Introduction to

Weld Testing
Methods of Weld Testing

Destructive Non Destructive

 Nick
B reak
Acid Etch

Tensile Te st
Test Ben d

Methods of Weld Testing

Ult
ras e t ra nt
o nic uid Pen
Liq
X-ray

Pa rticle
et ic
Visual Magn
Non Destructive
Weld Testing
 Non Destructive Testing

 Ability to detect the condition of the object without destroying the

functionality of the object
 Non Destructive Testing

When are NDT Methods Used?

You can use NDT methods at almost any stage in the production
or life cycle of a component.

To screen or sort incoming materials.

To assist in product development
To verify proper assembly
To inspect for in-service damage
To monitor, improve or control manufacturing processes
To verify proper processing such as heat treating
 Non Destructive Testing – Visual Inspection
 Inspection of the object’s surface visually is called
Visual Inspection
 The types of accessories that can be used by the
inspector are:
 Gauges for identifying the dimensions of surface
 Magnifying glasses
 Bore scope for internal inspection
Non Destructive Testing – Penetrant Testing
 Is a method that reveals discontinuities open to surface by the
seepage of a liquid penetrant medium into a surface open
discontinuity which seeps out after removing the excess penetrant
revealing the discontinuity
Non Destructive Testing – Penetrant Testing
Non Destructive Testing – Penetrant Testing
Non Destructive Testing – Magnetic Particle

Very fine iron filings are mixed in

paraffin (often termed magnetic fluid).
The specimen under test is highly
magnetised usually by magnetic coils,
or by being placed in a store magnetic
field, and the fluid is then painted on
the weld metal, which must have a
machined or polished surface.

If there is any crack in the metal, an

alteration in the magnetic field occurs
at the crack, which is in reality a minute
air gap. As a result, the fine particles of
iron cling to the edges of the crack and
show it up ad a dark hair line.
Non Destructive Testing – Ultrasonic Testing
Ultrasonic testing employs waves above
the frequency limit of human audibility in
the frequency range of 0.6 – 5 MHz.

A pulse consisting of a number of these

waves is projected into the specimen
under test. If a flaw exists in the
specimen an echo is reflected from it and
from the type of echo the kind of flaw
that exists can be deduced.
Destructive
Weld Testing
Destructive Testing
 Destructive Testing – Acid Etch Testing
 For identification of internal
defects in welds.
 Different Etching acids available
are for different metals

(i) Steel – 10 - 20% nitric acid in water.

(ii) Aluminium and its alloys – 10% solution of Hydrofluoric acid in water.
(iii) Copper, Brass and Bronze – 25% solution of Nitric acid in water.

SAFETY
When using/storing etching fluids , penetrant fluids,
etc. COSHH regulations must be adhered to.
Destructive Testing – Butt Welds
 Destructive Testing – Bend Test

D + 2.2t

Three pieces taken at random points not less “D” OF FORMER = 4T

than 15mm from the ends, draw filed and sharp o
One bend at 180 should
edges removed.
be with the root (as
shown).
Clean off reinforcement One bend against the
root and the third as per
verbal instruction.
Draw file & polish
 Destructive Testing – Bend Test

Below shows an example of a 20mm material

thickness transverse specimens being tested with
the root of the weld in tension.

Most specifications require a root and a weld face

bends to be taken from each butt welded test
piece.
Destructive Testing – Bend Test
This shows a guided bend
test jig that uses a male
and a female former, the
commonest form of
equipment
Destructive Testing – Fillet Welds
 Destructive Testing – Nick Brake Test
FILLET WELD BUTT WELD
2-3mm Deep saw
Saw cut to full depth of
cut along centre
reinforcement along
50mm line of weld
centre line of weld

NICK BREAK 50mm

TEST PIECE
The specimens for this test are cut
transverse to the weld and are 50mm wide
The weld surfaces are slotted to ensure that the fracture
occurs along the centre line of the weld
The specimen can be bent in a press or fractured by
leverage or hammer blows in a vice
 Destructive Testing – Nick Break Test

This is a useful test when operators are learning to weld or when

the operator is setting a machine up for a specific task.
When broken, the weld could have many defects - these can be
quickly pointed out and remedied.
To ensure that the specimen breaks in the weld by making a nick
with a hacksaw along the weld to a depth of approximately 2 -
3mm.
The specimen is held in a vice and a force is applied until the weld
breaks.
Destructive Testing – Bend Test
 Destructive Testing – Tensile Test
Cut three transverse pieces 40mm wide

Prepare the specimen thus

25mm Radius 50
x
25
x
Fracture clear of the weld confirms a
satisfactory weld. 65 Parallel
When fracture occurs in the weld or at the Application of load
weld junctions a minimum ultimate stress
value for the metal may be stipulated,
calculated in the cross sectional area at ‘x - x’

TENSILE TESTING FOR 3mm & UNDER

 Destructive Testing – Tensile Testing
A tensile testing machine is used to grip a specimen
and exert a pulling force to test the weld for tensile
strength. When this test is applied the following
considerations must be taken into account:

After completion and cooling of the weld, the weld

metal itself may be strong yet brittle and hard. When
testing in a machine, the specimen could break
outside, in the parent metal, whereas in service due
to its brittleness, failure might easily occur in the
weld itself.

If the weld metal is softer than the parent metal, the

weld metal, when tested will yield and fracture will
occur in the weld.

Care must be taken to study carefully the results

and to interpret them correctly.
Destructive Testing – Tensile Testing
Learning Objectives
By the end of the session the learners will be able to:

1. Identify different types of welding defects, their causes and preventative

measures.
2. Gain knowledge of the different types of welding inspections.
3. Develop this understanding by completing a practical application of testing
welds.