DESTRUCTIVE TESTINGMECHANICAL METALLOGRAPHIC CHEMICAL

TESTING EXAMINATION ANALYSIS

1. TENSILE 1. MACRO 1. WET ANALYSIS

2. BEND 2. MICRO 2. DRY ANALYSIS

3. IMPACT 3. X-RAY -

4. HARDNESS FLORESCENCE

5. DROP WEIGHT 4. ATOMIC-

6. DROP WEIGHT TEAR ABSORPTION

7. NICK BREAK

8. FATIGUE

9. CREEP

PURPOSE OF TESTING1. To determine the fundamental properties.

2. To determine Mechanical, Chemical and Metallurgical properties in order to find out the

suitability for a specific purpose.

3. To record the data for a group of metals and alloys

for the purpose of design.

4. To check weather heat treatment imparted has been carried out satisfactorily.

5. To investigate into defects and flaws of the material so as to improve manufacturing techniques.

PURPOSE OF TESTING

II. As for as welding is concerned

1. Qualification of welding procedure.

2. Qualification of welding and welding operation.

3. Qualification of welding consumables.

4. Quality control

STANDARD TEST METODS(For Mechanical Testing)

TYPE ASTM BS IS

Tensile E8 EN10002-1 1608,1521

Bend E190 EN287-1 1599

Impact E23 EN 10045-21757

Hardness E10(Brinell) BS 240-1 1500

E18(Rockwell) BS 891-1 1586

E 92(Vickers) BS 427 1501

STANDARD CODES FOR DESTRUCTIVE TESTING

ASTM-A370 : Mechanical Testing of Steels

AWS-B4 : Standard methods for Mechanical testing of welds

BS-709 : Destructive testing for fusion welded Boiler

drums.

IBR Ch.-V : Fusion Welded Boiler Drums.

IBR Ch.-Viii : Qualification test for Welders.

IBR Ch.-XII : Shell type Boiler construction

AWS 5.1,5.4,5.5 : Electrode Qualification Tests

IS 814,5206,1395 : Electrode Qualification Tests

ASME Sec.IX : Procedure & performance Qualification of welding

API-5L : For seamless and welded steel tubes & pipes.

TEST PLATE FOR PERFORMANCE QUALIFICATION (as per IBR)

B

250 mm

406 mm

B1 T1 B2

M

m

B1 T2 B2

16mm

weld

TEST PIPE & TUBE FOR PERFORMANCE QUALIFICATION (as per IBR

Face

Face

RootMacro

Macro250mm

Root

PIPE Ø127x12.5mm, CS Tube Ø63.5x5.2mm, AS Tube Ø54x5mm

weld

PROCEDURE QUALIFICATION(ASME SEC. IX)

QW-463.1(a) : Less than 3/4” PLATES

300mm

250mm

Discard DiscardReduced Sec. Tensile Specimen

Root Bend Face Bend

Root Bend

Face BendTensile Specimen

Discard Discard

Reduced Sec.

PROCEDURE QUALIFICATION(ASME SEC. IX)

QW-463 1(b) :Over 3/4” PLATES

300

Discard Discard

Discard Discard

Reduced Sec.

Side

SideSide

Side

Bend

Bend

Bend

Bend

Tensile Specimen

250

Reduced Sec. Tensile Specimen

TENSILE SPECIMENS

TRANSEVERSE TENSILE

ALL WELD TENSILE

ELECTRODE QUALIFICATION TEST(AS PER AWS)

WELD

ALL WELD TENSILE

170mm min. (1No.)

2525

15 IMPACT SPECIMEN (5Nos.)

DISCARDDISCARD

ALL WELD TENSILE SPECIMEN (as per IS) R5

FOR SIZE 3.15 mm and BELOW

FOR SIZE 4mm AND ABOVE

G L 50

10±0.09

PL 60

12 min

70mm min

6.4 ±0.075GL 32

44.838.9

9.5

THE SURFACE FINISH WIT THE PL SHALL BE 1.6

ALL WELD TENSILE SPECIMEN (AWS)

THE SURFACE FINISH WITH THE PL SHALL BE 1.6

R 9.5

SIZE OF ELECTRODE 3.15 mm and BELOW

Ø12.7±0.25

GL 50.8 ±0.13

PL 57.1

Ø19.1

R 4.6

GL 25.4 ±0.13GL 31.8

Ø 9.5

SL SL

SL SL

SIZE OF ELCTRODE 4 mm and ABOVE

Ø6.4±0.13

UNIVERSAL TESTING MACHINE

CALIBRATION:

ASTM-E4,

BIS: 1828,

EN: 10002-2

CALIBRATION : EN 10045-2, BIS 3766

0.

