WELD WELD

TESTING TESTING TESTING TESTING

DESTRUCTIVE
AND AND
NON-DESTRUCTIVE
DESTRUCTIVE TESTING
These can be
divided into two
parts,
Tests capable of
being performed in
the workshop. the workshop.
Laboratory tests.
microscopic-
macroscopic ,
chemical and
corrosive.
REASONS
Defects occur during welding which
affect the quality and hardness of the
plate plate
Other defects occur through lack of
knowledge of and skill of the welder
For the training of welders
WORKSHOP TESTS
TENSILE BENDING
IMPACT HARDNES IMPACT HARDNES
FATIGUE CRACKING
TENSILE
Material is sectioned
and edges rounded of
to prevent cracking.
Punch marks are made Punch marks are made
to see elongation.
TENSILE
BEND TESTING
Shows
Physical condition of the weld
Determine welds efficiency Determine welds efficiency
Tensile strength
Ductility
Fusion and penetration
BEND TEST
Bend through 180
O
the specimen should be a minimum of 30mm wide
The fulcrums diameter is 3x thickness of the plate
The bottom rollers have a distance of the diameter The bottom rollers have a distance of the diameter
of the former + 2.2 times the thickness of the plate
Upper and lower surfaces ground or filed flat and
edges rounded off.
the tests should be one against the root -another
against the face ,and in some cases a side bend.
Root bend
FACE BEND
IMPACT
CHARPY AND IZOD
Gives the toughness and shock loading of the
material and weld at varying temperatures
with a notch such as under cut with a notch such as under cut
The measurement is the energy required to
to break a specimen with a given notch
2mm depth at a 45
o
bevel or a U notch.
TEST MACHINE
CHARPY
IZOD
ANY QUESTIONS
HARDNESS TESTS.
This gives the metals ability to show
resistance to indentation which show its
resistance to wear and abrasion.
The tests are The tests are
Brinell
Rockwell
Vickers diamond pyramid
Scleroscope
VICKERS HARDNES
FATIGUE
the testing of Material that is subject to
fluctuating loads
HAIGH Electro magnetic tester.
WOHLER Uses rotating chuck with weight
CRACKING
REEVES Test study the hardening and cracking
of welds.
The compatibility of electrodes for the metal
being joined. being joined.
CRACKING
Three Sides Are
Welded With Known
Compatible
Electrodes. Electrodes.
The front edge is
welded with the test
electrode.
if incompatible it will
crack.
MICROSCOPIC
Used to determine
the actual structure
of the weld and
parent metal parent metal
Up to 50,000 times
magnification with an
electron beam
microscope
Polishing must be of a
very high standard
MACROSCOPIC
Examined using a
magnifying glass .
magnification from 2
to 20 time. to 20 time.
it will show up slag
entrapment or cracks
.
polishing not as high
as micro.
ETCHING REAGENTS
These are acids used to show up different
structures in metals
For steels the most common is 1-2 % nitric
acid in distilled water or alcohol. acid in distilled water or alcohol.
Aluminum uses a solution of 10-20%caustic
soda in water
HAVE YOU ANY
QUESTIONS
NON-DESTRUCTIVE
TESTING TESTING
VISUAL
While welding
The rate the electrode
melts
The way the weld metal
After welding
Under cut
Lack of root fusion
Any pin holes from gas
The way the weld metal
flows
Sound of the arc
The light given of
Any pin holes from gas
or slag
Amount of spatter
Dimensions of weld
DYE PENETRANTS
These are an aid to visual inspection
Will only find surface defects Will only find surface defects
Use correct type
DYE PENETRANTS
DYE PENETRANTS
Types
Red
Flouresant
CAUTION
Oil based
Water washable
DETECTION
MAGNETIC PARTICLE
Mainly for surface
defects
Some sub surface
defects can be found defects can be found
Only ferrous metal
ACOUSTICS
Striking with a rounded
object
Ringing tone if no
defect
Tone changes when
object is cracked
APPLICATION OF A LOAD
Used to test pressure vessels
Pipe lines
The item for testing is filled with water or oil
it is then pressurised using a pump it is then pressurised using a pump
A safety valve is set 1.5 to 2 times below the
working pressure.
PRESSURE TEST
RADIOGRAPHIC
X-RAY
GAMMA RAY
Electro magnetic Electro magnetic
radiation of short
duration
Both of these methods
are a danger to
health
X- RAY
X-RAY VIEWER
Pictures taken are
viewed as negatives
will only give flat image
not in three not in three
dimensional
darkened area must be
used for viewing
ULTRASONIC TESTING
This uses high pitched
sound
The sound will not pass
through an air gap so through an air gap so
bounces back and is
picked up on a
receiver
The reader is a
oscilloscope
ULTRA SONIC
THIS IS THE END OF THE
LESSON
ARE THERE ANY ARE THERE ANY
QUESTIONS