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This chapter describes three important destructive testing methods of welded joints
namely toughness test, fatigue test and fracture toughness testing. Additionally, concept
of fracture toughness and conditions required for fracture toughness test for different
stress conditions has also been presented. Further, non-destructive testing methods
have also been presented.
Keywords: Impact test, Izod and Charpy test, fatigue test, endurance limit,
fracture toughness, plain strain condition, CT specimen, three point bending
specimen, Dye penetrant test, magnetic particle test, eddy current test and
ultrasonic test
Fig. 32.1
1 Principle diagram
d of toughness test.
To study the be
ehaviour of material un
nder dynam
mic load con
nditions (at high rate o
of
ng) toughne
loadin ess test is frequently conducted. There are two metho
ods used fo
or
tough ng namely Izod and Ch
hness testin harpy test, based on tthe common
n principle o
of
apply
ying the load
d at high ratte and meas
suring the a
amount of en
nergy absorrbed (kg m o
or
Joule
e) in breakin
ng the sam
mple due to impact (Fig
g. 32.1). Ho
owever, the
ere are som
me
differrences also in these tw
wo methods in terms of sample size and shap
pe, method o
of
holdin
ng of the sa
ample and maximum
m en
nergy conte nt of pendulum that hits the samplle
during the test.
Sr. ess
Toughne Samp
ple Holding
No. test
Fig. 32.2
3 Standarrd specimen d and b) cha rpy impact ttest
ns for a) izod
Since
e most of the
e engineerin
ng componen
nts are invarriably design
ned with notcch and stresss
raisers therefore
e, it become
es importantt to know a bout the be
ehaviour of material witth
h under impact loading. Hence, tou
notch ughness testt is usually conducted u
using samplle
with notch.
n Moreover, un-nottched samples can also
o be used fo
or the toughn
ness test an
nd
the re
esults are ex
xpressed acc
cordingly.
Resu
ults of impac
ct tests are expressed in terms off either amo
ount of enerrgy absorbe
ed
(Nm) or amount of energy ab ea (Nm/cm2) by standarrd
bsorbed perr unit cross ssectional are
ple. It may be noted th
samp hat values of toughnesss are not directly use
ed for desig
gn
purpo
ose but the
ese only in
ndicate the ability of the materia
al to withstand againsst
shock
k/impact loa
ad i.e. load
d applied at
a very high
h rate. The
ese tests arre useful fo
or
comp
paring the re
esistance to impact loading of differe
ent materialss or the sam
me material in
differrent process
sing conditio
ons such as
a heat trea
atment, pro
ocedure and
d mechanica
al
workiing etc. Res
sistance to th
he impact lo
oading of a m
material app
preciably depends on th
he
surro
ounding temp
perature (Fig
g. 32.3). Therefore, tem
mperature att which toug
ghness test is
b reported with results.
conducted must be
Fig. 32.3
3 Schema
atic diagram
m showing inffluence of te
est temperature on tough
hness
a) b)
Fig. 32.4
3 Standarrd specimen
n for fatigue testing
t
To co
onducting fa
atigue test, first step is
s conduct th
he tensile te
est on the w
weld joint fo
or
estab
blishing the yielding stre
ength of me
etal as maxximum stresss becomes 0.9 times o
of
yield strength of material. For number of cycle (S-N) ccurve, fatigu
F plotting the stress-n ue
test is first condu
ucted with maximum
m ap
pplied tensile
e load corre
esponding to
o 0.9 times o
of
yield strength of weld joint under
u study to determin e the numb
ber of load ccycle require
ed
acture and then
for fra t in the same
s way te
est is repeate
ed at 0.85, 0
0.8, 0.75, 0.7
7 …. times o
of
yield strength of weld joint until
u enduran
nce limits orr desired fattigue life is not achieve
ed
cal dimensio
(Fig. 32.6). Typic ons of a stan
ndard specim
men as per A
ASTM 466 a
are as-underr.
Continuo
ous radius (R):
( 100mm
m
Width (W
W): 10.3mm
Thicknes
ss *T): 11mm (as received)
Gripping length: 50m
mm
a)
b)
Fig. 32.5
3 Fatigue
e test sample
e a) Schema
atic diagram
m of standard
d fatigue test sample witth
contin
nuous radius
s between ends
e and b) photograph
p of typical sp
pecimen
0.6
0
Peak stress/Ultimate stress
0.5
56
0.5
52
0.4
48
0.4
44
0.4
0
100000 1000000 1000000
00
No. of cycles
s
Fig. 32.6
3 Typical data on fatig
gue test sho
owing peak sstress/ultima
ate stress vss. number of
cycle
e relationship
p for structurre steel
P
W-a a
0.3 B
W
a
4W
W P/2 P/2
a) b)
W=2B, a=B, W-a=B and radius of hole r = 0.25B where B is plate thickness
Fig. 32.7 Schematic of fracture toughness specimens using a) compact tension and b)
three point bending approaches
Although different standards have historically been published for determining K, CTOD
and J-integral, the tests are very similar, and generally all three values can be
established from one type of test.
