Destructive Examination &

Testing
 Destructive Examination

• Destructive Examination renders the weld

or material unfit for further service.
 Common methods used in
Destructive Examination
• Bend testing
• Tensile testing
• Impact testing
• Hardness testing
• Chemical analysis
• Hydrostatic testing to destruction
• Peel testing
• Spark 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
– Unguided bend testing
Bend Testing Sample Removal
Bend Testing Sample
Preparation
Face Bend Testing
Root Bend Testing
Side Bend Testing
Longitudinal Face Bend Testing
Longitudinal Root Bend Testing
Fillet Bend Testing
Pipe 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
 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 may be defined as the
resistance to permanent indentation.
• 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
 Hardness testing
• The Sceleroscpoe 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.
 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.
 Chemical Analysis

• Chemical analysis is used in metallurgical

laboratories to determine the metals grain
and crystalline structures.
• Samples are then place under a high power
microscope to view the results.
• This is referred to as “Metalography”
 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.
 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.
 Spark Testing
• The shape and
characteristic of sparks
created when metal is
ground will help
determine its
properties.
• IE: carbon steel , mild
steel.
 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
 Modern Welding
York County School of Technology