Destructive Examination &

Testing
DESTRUCTIVE TESTING
 Destructive Examination
• Destructive Examination renders the weld or
material unfit for further service.
• To find out how strong, resilient, flexible, or long-
lived a material is often requires the ultimate
sacrifice: the destruction of the sample by
equipment and instruments designed to precisely
measure its performance in the face of an
overwhelming force.
• In destructive testing, tests are carried out to the
specimen's failure, in order to understand a specimen's
structural performance or material behaviour under
different loads. These tests are generally much easier to
carry out, yield more information, and are easier to
interpret than nondestructive testing.
• Destructive testing is most suitable, and economic, for
objects which will be mass produced, as the cost of
destroying a small number of specimens is negligible. It is
usually not economical to do destructive testing where
only one or very few items are to be produced
 Common methods used in
Destructive Examination
• Bend testing
• Tensile testing
• Impact testing
• Hardness testing
• Hydrostatic Testing to Destruction
• Peel testing
• Spark testing
• Fatigue Testing
 Bend Testing

• Bend test samples are referred to as

“Test Coupons”
• The most common bend tests are
– Guided face and root bend testing
– Guided side bend testing
– Longitudinal root and side bend testing
– Fillet weld bend testing
 Bend Testing
• Bend testing determines the ductility or the strength of a
material by bending the material over a given radius.
Following the bend, the sample is inspected for cracks on
the outer surface. Bend testing provides insight into the
modulus of elasticity and the bending strength or a
material. Metallurgical offers three and four point bend
setups with interchangeable rollers for a variety of test
configurations.
Bend Testing Sample
Preparation
Face Bend Testing
Root Bend Testing
Side Bend Testing
Longitudinal Face Bend Testing
Longitudinal Root Bend Testing
Fillet Bend Testing
 Tensile Strength Testing
• “Tensile” is a test in which a prepared
sample is pulled until the sample breaks.
• Test Measurements are recorded in PSI
(Pounds per Square Inch) E7018 = 70,000 PSI Tensile
• Test samples called “Tensile Bolts” can
reveal a welds Tensile strength, Elastic
limit, Yield point, and Ductility.
 Tensile Strength Testing
• The Elastic Limit of metal is the stress
(load) it can withstand and still return to the
original length after the load is released.
• Yield Strength occurs when the test sample
stretches however will not return to its
original length.
• Ductility is the ability of a metal to stretch
or elongate before it breaks.
Tensile Testing Strength
Graph
TENSILE TESTING PARTS
MACHINE
 Impact Testing
• An Impact tester uses a heavy pendulum
that is able to measure the amount of force
required to shear or fracture a test sample
taken from welds “Heat Affected Zone”
(HAZ)
• Impact testing may be performed using
either the Izod or Charpy method. (Both
methods are similar)
 Impact Testing
• A Charpy or Izod test measures the welds
ability to withstand an Impact force.
• Low Charpy test readings indicate brittle
weld metal
• Higher Charpy readings indicate the
samples toughness.
 Hardness testing
• Hardness testing measures the resistance of a material to a
permanent indention of particular geometry over a
specified length of time. Hardness testing is an effective
and efficient means to characterize a material and requires
minimal sample preparation.
• Three common hardness measuring tests are
– Rockwell test
– Scleroscope test
– Brinell
– Microhardness test
 Hardness testing
• The Rockwell testing machine operates
somewhat like a press, using a indenter to
penetrate the surface of the test sample.

• The depth of the indentation determines the

materials hardness on a scale of 0-100
Rockwell
TESTING
MACHINE
 Hardness testing
• The Sceleroscope testing machine measures
the amount “bounce” that a diamond tip
hammer rebounds off the test sample after
being dropped.
• The Brinell method presses the “indenter”
into a sample for a given period of time.
• The ability for the sample to resist
indentation determines hardness.
SCELEROSCOPE
TESTING
MACHINE
 Hardness testing
• Microhardness testers allow you to measure
a materials hardness while leaving the least
amount of damage possible on the metals
surface.
• After the indenter is used a powerful
microscope is used to determine the the
amount of indentation into the components
surface.
MICROHARDNESS
TESTERS
 Hydrostatic Testing to Destruction

• Pressure testing or leak testing can be

performed with either gasses or liquids.
• When this pressure exceeds the limitations
of the structures design it will rupture under
force.
• This rupture will allow engineers to
understand the welds weakest areas.
AIR PRESSURE
TESTING
 Peel testing

• Lap joints may be tested to destruction

using a Peel test.
• Peel testing is most commonly used to
check the strength of resistance spot welds
or stud weld
• Spot weld peel tests are considered
successful when the spot weld nugget is
torn out of the test sample pieces in tact.
PEEL TESTING
SAMPLE
 Spark Testing
• The shape and
characteristic of sparks
created when metal is
ground will help
determine its
properties.
• IE: carbon steel , mild
steel.
 Spark Testing
• Spark testing is a method of determining the
general classification of ferrous materials. It normally entails taking a
piece of metal, usually scrap, and applying it to a grinding wheel in
order to observe the sparks emitted. These sparks can be compared to a
chart or to sparks from a known test sample to determine the
classification. Spark testing also can be used to sort ferrous materials,
establishing the difference from one another by noting whether the
spark is the same or different.
 Fatigue Testing
• Fatigue testing is used to apply a cyclical load to
a test specimen in order to better understand how
that material will behave under similar loading
cycles in a real world application. The applied
load is often repeated to failure with several
hundred loading cycles per second. Metallurgical
offers high cycle fatigue testing.
 Quiz time

• Which of the following is a destructive

test ?
A: magnet particle
B: tensile testing
C: die penetrate testing
D: ultrasonic testing
 Quiz time
• The _______ type hardness test leaves the least
amount of damage on the metals surface.

A: Rockwell
B: Brinell
C: Scleroscope
D: Microhardness
 Quiz time
• When a metal stretches, but dose not break under
a certain load, this point is called the _________
Point.

A: yield
B: tensile
C: stretch
D: ultimate strength
 Quiz time
• Ductility is the ability of a metal to ________
before it breaks.

A: Bend
B: Stretch or elongate
C: Be forged
D: Be indented
 Quiz time
• A Charpy test measures a welds ability to
withstand _________ force.

A: Impact
B: Bending
C: Penetrating
D: Stretching
 Quiz time
• Hardness may be defined as the resistance to
__________?

• Indentation
DESTRUCTIVE TESTING