Mechanical Testing Procedure
Saleem Manhappulath
Dear Team,
Does anyone have a procedure for mechanical testing, including tensile test, bend test, Vickers hardness test, impact test, macro examination, fillet fracture test, ferrite testing, and chemical analysis?
sridhar cn
1. Tensile Test (ISO 4136 / ASTM E8)
Purpose: Determine yield strength, UTS, and elongation.
Specimen: Transverse or all-weld-metal, machined to standard dimensions.
Procedure: Mount the two specimens in a calibrated tensile machine.
Apply load at controlled strain rate until fracture. Record YS, UTS, EL%.
Acceptance: Tensile ≥ minimum specified; fracture location acceptable.
2. Bend Test (ISO 5173 / ASTM E190 /AWS B4.0)
Purpose: Check ductility and weld soundness.
Specimen: Face/root/side bend, edges smoothed.
Procedure: Bend to 180° around specified mandrel.
Inspect tension surface.
Acceptance: No cracks > 3 mm; no open defects.
3. Vickers Hardness Test (ISO 6507 / ASTM E92 / AWS A4.2)
Purpose: Evaluate hardness of WM, HAZ, BM.
Specimen: Polished transverse section; HV10 or HV5 load.
Procedure: Apply load for 10–15 s.
Take impressions across the weld line. Record hardness profile.
Acceptance: Project-specific (e.g., ≤ 250 HV10 for CS).
4. Impact Test – Charpy V (ISO 9016 / ASTM E23)
Purpose: Determine toughness at specified temperature.
Specimen: 10×10×55 mm V-notch, notch at WM/HAZ/BM.
Procedure: Condition to test temperature.
Strike with a pendulum hammer. Record absorbed energy (J).
Acceptance: Meets minimum J values specified.
5. Macro Examination (ISO 17639 / AWS B4.0)
Purpose: Examine weld profile, penetration, fusion.
Specimen: Cross-section, polished and etched (Nital for CS).
Procedure: Etch until weld structure is visible.
Measure throat, penetration, reinforcement. Check for fusion and defects.
Acceptance: No lack of fusion, cracks; dimensions per WPS.
6. Fillet Fracture Test (ISO 9017 / AWS D1.1)
Purpose: Assess internal soundness of fillet weld.
Specimen: T-joint coupon of test fillet size.
Procedure: Fracture via bending or pressing.
Inspect fracture surface.
Acceptance: No cracks, incomplete fusion, large porosity.
7. Ferrite Testing (ISO 8249 / AWS A4.2)
Purpose: Determine ferrite number (FN) in SS welds.
Specimen: Smooth, clean WM surface.
Procedure: Calibrate ferrite scope. Take multiple FN readings.
Acceptance: Austenitic: 3–10 FN; duplex per WPS (typically 30–60%).
8. Chemical Analysis (ASTM E415 / E1086 / Spectroscopy)
Purpose: Confirm chemical composition of BM/WM/filler.
Specimen: Clean, polished area.
Procedure: Perform OES/XRF. Compare elements with grade/wire specification.
Acceptance: Must match specified chemistry limits.
Trust it is clear.
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