Upload
jasminnee
View
53
Download
11
Embed Size (px)
DESCRIPTION
Destructive Testing1
Citation preview
DESTRUCTIVE TESTINGMECHANICAL METALLOGRAPHIC CHEMICAL
TESTING EXAMINATION ANALYSIS
1. TENSILE 1. MACRO 1. WET ANALYSIS
2. BEND 2. MICRO 2. DRY ANALYSIS
3. IMPACT 3. X-RAY -
4. HARDNESS FLORESCENCE
5. DROP WEIGHT 4. ATOMIC-
6. DROP WEIGHT TEAR ABSORPTION
7. NICK BREAK
8. FATIGUE
9. CREEP
PURPOSE OF TESTING1. To determine the fundamental properties.
2. To determine Mechanical, Chemical and Metallurgical properties in order to find out the
suitability for a specific purpose.
3. To record the data for a group of metals and alloys
for the purpose of design.
4. To check weather heat treatment imparted has been carried out satisfactorily.
5. To investigate into defects and flaws of the material so as to improve manufacturing techniques.
PURPOSE OF TESTING
II. As for as welding is concerned
1. Qualification of welding procedure.
2. Qualification of welding and welding operation.
3. Qualification of welding consumables.
4. Quality control
STANDARD TEST METODS(For Mechanical Testing)
TYPE ASTM BS IS
Tensile E8 EN10002-1 1608,1521
Bend E190 EN287-1 1599
Impact E23 EN 10045-21757
Hardness E10(Brinell) BS 240-1 1500
E18(Rockwell) BS 891-1 1586
E 92(Vickers) BS 427 1501
STANDARD CODES FOR DESTRUCTIVE TESTING
ASTM-A370 : Mechanical Testing of Steels
AWS-B4 : Standard methods for Mechanical testing of welds
BS-709 : Destructive testing for fusion welded Boiler
drums.
IBR Ch.-V : Fusion Welded Boiler Drums.
IBR Ch.-Viii : Qualification test for Welders.
IBR Ch.-XII : Shell type Boiler construction
AWS 5.1,5.4,5.5 : Electrode Qualification Tests
IS 814,5206,1395 : Electrode Qualification Tests
ASME Sec.IX : Procedure & performance Qualification of welding
API-5L : For seamless and welded steel tubes & pipes.
TEST PLATE FOR PERFORMANCE QUALIFICATION (as per IBR)
B
250 mm
406 mm
B1 T1 B2
M
m
B1 T2 B2
16mm
weld
TEST PIPE & TUBE FOR PERFORMANCE QUALIFICATION (as per IBR
Face
Face
RootMacro
Macro250mm
Root
PIPE Ø127x12.5mm, CS Tube Ø63.5x5.2mm, AS Tube Ø54x5mm
weld
PROCEDURE QUALIFICATION(ASME SEC. IX)
QW-463.1(a) : Less than 3/4” PLATES
300mm
250mm
Discard DiscardReduced Sec. Tensile Specimen
Root Bend Face Bend
Root Bend
Face BendTensile Specimen
Discard Discard
Reduced Sec.
PROCEDURE QUALIFICATION(ASME SEC. IX)
QW-463 1(b) :Over 3/4” PLATES
300
Discard Discard
Discard Discard
Reduced Sec.
Side
SideSide
Side
Bend
Bend
Bend
Bend
Tensile Specimen
250
Reduced Sec. Tensile Specimen
TENSILE SPECIMENS
TRANSEVERSE TENSILE
ALL WELD TENSILE
ELECTRODE QUALIFICATION TEST(AS PER AWS)
WELD
ALL WELD TENSILE
170mm min. (1No.)
2525
15 IMPACT SPECIMEN (5Nos.)
DISCARDDISCARD
ALL WELD TENSILE SPECIMEN (as per IS) R5
FOR SIZE 3.15 mm and BELOW
FOR SIZE 4mm AND ABOVE
G L 50
10±0.09
PL 60
12 min
70mm min
6.4 ±0.075GL 32
44.838.9
9.5
THE SURFACE FINISH WIT THE PL SHALL BE 1.6
ALL WELD TENSILE SPECIMEN (AWS)
THE SURFACE FINISH WITH THE PL SHALL BE 1.6
R 9.5
SIZE OF ELECTRODE 3.15 mm and BELOW
Ø12.7±0.25
GL 50.8 ±0.13
PL 57.1
Ø19.1
R 4.6
GL 25.4 ±0.13GL 31.8
Ø 9.5
SL SL
SL SL
SIZE OF ELCTRODE 4 mm and ABOVE
Ø6.4±0.13
UNIVERSAL TESTING MACHINE
CALIBRATION:
ASTM-E4,
BIS: 1828,
EN: 10002-2
CALIBRATION : EN 10045-2, BIS 3766
0.
