Faculty of Engineering Credit Hours Programs

Materials fabrication
Welding Test
Prepared by: Walid Sayed Abd Allah SMANF 07p4016 Submitted to: Dr. Adel El Shabasy

11/21/2011

Weld verification
In manufacturing, welds are commonly used to join two or more metal surfaces. Because these connections may encounter loads and fatigue during product lifetime, there is a chance that they may fail if not created to proper specification. For example, the base metal must reach a certain temperature during the welding process, must cool at a specific rate, and must be welded with compatible materials or the joint may not be strong enough to hold the surfaces together, or cracks may form in the weld causing it to fail. The typical welding defects, lack of fusion of the weld to the base metal, cracks or porosity inside the weld, and variations in weld density, could cause a structure to break or a pipeline to rupture.

Why weld testing?

Defects occur during welding which affect the quality and hardness of the plate Other defects occur through lack of knowledge of and skill of the welder For the training of welders

Weld testing types

weld testing

destructive testing

Non-destructive testing

Destructive testing
Destructive testing can be divided into two parts: Tests capable of being performed in the workshop o Tensile o Bending o Impact o Hardness o Fatigue o cracking Laboratory tests o Macroscopic o Microscopic o Chemical o corrosive

Tensile testing
Material is sectioned and edges rounded to prevent cracking. Punch marks are made to see elongation.

Bend testing
1. Shows Physical condition of the weld 2. Determine welds efficiency a. Tensile strength b. Ductility c. Fusion and penetration Procedures: Bend through 180O the specimen should be a minimum of 30mm wide The fulcrums diameter is 3x thickness of the plate The bottom rollers have a distance of the diameter of the former + 2.2 times the thickness of the plate Upper and lower surfaces ground or filed flat and edges rounded off. the tests should be one against the root -another against the face ,and in some cases a side bend

Root bend

Face bend

Impact testing
There are two types: 1. CHARPY 2. IZOD Impact testing gives the toughness and shock loading of the material and weld at varying temperatures with a notch such as under cut The measurement is the energy required to to break a specimen with a given notch 2mm depth at a 45o bevel or a U notch

Charpy

Izod

Hardness testing
This gives the metals ability to show resistance to indentation which show its resistance to wear and abrasion The tests are Brinell Rockwell Vickers diamond pyramid Scleroscope

Vickers Hardness

Fatigue testing

Testing of Material that is subject to fluctuating loads HIGH Electromagnetic tester WOHLER Uses rotating chuck with weight

Cracking testing
REEVES Test study the hardening and cracking of welds.

The compatibility of electrodes for the metal being joined. Three Sides Are Welded With Known Compatible Electrodes The front edge is welded with the test electrode if incompatible it will crack

Microscopic

Used to determine the actual structure of the weld and parent metal Up to 50,000 times magnification with an electron beam microscope Polishing must be of a very high standard

Macroscopic

Examined using a magnifying glass. Magnification from 2 to 20 times. It will show up slag entrapment or cracks. Polishing not as high as micro

Etching Reagents
These are acids used to show up different structures in metals For steels the most common is 1-2 % nitric acid in distilled water or alcohol. Aluminum uses a solution of 10-20%caustic soda in water

Non-destructive testing
The rate the electrode melts The way the weld metal flows Sound of the arc

while welding

Visual

The light given of Under cut Lack of root fusion after welding Any pin holes from gas or slag Amount of spatter

Dimensions of weld

DYE PENETRANTS
These are an aid to visual inspection Will only find surface defects Types Red Flouresant

CAUTION Oil based Water washable

MAGNETIC PARTICLE
Mainly for surface defects Some sub surface defects can be found Only ferrous metal

ACOUSTICS
Striking with a rounded object Ringing tone if no defect Tone changes when object is cracked

APPLICATION OF A LOAD
Used to test pressure vessels Pipe lines The item for testing is filled with water or oil it is then pressurised using a pump A safety valve is set 1.5 to 2 times below the working pressure

PRESSURE TEST

RADIOGRAPHIC
X-RAY GAMMA RAY Electromagnetic radiation of short duration Both of these methods are a danger to health

ULTRASONIC TESTING
This uses high pitched sound The sound will not pass through an air gap so bounces back and is picked up on a receiver The reader is a oscilloscope

References
www.wikipedia.com www.engfunda.com