This is one of the simplest non-destructive testing methods primarily used for detecting
the presence of surface defects only. In this method surface to be tested a thin low
viscosity and low surface tension liquid containing suitable dye is applied (Fig. 32.8). The
thin liquid penetrates (by capillary action) into fine cavities, pores and cracks, if any,
present on the surface. Excess liquid present at surface is wiped out. Then suitable
developer like talc or chalk powder is sprinkled over the surface. Developer sucks out
thin liquid with dye wherever it is present inside the surface discontinuities present on
the weld joints. Dye with liquid changes colour of developer and indicates location, and
size of surface defects.
Fig. 32.8
3 Schema
atic showing
g four steps of
o dye penettrant test
Fig. 32.9
3 Principle
e of magnetiic particle te
est
smission ap
Trans pproach
The transmission
n approach of ultrason
nic testing u eparate devvices namely
uses two se
transmitter of viibration and
d receiver. Transmitting
g probe ge
enerates and sends th
he
sonic vibrattions and receiver
ultras r getts these viibrations att other end
d. Therefore
e,
transmission app
proach need
ds access to both the sid
des of the ccomponents to be tested
d.
Inputts from transmitting and
d receiving probes are given to o
oscilloscope (Fig. 32.10
0).
Metal system witthout discon
ntinuities sho
ows the two
o peaks in o
oscilloscope i.e. one from
m
op surface and
the to a another from the bo
ottom surface
e. In presen
nce of discon
ntinuity in th
he
metal being testted, ultrason
nic vibration
ns are refleccted so the
ey don’t reach up to th
he
ving end an
receiv nd so no signal is rec
ceived. Unde
er this cond
dition, only one peak iin
observed in the oscilloscope
o and absenc
ce of anothe r peak from bottom surfface suggestts
prese continuity in the metal tested. One
ence of disc e by one en
ntire surface
e area of th
he
comp
ponent to be
e tested is scanned
s using transmittting and recceiving probe
es. Howeve
er,
transmission app
proach is nott very usefull due to two reasons a) requirementt of access tto
both sides of com
mponent to be
b tested an
nd b) difficul ty in placem
ment of receiiving probe iin
line of
o transmittin
ng probe sen
nding ultraso
onic vibratio
ons especiallly in case off componentts
havin
ng thick sections.
Fig. 32.10
3 Transm e of ultrasonic testing
mission type
http:///www.tms.org/pubs/jourrnals/JOM/03
301/Kim/Kim‐‐0301.html
ection Apprroach
Refle
The reflection
r approach uses
s single prob
be which actts as a transsmitter as we
ell as receive
er
of ulttrasonic vibrrations. In metal
m system without disscontinuities,, application
n of ultrasonic
vibrattions results
s in the two
o peaks in oscilloscope
o e i.e. one frrom the top surface an
nd
anoth approach (Fig. 32.11). In
her from the bottom surfface like transmission a n presence o
of
disco
ontinuity in the
t metal being
b tested, ultrasonic vibrations are reflecte
ed. Vibration
ns
reflec
cted from the
e discontinu
uity shows ad
dditional pea
aks between
n the surface and bottom
m
peaks
s in the osc
cilloscope. Relative
R location of the i ntermediate
e peaks (between the to
op
and bottom
b surfa
ace peaks) suggests
s the
e distance off discontinuitty from the ssurfaces. Th
he
reflec
ction approa
ach overcom
mes both lim
mitations off transmissio
on approacch as it use
es
single
e probe so itt does not re
equire a) acc
cess of both
h sides of the
e componen
nt to be teste
ed
and b)
b alignmentt of transmission and rec
ceiving probe
es.
Fig. 32.11
3 Reflec
ction type of ultrasonic te
esting
h Catch metthod
Pitch
Coupler
For effective transmission of ultrasonic vibrations from the transmitting / source probe to
the metal surface, generally a fluid mostly in the form of water or low viscosity liquid
called coupler is used. The coupler ensures proper contact and transmission of vibration
from source probe to metal surface with minimum losses. Water is considered as the
best coupling media because it is readily available, low viscosity, and relatively safe to
use with most construction materials. In the pitch-catch method, a water-based gel has
proven to be the most practical coupling agent.