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Re: [MW:35985] Mechanical Testing Procedure

By Materials & Welding

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.

Sridhar.
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On Mon, 2 Feb 2026 at 17:50, Saleem Manhappulath <manhappulathsaleem@gmail.com> wrote:

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?

 
Thanks & Best Regards
Saleem manhappulath

Mob:+966533595849
WhatsApp:+919526445936

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