Metals Testing Solutions

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Pipe and tube products are produced
through a variety of forged, seamless,
and welded manufacturing processes.
Nearly every conceivable type of metal
may be used in the production of pipe
and tube products, ranging from cast
iron to high temperature super alloys.
Applications vary from underground
sewage systems to nuclear reactors,
oil well casings, and copper water pipes
in the home.
The nearly infinite range of sizes and
applications requires many different
tests to verify manufacturing processes
and suitability for end use. There are
also numerous specifications pertaining
to the end products in which pipes or
tubes are used. Standards organizations
such as ASTM, ISO, EN, API, and JIS
have all published test methods for pipe
and tube testing. Tests may be required
at ambient, sub-zero, and elevated
temperature depending upon the
material and application.
Compression
The Challenge
Compression tests are used to evaluate the
ductility and structural rigidity of a pipe.
Determining the ability of a buried pipe or
tube to withstand forces such as earthquakes
or heavy equipment driven over it is important
in proper product selection. To simulate
compressive loading service conditions, force
is applied to partially or fully-flatten the test
sample. Common pass/ fail criteria involve
inspecting the surface of the pipe for cracks
or breaks.
Our Solution
Rings are cut as cross-sections from the pipe
and tested between parallel compression plates
to determine the amount of force needed to
deform (crush or flatten) the specimen. For
large pipe samples (such as sewer lines or
oil transfer lines) Instron

offers single test

space KN models with large test openings.
These systems feature a top-mounted
hydraulic actuator so that the test space is
close to the floor. The set-up makes it easy
for operators to load large, heavy samples
using a fork lift or other conventional material
handling equipment. Smaller, easy-to-handle
samples can be tested on more traditional
testing machines .
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SATEC

series 600DX with platens for compression

testing of pipe samples.
d
Full pipe sample. The
cross-sectional area is
calculated based on the
inner (1) and outer (2)
diameter of the pipe.
Flat samples cut from large diameter pipe. The
cross-sectional area to computed based on width
(1), outer diameter (2) and inner diameter (3).
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600 kN (135,000 lbf) SATEC

series universal
testing machine with open-front crossheads and
in-head wedge grips for testing full pipe samples.
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Curved grip faces match the ID and OD of pipe
samples to provide a secure grip when testing
unflattened samples.
d
Axial testing of cross-sectional area of pipe.
d
Tension
The Challenge
The size and shape of pipe products present
unique tensile testing challenges. Without
proper test equipment, operators may
inadvertently crush the ends of a sample while
gripping. Furthermore, because full pipe
samples are typically larger than solid round
samples, they require grips with a large
opening. Some pipe samples are so large that
operators must cut a reduced section from the
pipe sidewall. These sidewall samples can be
fashioned in the form of flat strip specimens or
machined round specimens.
Additionally, it can be difficult to find
an extensometer designed for pipe and
tube testing.
Finally, due to pipe curvature there is a
greater outer diameter (OD) surface area
than inner diameter (ID) surface area. This
must be taken into account when computing
the cross-sectional area of the specimen for
stress calculations.
Our Solution
To prevent the test machine's grip jaws from
crushing full pipe samples, metal plugs are
commonly inserted into the ends of pipe
(reference: ASTM A 370). This technique is
commonly used on pipe under 50 mm (2 in)
in diameter. Using this method, operators can
select from a wide variety of Instron

wedge
grips with V-grooved jaws:
g Instron's high capacity hydraulically
powered testing machines with in-head
crosshead grips provide an economical
solution for testing large full pipe samples.
g Instron's external hydraulically actuated
grips are ideal for fast loading of larger
pipe samples.
g Smaller-diameter specimens can be
tested in a variety of Instron external
wedge-action grips. These grips can be
mechanically, pneumatically, or
hydraulically clamped.
When testing flat samples (cut from the side
wall of a pipe) operators can flatten the
specimen ends and use either Instron's
conventional grip faces or grip faces with
curved surfaces. Instron manufactures curved
faces to match the customer's sample.
Instron's software-driven sample type selection
allows for simple entry of specimen
dimensions to automatically calculate the
correct area for either a full-section pipe or a
machined specimen section. This feature
eliminates the need for tedious manual
calculations and reduces the risk of errors.
Instron offers a range of extensometers
designed for testing large diameter specimens
up to 89 mm (3.5 in). These extensometers
feature a heavy-duty frame design for
industrial applications.
In addition, to testing full pipe samples and
sections, several standards require
manufacturers to perform a tension test on the
welded seam of a pipe. For more information
on tension testing of welds please see the Welds
section (page 32).
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Hardness
The challenge
From massive transport piping to small
diameter thin-walled medical tubing, the
hardness of fabrication material is critical in
ensuring performance and durability. As an
important characteristic of tubing, hardness
contributes to the rigidity, strength, density,
and microstructure of the dedicated material.
Because of the variety of diameters, wall
thicknesses, and materials, pipe and tube
testing is challenged by fixturing and
mounting techniques as well as specialized
industry standard requirements. Improper
support or location of the material can result
in compromised test results and potentially
inaccurate data. Further complicating the
situation are differing requirements for testing
the internal or external wall or a cross-section
of the pipe end, and ensuring that the curved
geometry does not adversely effect testing.
Our Solution
The most common method of hardness testing
pipe and tube is the Rockwell