TRANSEVERSE TENSILE SPECIMEN

WPLSL SL T

RECTANGULAR TENSILE TEST SPECIMEN

200

225 7575

13 min(FOR PLATE as per ASTM E8M )

ASTM

BS

IBR

IS

50 mm

5.65A

4 A

5.65 A

5min.

50

STANDARD ROUND TENSILE (GL) FLAT TENSILE (GL)

5d

5d

4d

5d

GAUGE LENGTH AS PER VARIOUS STDS.& CODES.

40

BEND TEST METHODS

1. Guided bend

2. Free Bend

ROOT BEND TEST

t

ROOT BEND TEST

t

5.2t1.5t

3t

FACE BEND TEST

t

5.2t1.5t

3t

SIDE BEND TEST

W

5.2t t

3t

CALIBRATION : EN 10045-2, BIS 3766

Specimen Supporter

Specimen

CALIBRATION : EN 10045-2, BIS 3766

STRICKER

TENIUS OLSON IMPACT TESTER

CAL : ASTM - E23

IMPACT TEST SPECIMEN

10±0.025

55±0.127.5

10 ±0.02545°±0.1°

2±0.1

55±0.127.5

10 ±0.025

5±0.1

2

CHARPY ‘V’NOTCH TEST SPECIMEN

CHARPY ‘U’NOTCH TEST SPECIMEN

10±0.025

IZOD IMPACT TEST SPECIMEN

75 27.5 10

102

HARDNESS TEST 1.BRINELL HARDNESS 2. ROCKWELL HARDNESS

3.VICKERS HARDNESS 4. MICRO HARDNESS

BRINELL HARDNESS TEST

•HARDENED STEEL BALL IS USED FOR MEASURING UPTO 500 BHN

•FOR 500 BHN TUNGSTON STEEL BALL IS USED F

• FOR IRON AND STEEL 3000Kg OF LOAD IS APPLIED

•FOR INTERMEDIATE HARD MATERIALS 1500Kg, 500Kg OF LOADS ARE USED.

•FOR SOFT MATERIALS 100 Kg OF WEIGHT IS USED.

•RATE OF LOADING IS AN IMPORTANT CRITERIA, RAPID RATE OF LOADING AFECTS THE INDENTATION.

BHN=APPLIED LOAD/AREA OF INDENTATION

BHN=P/[( D/2) X (D-D2 - d2)]

WHERE P=LOAD IN Kg,

D=DIAMETER OF STEEL BALL IN mm, d= DIAMETER OF THE INDENTATION IN mm. APPLICATION

FOR C.STEEL, CAST IRON,COPPERALLOYS, ALUMINIUM ALLOYS, LEAD AND TIN ETC.

POLISHED SURFACE

UNIVERSAL HARDNESS TESTER

TEST IS CARRIED OUT BY IN ACCORDENCE ASTM E92 TEST IS CARRID OUT BY IN ACCORDENCE ASTM E92

Minor Load Major Load

ROCKWELL HARDNESS TEST

TEST IS CARRIED OUT BY IN ACCORDENCE ASTM E92 TEST IS CARRID OUT BY IN ACCORDENCE ASTM E92

VICKERS HARDNESS TEST

VICKERS HARDNESS TEST

Angle between faces of the pyramid is 136°

VHN=1.854 P/ D2

P=Load in Kgf

D= Average of measured diagonals of impression in mm

TEST IS CARRIED OUT BY IN ACCORDENCE WITH ASTM E92

DROP WEIGHT TEST

STANDARD DROP WEIGHT TEST SPECIMENP1=25X90X360

P2=19X50X130

P3=16X50X130

DROP WEIGHT TEST

DROP WEIGHT TEST IS CONDUCTED IN ACCORDANCE WITH ASTM E208

SPECIMEN

SPECIMEN

SUPPORTER

MACRO EXAMINATION

It involves the visual observation of the gross structural details of materials after preparation of the surface,

either by unaided or with the aid of low power microscope . Usually under 10X.

When macroscopic examinations appropriately carried out, some important metallic characteristics are determined by such studies.

Example : As for as welding is concerned macro will reveal

Undercut, Excess penetration, Incomplete penetration, Dilution lack of fusion pores and cracks etc.

MICRO EXAMINATION

The most important part of metallography deals with the microscopic examinations of a prepared metal specimen,employing magnification with the optical microscope from 100X to as high as 2000X.

Such microscopic studies are of much broader scope than macro examinations.

It will reveal clear picture of structural characteristics as grain size, shape, distribution secondary phases, non metallic inclusions, segregation and other heterogeneous conditions.

Microstructure reflects almost complete history of the mechanical and thermal treatment that a metal has received.

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