Evaluation of Welds - Macro-Examination - Hardness PDF

Practicalities
All participants will be in listen-only mode during

the seminar.
But feel free to post questions in the Q&A module,
during the session.
The questions will be answered at the end or via e-
mail after the session.
www.struers.com
Welcome to Struers e-Seminar
Evaluation of Welds
Presenter: B.Sc. Application Specialist
Morten Andersen
www.struers.com
Evaluation of Welds; macro-examination and hardness
testing
Evaluation of Welds
Macro test examination and hardness testing
Agenda
 Introduction
 Macro test examination of welds
 Weld geometry and imperfections
 Example 1: Macro-study of a circumferential butt joint in stainless steel

- Cutting
- Preparation method
- Etching
- Macro examination
 Example 2: Hardness testing of X-groove butt weld in carbon steel

- Mech. Preparation
- Etching
- Hardness testing
 Summary
www.struers.com 04-11-2014 4
Evaluation of Welds
Macro test examination and hardness testing - introduction
e.g. wings and fuselages
e.g. Panels for decks e.g. Off shore production platforms & pipelines
www.struers.com
Evaluation of Welds
Introduction
Until the end of the 19th century, sections of metal

joined together by heating and hammering process
called forge welding
Today
Welding is an important technology, and a variety of

welding processes are available as fabrication process
for joining of materials in a wide range of applications in
different industries.
Common processes are Gas Metal Arc (solid wire),

Flux Cored Arc, Gas Tungsten Arc (TIG), SMAW (stick
electrode), Submerged Arc Welding.
But also specialized processes such as laser, plasma,
friction and electron beam welding are used more
frequently.
Evaluation of Welds
During welding the materials to be welded are raised above

their melting point in order for fusion to take place, and both the
weld metal, the fusion zone and the heat-affected zone is
subject to complex metallurgical changes.
Temp. 0C
1500 0C
The differences in
the HAZ in
correlation to Fe-C
phase diagram.
0,2 C%
Evaluation of Welds
These changes can have a profound influence upon the joint

properties and suitability for service.
Therefore a request for various examinations and testing is

called for.
For welded joints a macro-examination and hardness testing is

a common requirement.
Location of test specimens in a

welded T-joint
(Example acc. To EN/ISO 15614-1 -
Welding procedure test).
Evaluation and Metallography of Welds
Process
Control
Research
Failure
Analysis
Metallography Metallographic Weld

Preparation Method
The macro(structural) examination of a welded joint often includes:
 The number and size of passes/runs (weld structure)

 Depth of penetration and fusion geometry
 Extent of HAZ (Heat Affected Zone)
 Type and size of imperfections and defects,
 Hardness measurement
Evaluation of Welds
Weld joint geometry and possible types of imperfections/defects
Evaluation of Welds
Example 1 :
Preparation of circumferential butt joint in
stainless steel 304 L (thin plate).
 Cutting
 Mechanical preparation
 Etching
 Macro-examination
Evaluation of Welds
Cutting, example 1:
Circumferential butt joint in stainless steel.
Evaluation of Welds
Cutting, example 1:
Circumferential butt joint in stainless steel, after cutting.
Evaluation of Welds
Cutting of the stainless steel weldment.

Guiding hardness measurements (5 pcs): Between 175 to 200 HV 10.
Use of selection guide for soft ferrous metals on Secotom-50.
Cut-off wheel type 30A20.
2200 RPM
Feed speed 0,2 mm/s
Load: up to 30 %
Example of thermal
damage during cutting
of weld:
Selection of cut-off wheel
Cutting of example 1:
Selection of
appropriate cut-off
wheel for Secotom-50
www.struers.com
Evaluation of Welds
Mounting or not mounting of stainless steel weldment:

For this examination it was considered to mount, but 1) it is possible to grind manually
and 2) the specimen (although irregular) can stand on top of the WE-5 (see photo).
Examples of mounted welds
Evaluation of Welds
Mech. preparation of stainless steel weldment, example 1:

Manual grinding and polishing was chosen, in order to save time (no mounting)
Use of SiC-foil in grit sizes #220  #500  #800  #1000  #1200  #2000
Manually grinding was performed using Tegramin-30, see photo:
Evaluation of Welds
Etching of stainless steel weldment, example 1:

