Professional Documents
Culture Documents
NDT & DT
Destructive Testing
Testing Methods
Specimen as per code
Non Destructive Testing
Testing Methods
Visual Inspection
Specimen Selection Criteria
Acceptance Criteria as per Codes
AN OVERVIEW
The term mechanical testing is used to describe a group of test methods
for establishing or confirming the mechanical properties of a material or a
completed weld. Most of these tests involve sectioning or otherwise destroying
some part of the object being tested and thus they are sometimes called
destructive tests. The tests are generally classified by the property they are
intended to define. Each follows a well-established procedure, which is part of a
published standard, allowing individual test results to be compared to other
results or statistical norms. This section describes the following mechanical tests,
some of which are destructive, that are carried out on welds:
macroscopic & microscopic examinations
bend test
tension test
hardness test
charpy vee notch test
Izod test
crack tip open displacement test
nick break test
chemical test
Bend Test :
The bend test is a popular test method that is found in many welding standards and
specifications throughout the world due to the simplicity of the test method and
equipment required. The history of the bend test dates back to the early years of wrought
iron and steel testing before the advent of modern testing equipment. Bend specimens
are prepared typically from a test plate rather than from an expensive finished product
and are used to evaluate the ductility and soundness of welded joints.
There are two different bend testing methods:
guided bend test
free bend test
Guided Bend Test
The guided bend test is commonly used in welder and procedure qualification tests
to determine the ability of the welder to make sound welds. The test is performed by
bending prepared specimens of a specific dimension (usually specified in the relevant
code) in a special jig. The dimensions of the jig will vary with specimen thickness and
material.
TENSION TEST
Tension tests are performed for the following reasons:
- test results are used in selecting materials for engineering applications
- tensile properties are frequently included in the material specifications
to ensure quality
- often tensile properties are measured during the development of new
materials and processes so that different materials and processes can be
compared.
- tensile properties are often used to predict the behavior of a material
under different forms of loading, other than uniaxial tension.
The strength and ductility of metals are generally obtained from a
simple uniaxial tension test in which a machined specimen is subjected
to an increasing load while simultaneous observations of extension are
made. If the loading is continued the specimen will eventually break. A
typical stress-strain curve that is produced from a tension test is shown
in the diagram. (Appendix C Fig 48)
HARDNESS TESTING
Hardness can be described as the ability of a material to resist permanent or plastic
deformation, and is usually measured by its resistance to indentation by an indenter of a
standard shape and size.
The hardness test is by far one of the most valuable and the most widely used
mechanical test for evaluating the properties of metals as well as certain other materials.
In general, an indenter is pressed into the surface of the metal to be tested under a
specific load for a definite time interval, and a measurement is made of the size or depth
of the indentation.
The main purpose of the hardness test is to determine the suitability of a material, or
the particular treatment to which the material has been subjected to
Non-Destructive Testing
Testing Methods
Visual Inspection
Specimen Selection Criteria
Various NDT Info
Penetrant Testing (PT)
Magnetic Particle Testing (MT)
Radiographic Testing
Ultrasonic Testing (UT)
Visual Inspection Acceptance Criteria
Acceptance Criteria
1 Testing Methods
There are Numerous Non-Destructive tests used to evaluate the base metal to be
joined as well as completed welds. However these all NDT shares several
common elements, these essential elements are summarized below:
A Source of Probing energy or Medium
A Discontinuity must cause change or alteration of probing energy
A means of detecting this change
A means of indicating this change
A means of observing or recording this indication so that an interpretation can
made.
Over the years Numerous Non-Destructive Testing Methods have been developed,
each one has associated with its various advantage & Limitations.
Followings are the Noted NDT Methods
Visual Testing (VT)
Penetrant Test (PT)
Magnetic Particle Test (MT)
Radiographic Test (RT)
Ultrasonic Test (UT)
Eddy Current Test (ET)
Visual Inspection
In any effective Quality control program, visual inspection provides the basic element
for evaluation of the structure or components being fabricated. In order to gain some
assurance as to the suitability of the welding for its intended service, code & standard
will always stipulate the performance of visual inspection as the minimum level of
acceptance/rejection evaluation.
It has been proven fact in numerous situations that an effective program of
visual inspection will results in discovery of vast majority of those defects which
will be found later using some other expensive NDT Methods.
