SWI 3.

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WHAT IS
MECHANICAL
TESTING ?
The ultimate means by which the mechanical
strength and toughness of a prepared test
object can be determined by subjecting it to
mechanical forces beyond the limits of its own
mechanical resistance
 SWI 3.2

Mechanical Testing

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Destructive testing of welded joints are
usually carried out to:

 Approve welding procedures

 Approve welders
 Production quality control
 SWI 3.2

Mechanical Tests

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The following mechanical tests have units and are
termed quantitative tests

 Tensile tests

 Toughness testing (Charpy, Izod)

 Hardness tests
 SWI 3.2

Mechanical Tests

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The following mechanical tests have no units and
are termed qualitative tests
 Macro testing

 Bend testing

 Fillet weld fracture testing

 Butt weld nick-break testing

 SWI 3.2

Definitions

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 Malleability  Can be deformed a
 Ductile great deal by
 Toughness compression before
cracking
 Hardness
 SWI 3.2

Definitions

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 Malleability  Can be deformed
 Ductile considerably by
 Toughness tension before it
fractures
 Hardness
 SWI 3.2

Definitions

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 Malleability  Ability to withstand
 Ductile bending without
 Toughness fracture
 Hardness
 SWI 3.2

Definitions

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 Malleability  Measure of the
 Ductile resistance of a
 Toughness material to
indentation
 Hardness
 SWI 3.2

Bend Tests

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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
1. Face bend
2. Root bend
3. Side bend
 SWI 3.2

Bend Tests

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Former (4t)

Weld dressed flush Support

Root bend Face bend

 SWI 3.2

Bend Tests

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Face bend
Side bend

Root bend

Defect indication Minor ruptures on

Generally this specimen tension surface
would be unacceptable Acceptance depends
upon code
requirements
 SWI 3.2

Bend Tests

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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)

 Appearance of joint after bending e.g. type

and location of any flaws.
 SWI 3.2

Bend Tests

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Different tensile tests include:

 Transverse tensile.

 All-weld metal tensile test

 Cruciform tensile test

 Short tensile test

 SWI 3.2

Tensile Tests

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Transverse Tensile
Specimen

All-Weld Metal Tensile

Specimen
 SWI 3.2

Transverse Tensile Tests

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Object of test:
To measure the transverse tensile strength of a
butt joint under a static load

Weld metal area

Reduced section specimen

Radius reduced specimen

None reduced section specimen

 SWI 3.2

Transverse Tensile Tests

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Maximum load applied = 220 kN.
Least cross sectional area = 25 mm X 12 mm

U.t.s. = Maximum load applied

Least c.s.a.

U.t.s = 220000 N
25mm X 12mm

U.t.s = 733.33 N/mm2

 SWI 3.2

Transverse Tensile Tests

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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

 Location of fracture.

 Location and type of any flaws present if any

 SWI 3.2

All-Weld Metal Tensile

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Gauge length
Object of test

 Ultimate tensile
strength

 Yield strength

 Elongation %
(ductility)

Increased gauge length

 SWI 3.2

All-Weld Metal Tensile

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Original gauge length = 50mm
Increased gauge length = 64

Elongation % = Increase of gauge length X 100

Original gauge length

Elongation % = 14 X 100
50

Elongation = 28%
 SWI 3.2

All-Weld Metal Tensile

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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 %

 Location and type of any flaws present if any

 SWI 3.2

Short Tensile Tests

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A test for a materials susceptibility to lamellar tearing

Friction Welded Caps

Short Tensile Specimen
Sample of Parent Material
Through
Thickness
Ductility

The results are given as a STRA value

Short Transverse Reduction in Area
 SWI 3.2

Charpy Impact Test

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Object of Test
To determine the amount of energy absorbed in
fracturing a standardised test piece
1. Specimens are usually taken in groups of
three to allow for scatter results
2. Test temperature should be specified
3. Test results are give in joules
4. Tough specimens absorb more energy than
brittle specimens
 SWI 3.2

Charpy Impact Test

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Direction of striker

45o

Root radius
0.25mm
2mm

10
10
55
 SWI 3.2

Izod Impact Test

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Direction of impact

Test specimen

Vice type fixture

28mm
2mm

10mm

75mm
 SWI 3.2

Charpy Impact Test

22 I/2o

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10 mm
100% Brittle
2 mm
Machined
notch

Fracture surface
8 mm

100% bright
crystalline brittle
fracture

100% Ductile
Machined
notch

Large reduction
in area, shear
lips
Randomly torn,
dull gray fracture
surface
 SWI 3.2