The specimen was etched electrolytically using oxalic acid (10g/100ml).
This is a common, fast and easy method for stainless steels.
Equipment: LectroPol-5.
Approx. 5 V DC in 40 seconds.
Evaluation of Welds
Macro examination.
Often a macro test examination is required in order to meet
relevant standards and requirements.
For examination of the weld in question (stainless steel

example) the use of Welding Expert WE-5 was applied.
The following imperfections (or geometric weld features)

were defined for inspection in this case:
• Thickness of plates
• The root gap
• Angle a + b (incorrect weld toe)
• Penetration width (excess weld metal)
• Penetration depth
• Incomplete filling
Evaluation of Welds
Evaluation of Welds
Welding drawing detail
Measurements performed on
Welding Expert (WE-5).
All measurements are shown
on the image and stated in
the table belows.
See next slide
Evaluation of Welds
The measurements are all shown in the green fields. The fields are green
because they comply with the specified tolerances.
The specified tolerances are stated below the measurements.
Evaluation of Welds
Measurements saved
and figures added on
the image (upperleft
corner)
Evaluation of Welds
Report generated in WE-5 of

the specific weld bead for
documentation purposes
Evaluation of Welds
Summary
Metallographic preparation and macro test examination of a weld

in stainless steel including measurements of essential geometric
weld features (and imperfections) for this weld has been
demonstrated.
Also it has been shown, how the results can be documented in an
easy way using a suitable and dedicated imaging system and
software.
Hardness testing of weld
Example 2
Hardness testing of X-groove buttweld
low carbon steel
www.struers.com
Hardness testing of X-groove buttweld
low carbon steel
Two different ways to place the hardness indentations:
≤ 2 mm
A. In three rows B. Individual indentations
• Hardness testing after • Hardness testing after

MD-Allegro (9 µm) MD-Allegro (9 µm)
• Hardness testing after MD-Dur (3µm)
www.struers.com
Hardness testing of buttweld
low carbon steel
Plane parallel specimens
Specimen – same height
Maximum height: 12-14 mm
Clean surfaces with alcohol
Use double adhesive tape
Dummies
www.struers.com
Grit/Grain size comparison*
*Guideline values only

** Not part of FEPA P standardization
www.struers.com
low carbon steel
Step Test 1 Test 2 FEPA P Grain
(europe) size
1 # 1000 18 µm
MD-Piano #80 MD-Piano #80 # 1200 15 µm

# 2000 10 µm
2
MD-Piano #220 MD-Piano #220
3
MD-Allegro (9 µm) MD-Allegro (9 µm)
4
Silk (3 µm)
www.struers.com
low carbon steel
Etchant:
100 ml distilled water
10 g ammoniumpersulphate
3 µm with MD-Dur
(silk cloth)
www.struers.com
low carbon steel - results
Hardness testing after MD-Allegro Indentation Hardness
point HV10
Overview camera of hardness tester
1 148
2 155
3 157
4 156
5 203
6 183
7 180
8 175
9 191
10 174
11 197
12 170
13 186
www.struers.com
After preparation with silk cloth (3 µm)
250
200
Hardness HV10
150
Row 1
100 Centre row
Row 3
50
0
0 5 10 15 20 25 30
Distance [mm]
www.struers.com
Automatic hardness tester:
MD-Allegro 9 µm MD-Dur 3 µm (silk cloth)
Most indentations corners No correction needed

needed correction.
www.struers.com
low carbon steel
Conclusion:
Automatic Hardness testing is an easy tool for evaluation of welds if the surface
has been prepared in a suitable way.
To enhance the performance of automatic hardness testers a polished surface

can be used.
www.struers.com
Questions
? ??
http://www.struers.com/knowledge
www.struers.com
Ensuring Certainty
www.struers.com

Evaluation of Welds - Macro-Examination - Hardness PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Evaluation of Welds - Macro-Examination - Hardness PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Practicalities

All participants will be in listen-only mode during

 Macro test examination of welds

 Weld geometry and imperfections

 Example 1: Macro-study of a circumferential butt joint in stainless steel

 Example 2: Hardness testing of X-groove butt weld in carbon steel

e.g. wings and fuselages

Until the end of the 19th century, sections of metal

Welding is an important technology, and a variety of

Common processes are Gas Metal Arc (solid wire),

During welding the materials to be welded are raised above

These changes can have a profound influence upon the joint

Therefore a request for various examinations and testing is

For welded joints a macro-examination and hardness testing is

Location of test specimens in a

Metallography Metallographic Weld

The macro(structural) examination of a welded joint often includes:

 The number and size of passes/runs (weld structure)

Weld joint geometry and possible types of imperfections/defects

Cutting of the stainless steel weldment.

Mounting or not mounting of stainless steel weldment:

Examples of mounted welds

Mech. preparation of stainless steel weldment, example 1:

Etching of stainless steel weldment, example 1:

For examination of the weld in question (stainless steel

The following imperfections (or geometric weld features)

Welding drawing detail

See next slide

Report generated in WE-5 of

Metallographic preparation and macro test examination of a weld

A. In three rows B. Individual indentations

• Hardness testing after • Hardness testing after

• Hardness testing after MD-Dur (3µm)

Specimen – same height

Maximum height: 12-14 mm

Clean surfaces with alcohol

Use double adhesive tape

*Guideline values only

MD-Piano #80 MD-Piano #80 # 1200 15 µm

Most indentations corners No correction needed

To enhance the performance of automatic hardness testers a polished surface

Das könnte Ihnen auch gefallen