Its important to realize, however, this is possible only when the visual inspection is
accomplished before, during & after welding, by qualified welding inspector. Simply
looking at the finished weld without the benefit of seeing those preceding fabrication
steps can only provide a limited assurance of weld suitability.
It has been considered that the only way in which the visual inspection can be
considered to effectively evaluate the quality of welds is to apply that inspection at every
step of the fabrication process
During Welding
Check welding variable in compliance with welding procedure
Check quality of individual weld passes
Check inter pass cleaning
Check inter pass temperature
Check placement & sequencing of individual weld passes
Check backgouged surfaces
Monitor in-process NDT if required
After Welding
Check finished weld appearance
Check weld size
Check weld length
Check dimensional accuracy of weldments
Monitor additional NDT if required
Monitor PWHT if required
Prepare Inspection Reports
MPI uses magnetic fields and small magnetic particles, such as iron filings to detect flaws
in components. The only requirement from an inspectability standpoint is that the component being
inspected must be made of a ferromagnetic material such iron, nickel, cobalt, or some of their
alloys. Ferromagnetic materials are materials that can be magnetized to a level that will allow
the inspection to be effective.
The method is used to inspect a variety of product forms such as castings, forgings, and
weldments. Many different industries use magnetic particle inspection for determining a
component's fitness-for-use. Some examples of industries that use magnetic particle inspection are
the structural steel, automotive, petrochemical, power generation, and aerospace industries.
Underwater inspection is another area where magnetic particle inspection may be used to test items
such as offshore structures and underwater pipelines.
Beam spread occurs because the vibrating particle of the material (through which
the wave is traveling) do not always transfer all of their energy in the direction of wave
propagation. Recall that waves propagate through that transfer of energy from one
particle to another in the medium. If the particles are not directly aligned in the direction
of wave propagation, some of the energy will get transferred off at an angle. (Picture
what happens when one ball hits another second ball slightly off center). In the near field
constructive and destructive wave interference fill the sound field with fluctuation. At the
start of the far field, however, the beam strength is always greatest at the center of the
beam and diminishes as it spreads outward.
Beam spread is largely determined by the frequency and diameter of the
transducer. Beam spread is greater when using a low frequency transducer than when
using a high frequency transducer. As the diameter of the transducer increases the
beam spread will be reduced.
Beam angle is an important consideration in transducer selection for a couple of
reasons. First, beam spread lowers the amplitude of reflections since sound fields are
less concentrated and, therefore, weaker. Second, beam spread may result in more
difficult to interpret signals due to reflections from the lateral sides of the test object or
other features outside of the inspection area. Characterization of the sound field
generated by a transducer is a prerequisite to understanding observed signals.
SR.NO.
DESCRIPTION
SHELL/DRUM
L SEAMS
RT
100%
UT
MT
PT
C SEAMS
RT
100%
UT
MT
PT
RT
100%
TUBES/ PIPES/
STAND PIPES/
HEADERS
(Ref. UW-11(a)(2))
>NPS 10or>29 mm
(Wall Thk.)
RT
100%
UT
MT
PT
II
III
Notes :
Appendix C
Non-Destructive Testing
DP Test
Fig 8
Fig 9
DP Test Result
Fig 10
Non-Destructive Testing
MT Test
Fig 14
MT Yoke
Test Set-up
Magnetic Field
Strength Checkup
Fig 16
Non-Destructive
Testing
Fig 11
Fig 12
Fig 13
MT With Powder
Crack Detection
thru MPI
Fig 15
Crack Detection
thru MPI
MT Test Fluorescent
Fig 17
Fig 18
Fig 19
Fig 20
Non-Destructive Testing
Radiography Films
Fig 21 Cold Lap
Fig 25 Lack of
Penetration
Fig 27 Suck
Back
Fig 29 External
Undercut
Fig 22 Porosity
Fig 26 Incomplete
Fusion
Fig 28 Internal
Undercut
Fig 30 Offset or
Mismatch
l
Fig 31 underfil
Fig 33 Crack
Destructive Testing
Fig 36
Fig 37
Fig 39
Fig 40
Fig 42
tension test
specimen
Fig 40
Transverse weld
Fig 41
Longitudinal
Fig 43
Fig 44
Fig 45
Fig 46
Fig 47
Fig 48
Fig 49
Fig 50
Izod impact specimen dimensions
Fig 51