% higher load carrying capacity than the
bigger ¼-inch fillet weld.

This simple macro etch test provided the fabricator with proof that a better
welding procedure could provide a smaller weld and higher strength.  The
procedure was later implemented.  The new welding procedure specification
(WPS) was written as an AWS D1.1 prequalified welding procedure based on
the instructions in Qualification of Welding Procedures, Welders and Welding
Operators.  However, due to the sensitive nature of this joint a full procedure
qualification test was conducted according Clause 4 of AWS D1.1.
The end result was a savings of 25% in filler metal, gases and welding time
and an increase in strength.  The reduction of approximately 25% in welding
time resulted in a total cycle time reduction of 9%. This added capacity was
worth tens of thousands of dollars per year to this fabricator.  All of this
facilitated by a simple macro etch test.

If you are looking to do macro etch testing of your welds all you need is the
following:

 Band saw (or any way to cut a cross section of the weld – cutoff wheel,
oxyfuel, plasma, etc.)

 Grinder

 Polisher (can use a grinder with a very fine disc)

 Etching solution – depending on the base material you will need

different solutions – for a list of different options read Etching Solutions
for Steel, Stainless, Aluminum and Other Metals.
Maybe it’s time you looked inside some of your welds and improve quality
and productivity.  If you have any questions on performing macro etch
please just let us know.