hardness test.
As the originator of the Rockwell tester,
Wilson

Instruments has over 75 years of

experience providing hardness testing
equipment to the pipe and tube industry. The
Rockwell test is a simple process that enables
the user to perform an accurate hardness test
on a variety of pipe and tube types in just a
few seconds. In addition, the relatively
inexpensive cost and flexibility in the test
equipment as well as the non-destructive
nature of the test make it the ideal option in
pipe and tube hardness testing.
Depending on the material, diameter, wall
thickness, and length, support and centering
devices are required to provide a stable and
accurate test process. The flexible options in
Rockwell test types allow for a range of test
methods, including light-force application
testing - critical in extremely thin-walled
tube. Paramount to testing the external
portion of thin-walled and/ or thin-diameter
material is support of the inner wall. Properly
positioned internal support will prevent
deformation of the overall tube diameter, a
phenomenon that will significantly alter test
results. Utilizing an internal support anvil
commonly known as a Gooseneck anvil, a
thin-walled or small diameter tube can be
supported, effectively allowing an accurate
and uncompromised hardness test on the
external wall on tube ends.
For internal tests on sectioned pipe ends, an
internal Gooseneck adapter that arcs around
the upper wall and projects inside the pipe
can be attached directly to a Rockwell tester.
When combined with a V-shaped anvil that
centers and supports the pipe section, an
accurate internal test can be performed.
In another application, various industry
standards dictate stringent test methods on
heavy piping such as that used in petroleum
transport. Multiple tests on a sectioned pipe
edge, in precise locations, are often required
to verify material integrity throughout the
wall cross-section. A Rockwell tester fitted
with a motorized stage and precision
traversing software can define and
automatically index to the exact test points,
perform the test series, and display the results,
minimizing human intervention.
d
Standard gooseneck adapter for hardness testing
of material IDs.
Bend Testing
of Welded Seams
Several standards require manufacturers to
perform a guided bend test on the welded
seam of a pipe. These tests evaluate the
ductility of the weld and ensure that any
cracks do not exceed the gap widths
established by relevant standards. For more
information on Instron

's solutions for bend

testing of welds please see the Weld section
(page 32).
d
Welded sample in guided bend test.
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Gooseneck extension for ease of internal testing.
Impact
The Challenge
How the material of a pipe or tube reacts
to impact forces is one of the material selection
factors used by design engineers. Too brittle,
and failure may occur at relatively low loads
from a minor impact. On the other hand, if
the material is too pliable, it may bend and
restrict flow or rupture from internal pressures
prematurely. Applications for pipe and tube
can potentially include both low temperature
and elevated temperature environments.
Varying environmental conditions may
significantly affect material properties,
making it necessary to understand how a
material reacts under those conditions. The
rate of impact is yet another variable that can
affect the material's properties
Using established test standards, the way that
metallic materials react to impact forces can
be measured and compared. This data is
useful for quality control to ensure that a
product meets expectations, as well as for
research and development to determine how
changes to manufacturing processes, material
composition, or heat-treating techniques affect
a material's ability to withstand impact forces.
Our Solution
Instron

impact testing machines range from

basic constant velocity pendulum impact
devices that simply provide the energy required
to fracture a specimen to fully-instrumented
computer controlled drop-weight systems for
high-rate loading. In addition, Instron testing
software provides data acquisition capabilities
to capture important information on energy
absorption (yield, fracture, etc.).
Instron offers machine designs and fixturing to
test standardized specimens such as required
for Charpy and Izod testing (ASTM E 23);
NDT Nil-Ductility Transition Temperature
(ASTM E 208); and drop-weight tear tests
(ASTM E 436, ASTM E 604, and API-5L3).
Instron also provides customized solutions
for testing a finished product or particular
service condition.
As an example of a custom solution, the
Instron Dynatup

model 8140 drop-weight

machine has been adapted to simulate the
impact caused by a back-hoe operator
digging over a natural gas pipeline. For this
application, a complete section of pipe was
placed in a V-groove fixture with additional
side supports to simulate the pressure of the
soil around the pipe. A pointed striker was
used to impact the specimen to determine
how much energy was required to puncture
the pipe.
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SI series pendulum impact machine.
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Dynatup pipe and bar support fixture.
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Creep and
Stress-Rupture
Occasionally, pipe and tube manufacturers or
end-user companies need to determine how
their products will perform when subjected to
constant loads at both ambient and elevated
temperatures. These tests are typically
conducted for an extended time in accordance
with standards such as ASTM E 139 and
ASTM E 292. For more information on
Instron's creep and stress-rupture testing
solutions see page 41.
Fatigue
Manufacturers or end-user companies often
need to determine how their products will
perform when subjected to forces such as
in-service loading conditions, high cycle and
low cycle fatigue, fracture mechanics, high
strain rate, and thermo-mechanic fatigue.
These tests are typically ASTM E 647 for
fatigue crack growth and ASTM 1820 for
fracture toughness. For more information on
Instron's fatigue testing solutions see page 41.
Fracture mechanics testing with CT grips and
COD gauge
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All of the specifications shown in this brochure are subject to change without notice. WB1212
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