Welding Technology

TL184730 – 3 Credits

Mechanical Testing on
Weldments

Yusuf Pradesar, Ph.D.

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Introduction
• Quality control can be Destructive Testing and Non-
Destructive Testing
• Destructive testing of welded materials / products
consists of
▪ Tensile Test
▪ Impact Test
▪ Bending Test
▪ Hardness test
▪ Metallographic observation

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Introduction
While the Non-Destructive Test consists of
• Liquid penetrant test
• Magnetic particle test
• Ultrasonic testing
• Radiographic testing

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Tensile Testing
• Tensile Testing is performed to determine whether a
weld joint able to receive tension load as predefined
criteria/ design.
• The criterion here refers to the tensile strength of base
material prior to welding, as well as the strength
required for its application.
• There are three position of weld that might be possible
to send for testing, yields:
▪ All weld metal test
▪ Longitudinal weld test
▪ Transverse weld test

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All weld metal test
• The purpose of all weld metal
tensile test is to determine the
tensile properties of weld metal
for qualification tests of filler
metals and for conformation of
filler metal specifications.
• The test specimen orientation is
parallel to the weld axis and should
not involving HAZ/ base metal

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Longitudinal weld test
• In the longitudinal weld test, the direction of loading of
the specimen is parallel to the weld axis, but contains
weld metal, HAZ and parent material in its cross
sections. During testing, all of the zones must strain
equally and simultaneously.

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 Transverse weld test
• This test if often used to qualify welding
procedure (WPS), i.e. to confirm that the
strength of weld metal will be equal to
or exceed the design strength
requirements.
• Its orientation is perpendicular to axis of
the weld, and therefore contains a full
cross section of the weld and parent
material, Heat Affected Zone (HAZ) and
weld metal.
• It should be noted that only the
location of the fracture and the
tensile strength of the material are
usually reported.
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Standard
• EN ISO 5178 Destructive tests on welds in metallic
materials – longitudinal tensile test.
• BS EN 895 Destructive tests on welds in metallic
materials – transverse tensile test
• JIS Z2241 Tensile Test Procedure for Ferrous Materials

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Based on results of this tensile test, the result
that has to be analyzed are:
• Tensile Strength
• The position of the specimen is broken
• Fracture profile

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Bending Test
• In order to study the ductility and soundness of joint,
the welded material is tested by bending test (as per
BS EN 910)
• In this test, the sample is placed on two rollers and the
indentor/ former, and then indentor presses the sample
until the deformation reach 90o, 120o or 180o, depends
on requirements
• Distance between anvil (roller) max Lf = d + 3a
(indentor diameter + 3 x specimen thickness).

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Bending test consists of consists of three
positions, which are
1. Face bend test
2. Transverse side bend test
3. Root bend test

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Transverse root and face bend tests of a butt weld
(RBB and FBB)
◻ The thickness of the specimen should be the same as
the base material thickness closest to the weld metal
◻ If the width of the weld (t) > 30 mm, some samples
shall be made to represent the overall thickness of the
weld plate.

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• The length Lt of test specimens shall be Lt ≥ l + 2R and
at least be such that the requirements of the
appropriate application standards are fulfilled.

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Transverse side bend tests of a butt weld (SBB)
◻ Specimen width (b) should be = thickness of weld
material
◻ The thickness of the specimen (a) is minimal (10 ±
0.5) mm, and the ratio b / a is b ≥ 1.5a.
◻ If the joint thickness is > 40 mm, then the test
specimen can be taken from several locations, with b
value between 20 mm - 40 mm.

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Longitudinal bend tests of a butt weld (RBB and FBB)
◻ For a longitudinal bend test specimen thickness (a) =
thickness of base material near the joint.
◻ If the connection thickness (t)> 12 mm, then the
thickness of the specimen should be equal to (12 ±
0.5) mm

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From the results of bending tests, analysis can be made:
◻ No crack found at required bend angle. Or refer to
standard, if crack is found with length <3 mm, it can be
ignored
◻ Elongation, by measuring the length after bending on
the outside of the specimen (outside curve which not
contact with the former / indentor)

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Report

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Impact Testing
◻ Impact test is performed to obtain the toughness
properties of weld and HAZ, and sensitivity to notch
◻ Toughness is, broadly, a measure of the amount of
energy required to cause an item - a test piece - to
fracture and fail. The more energy that is required then
the tougher the material.

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◻ The area beneath a stress/strain curve produced
from a tensile test is a measure of the toughness
of the test piece under slow loading conditions.
◻ However, in the context of an impact test we are
looking at notch toughness, a measure of the metal's
resistance to brittle or fast fracture in the presence of a
flaw or notch and fast loading conditions.

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Impact Testing
◻ Standard specimen: BS EN 875 Destructive tests on
welds in metallic materials - Impact tests - Test
specimen location, notch orientation and
examination
◻ Testing Standard EN 10045-1 Metallic Materials -
Charpy Impact test Part 1: test method
◻ Sample size: 55 mm length and 10 mm sides
◻ Notch: V-notch of 45o, 2mm deep with 0.25 mm radius
of curvature at base of notch

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Specimen and notch position

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◻ Distance between anvil = 40 mm
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◻ The test result is Impact Strength (IS) which is the
result of the Impact Energy (IE) divided by cross
section area.
◻ IE = Einitial – Efinal = W.hinitial - W.hfinal
◻ Where W is the weight of the pendulum

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◻ Ductile fracture : fibrous and grey color, deformation
exists
◻ Brittle fracture : flat and shiny color, minor deformation

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Hardness Testing
◻ Hardness testing on weld result is performed to study
the distribution of hardness in weld metal, HAZ and
base metal as result of thermal cycle during welding.
◻ Hardness testing methods commonly used are
Rockwell and Vickers hardness testing
◻ While the location of data collection is at the points
where there is a change in temperature during the
welding process

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◻ If necessary, hardness testing is performed with
multiple layers for wide workpieces and has groove

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◻ Evaluation
◻ Hardness on weld metal should be similar with base
metal
◻ A very high hardness of weld metal should be noticed,
since might correlated to toughness of joint
◻ Hardness of weld metal might correspond to impact
strength, where high impact strength may result high
hardness number.
◻ A very high hardness should be avoided, because this
represent the brittle properties of weld

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Task of Welding
• Review a paper about welding
• Write the review in a word document and
prepare the presentation
• The content of review should cover:
1. The purpose of the research
2. The method of welding
3. Analyzing the results
4. Give conclusion of the research including the
advantages and disadvantages

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