Comparison of Charpy Test Results

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Impact Energy Joules
Room Temperature -20oC Temperature

1. 197 1. 49
2. 191 2. 53
3. 186 3. 51
Average = 191 Average = 51
The test results show the specimens carried out at room temperature
absorb more energy than than the specimens carried out at -20oC
 SWI 3.2

Ductile/Brittle Transition Curve

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Ductile fracture
Temperature range

47 Joules

Transition range Ductile/Brittle

transition point

28 Joules
Brittle fracture

- 50 - 40 - 30 - 20 - 10 0
Degrees Centigrade
 SWI 3.2

Charpy Impact Test

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Reporting results
 Location and orientation of notch

 Testing temperature

 Energy absorbed in joules

 Description of fracture (brittle or ductile)

 Location of any defects present

 Dimensions of specimen
 SWI 3.2

Fillet Weld Fracture Test

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Object of test
To break open the joint through the weld to permit
examination of the fracture surfaces

1. Specimens are cut to the required length

2. A saw cut approximately 2mm in depth is
applied along the fillet welds length
3. Fracture is usually made by striking the
specimen with a single hammer blow
4. Visual inspection for defects
 SWI 3.2

Fillet Weld Fracture Test

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Hammer

Hammer
2mm
Notch

2mm
Notch

Fracture should break saw cut

to root
 SWI 3.2

Fillet Weld Fracture Test

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This fracture indicates lack
of fusion
This fracture has occurred
saw cut to root
 SWI 3.2

Fillet Weld Fracture Test

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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

 SWI 3.2

Nick-Break Test
Object of test

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To permit evaluation of any weld defects across
the fracture surface of a butt weld.

1. Specimens are cut transverse to the weld

2. A saw cut approximately 2mm in depth is
applied along the welds root and cap
3. Fracture is usually made by striking the
specimen with a single hammer blow
4. Visual inspection for defects
 SWI 3.2

Nick-Break Test Specimens

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Notch cut by hacksaw
3 mm

19 mm

3 mm
Approximately 230 mm

Weld reinforcement may or

may not be removed

Alternative nick-break test specimen,

notch applied all way around the
specimen
 SWI 3.2

Nick-Break Test

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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

 SWI 3.2

Macro / Micro

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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
 SWI 3.2

Macro / Micro

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Will Reveal

 Weld soundness
 Distribution of inclusions
 Number of weld passes
 Metallurgical structure of weld, fusion zone
and HAZ
 Location and depth of penetration of weld
 Measure the leg length and throat thickness
 SWI 3.2

Macro Micro
 Visual examination for  Visual examination for

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defects defects & grain structure
 Cut transversely from  Cut transversely from
the weld the weld

 Ground and polished  Ground and polished

P1200 grit paper
P400 grit paper
 Etched using 1-5%
 Etched using 10-15% nitric acid solution
nitric acid solution
 Wash and dry
 Wash and dry
 Visual inspection under
 Visual inspection under 100X-1000X magnification
5X magnification  Report on results
 Report on results
 SWI 3.2

Macro Report

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Sample Number MSR-1189

3
4
2

DEFECT TYPE DEFECT SIZE ACCEPT/REJECT

1. Lack of sidewall fusion + slag 4mm Reject
2. Slag inclusion 3.5mm Reject
3. Lack of sidewall fusion 5.8mm depth Reject
4. Cap undercut 0.6mm Accept
 SWI 3.2

Hardness Testing

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Various Methods

 Brinell

 Rockwell

 Vickers

 Equo tip
 SWI 3.2

Vickers Hardness Testing

 Square based pyramid

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 Indenter pressed into specimen with a load of between
1 and 100kg for 15 seconds
 Length of diagonals measured using adjustable
shutters and a built in microscope

Diamond
indentor Adjustable
shutters

Indentation
 SWI 3.2

Brinell Hardness Testing

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 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
 SWI 3.2

Equo Tip Hardness Testing

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 SWI 3.2

Questions

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QU 1. What mechanical properties can be measured in the all-
weld metal tensile test

QU 2. What is the purpose of a charpy V-notch test and what

units are the test results give in.

QU 3. Give a brief description of the following tests

a. Bend test
b. Nick-break test
c. Marco.

QU 4. From a transverse tensile test the following information is

known, calculate the ultimate tensile strength
Maximum load applied 235 Kilo Newtons
Least cross sectional area 25.20mm x 17.52mm