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WELD TESTING

WELD TESTING. DESTRUCTIVE AND NON-DESTRUCTIVE. DESTRUCTIVE TESTING . These can be divided into two parts, Tests capable of being performed in the workshop. Laboratory tests. microscopic-macroscopic , chemical and corrosive. REASONS.

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WELD TESTING

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  1. WELDTESTING

  2. DESTRUCTIVE AND NON-DESTRUCTIVE

  3. DESTRUCTIVE TESTING • These can be divided into two parts, • Tests capable of being performed in the workshop. • Laboratory tests. • microscopic-macroscopic , chemical and corrosive.

  4. REASONS • Defects occur during welding which affect the quality and hardness of the plate • Other defects occur through lack of knowledge of and skill of the welder • For the training of welders

  5. WORKSHOP TESTS TENSILE BENDING IMPACT HARDNES FATIGUE CRACKING

  6. TENSILE Material is sectioned and edges rounded of to prevent cracking. Punch marks are made to see elongation.

  7. TENSILE

  8. BEND TESTING • Shows Physical condition of the weld Determine welds efficiency • Tensile strength • Ductility • Fusion and penetration

  9. BEND TEST • Bend through 180O • the specimen should be a minimum of 30mm wide • The fulcrums diameter is 3x thickness of the plate • The bottom rollers have a distance of the diameter of the former + 2.2 times the thickness of the plate • Upper and lower surfaces ground or filed flat and edges rounded off. • the tests should be one against the root -another against the face ,and in some cases a side bend.

  10. Root bend

  11. FACE BEND

  12. ANY QUESTIONS

  13. IMPACT • CHARPY AND IZOD • Gives the toughness and shock loading of the material and weld at varying temperatures with a notch such as under cut • The measurement is the energy required to to break a specimen with a given notch • 2mm depth at a 45obevel or a “U” notch.

  14. TEST MACHINE

  15. CHARPY

  16. IZOD

  17. ANY QUESTIONS

  18. HARDNESS TESTS. • This gives the metals ability to show resistance to indentation which show it’s resistance to wear and abrasion. • The tests are • Brinell • Rockwell • Vickers diamond pyramid • Scleroscope

  19. VICKERS HARDNES

  20. FATIGUE • the testing of Material that is subject to fluctuating loads • HAIGH Electro magnetic tester. • W’O’HLER Uses rotating chuck with weight

  21. CRACKING • REEVES Test study the hardening and cracking of welds. • The compatibility of electrodes for the metal being joined.

  22. CRACKING • Three Sides Are Welded With Known Compatible Electrodes. • The front edge is welded with the test electrode. • if incompatible it will crack.

  23. MICROSCOPIC • Used to determine the actual structure of the weld and parent metal • Up to 50,000 times magnification with an electron beam microscope • Polishing must be of a very high standard

  24. MACROSCOPIC • Examined using a magnifying glass . • magnification from 2 to 20 time. • it will show up slag entrapment or cracks . • polishing not as high as micro.

  25. ETCHING REAGENTS • These are acids used to show up different structures in metals • For steels the most common is “1-2 % nitric acid in distilled water or alcohol. • Aluminum uses a solution of 10-20%caustic soda in water

  26. HAVE YOU ANY QUESTIONS

  27. NON-DESTRUCTIVE TESTING

  28. While welding The rate the electrode melts The way the weld metal flows Sound of the arc The light given of After welding Under cut Lack of root fusion Any pin holes from gas or slag Amount of spatter Dimensions of weld VISUAL

  29. DYE PENETRANTS • These are an aid to visual inspection • Will only find surface defects • Use correct type

  30. DYE PENETRANTS

  31. DYE PENETRANTS • Types • Red • Flouresant • CAUTION • Oil based • Water washable

  32. DETECTION

  33. MAGNETIC PARTICLE • Mainly for surface defects • Some sub surface defects can be found • Only ferrous metal

  34. ACOUSTICS Striking with a rounded object Ringing tone if no defect Tone changes when object is cracked

  35. APPLICATION OF A LOAD • Used to test pressure vessels • Pipe lines • The item for testing is filled with water or oil it is then pressurised using a pump • A safety valve is set 1.5 to 2 times below the working pressure.

  36. PRESSURE TEST

  37. RADIOGRAPHIC X-RAY GAMMA RAY Electro magnetic radiation of short duration Both of these methods are a danger to health

  38. X- RAY

  39. X-RAY VIEWER Pictures taken are viewed as negatives will only give flat image not in three dimensional darkened area must be used for viewing

  40. This uses high pitched sound The sound will not pass through an air gap so bounces back and is picked up on a receiver The reader is a oscilloscope ULTRASONIC TESTING

  41. ULTRA SONIC

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