TRANSEVERSE TENSILE SPECIMEN
WPLSL SL T
RECTANGULAR TENSILE TEST SPECIMEN
200
225 7575
13 min(FOR PLATE as per ASTM E8M )
ASTM
BS
IBR
IS
50 mm
5.65A
4 A
5.65 A
5min.
50
STANDARD ROUND TENSILE (GL) FLAT TENSILE (GL)
5d
5d
4d
5d
GAUGE LENGTH AS PER VARIOUS STDS.& CODES.
40
BEND TEST METHODS
1. Guided bend
2. Free Bend
ROOT BEND TEST
t
ROOT BEND TEST
t
5.2t1.5t
3t
FACE BEND TEST
t
5.2t1.5t
3t
SIDE BEND TEST
W
5.2t t
3t
CALIBRATION : EN 10045-2, BIS 3766
Specimen Supporter
Specimen
CALIBRATION : EN 10045-2, BIS 3766
STRICKER
TENIUS OLSON IMPACT TESTER
CAL : ASTM - E23
IMPACT TEST SPECIMEN
10±0.025
55±0.127.5
10 ±0.02545°±0.1°
2±0.1
55±0.127.5
10 ±0.025
5±0.1
2
CHARPY ‘V’NOTCH TEST SPECIMEN
CHARPY ‘U’NOTCH TEST SPECIMEN
10±0.025
IZOD IMPACT TEST SPECIMEN
75 27.5 10
102
HARDNESS TEST 1.BRINELL HARDNESS 2. ROCKWELL HARDNESS
3.VICKERS HARDNESS 4. MICRO HARDNESS
BRINELL HARDNESS TEST
•HARDENED STEEL BALL IS USED FOR MEASURING UPTO 500 BHN
•FOR 500 BHN TUNGSTON STEEL BALL IS USED F
• FOR IRON AND STEEL 3000Kg OF LOAD IS APPLIED
•FOR INTERMEDIATE HARD MATERIALS 1500Kg, 500Kg OF LOADS ARE USED.
•FOR SOFT MATERIALS 100 Kg OF WEIGHT IS USED.
•RATE OF LOADING IS AN IMPORTANT CRITERIA, RAPID RATE OF LOADING AFECTS THE INDENTATION.
BHN=APPLIED LOAD/AREA OF INDENTATION
BHN=P/[( D/2) X (D-D2 - d2)]
WHERE P=LOAD IN Kg,
D=DIAMETER OF STEEL BALL IN mm, d= DIAMETER OF THE INDENTATION IN mm. APPLICATION
FOR C.STEEL, CAST IRON,COPPERALLOYS, ALUMINIUM ALLOYS, LEAD AND TIN ETC.
POLISHED SURFACE
UNIVERSAL HARDNESS TESTER
TEST IS CARRIED OUT BY IN ACCORDENCE ASTM E92 TEST IS CARRID OUT BY IN ACCORDENCE ASTM E92
Minor Load Major Load
ROCKWELL HARDNESS TEST
TEST IS CARRIED OUT BY IN ACCORDENCE ASTM E92 TEST IS CARRID OUT BY IN ACCORDENCE ASTM E92
VICKERS HARDNESS TEST
VICKERS HARDNESS TEST
Angle between faces of the pyramid is 136°
VHN=1.854 P/ D2
P=Load in Kgf
D= Average of measured diagonals of impression in mm
TEST IS CARRIED OUT BY IN ACCORDENCE WITH ASTM E92
DROP WEIGHT TEST
STANDARD DROP WEIGHT TEST SPECIMENP1=25X90X360
P2=19X50X130
P3=16X50X130
DROP WEIGHT TEST
DROP WEIGHT TEST IS CONDUCTED IN ACCORDANCE WITH ASTM E208
SPECIMEN
SPECIMEN
SUPPORTER
MACRO EXAMINATION
It involves the visual observation of the gross structural details of materials after preparation of the surface,
either by unaided or with the aid of low power microscope . Usually under 10X.
When macroscopic examinations appropriately carried out, some important metallic characteristics are determined by such studies.
Example : As for as welding is concerned macro will reveal
Undercut, Excess penetration, Incomplete penetration, Dilution lack of fusion pores and cracks etc.
MICRO EXAMINATION
The most important part of metallography deals with the microscopic examinations of a prepared metal specimen,employing magnification with the optical microscope from 100X to as high as 2000X.
Such microscopic studies are of much broader scope than macro examinations.
It will reveal clear picture of structural characteristics as grain size, shape, distribution secondary phases, non metallic inclusions, segregation and other heterogeneous conditions.
Microstructure reflects almost complete history of the mechanical and thermal treatment that a metal has received.
THANK YOU